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Installation





2ZR-FE ENGINE MECHANICAL: ENGINE ASSEMBLY: INSTALLATION

1. INSTALL ENGINE WIRE

2. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle) Installation

3. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transaxle) Installation

4. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle) Installation

5. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle) Installation

6. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transaxle) Installation

7. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

HINT
Installation for C59.

8. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle)

HINT
Installation for U341E.

9. INSTALL STARTER ASSEMBLY Installation

10. INSTALL FLYWHEEL HOUSING SIDE COVER

11. INSTALL FRONT ENGINE MOUNTING INSULATOR

(a) Install the front engine mounting insulator with the nut and bolt.





Torque : 73 Nm (744 kgf-cm, 54 ft-lbf)

12. INSTALL REAR ENGINE MOUNTING INSULATOR

(a) Install the rear engine mounting insulator to the engine mounting bracket with the through bolt.





Torque : 65 Nm (663 kgf-cm, 48 ft-lbf)

13. INSTALL ENGINE MOUNTING INSULATOR LH

(a) Temporarily install the engine mounting insulator LH with the 4 bolts.





(b) Tighten the 4 bolts.

Torque : 52 Nm (530 kgf-cm, 38 ft-lbf)

HINT
Perform this procedure only when replacement of the engine mounting insulator is necessary.

14. INSTALL ENGINE MOUNTING INSULATOR RH

(a) Install the engine mounting insulator RH with the 3 bolts.





Torque : 52 Nm (530 kgf-cm, 38 ft-lbf)

HINT
Perform this procedure only when replacement of the engine mounting insulator is necessary.

(b) Install the radiator reserve tank with the 3 bolts.





Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)

(c) Install the relay block assembly.





15. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

(a) Set the engine assembly with transaxle and front suspension crossmember on the engine lifter.

(b) Operate the engine lifter and lift the engine assembly with transaxle and front suspension crossmember to the position where the engine mounting insulators RH and LH can be installed.

CAUTION:
Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

NOTICE:
* Make sure that the engine is clear of all wiring and hoses.
* While raising the engine into the vehicle, do not allow it to contact the vehicle.
(c) Install the engine mounting insulator LH with the through bolt and nut.





Torque : 56 Nm (571 kgf-cm, 41 ft-lbf)

(d) Install the engine mounting insulator RH with the bolt and 2 nuts.





Nut A - Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)

Nut B - Torque : 52 Nm (530 kgf-cm, 38 ft-lbf)

Bolt - Torque : 95 Nm (969 kgf-cm, 70 ft-lbf)

16. TEMPORARILY INSTALL CENTER ENGINE MOUNTING MEMBER SUB-ASSEMBLY Installation

17. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY Installation

18. FULLY TIGHTEN CENTER ENGINE MOUNTING MEMBER SUB-ASSEMBLY Installation

19. REMOVE ENGINE HANGER

(a) Remove the 2 bolts and 2 engine hangers.

(b) Install the wire harness bracket with the bolt.





Torque : 60 Nm (612 kgf-cm, 44 ft-lbf)

20. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transaxle) Installation

21. INSTALL FLYWHEEL HOUSING UNDER COVER (for Automatic Transaxle) Installation

22. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH Installation

23. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING RH Installation

24. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation

25. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation

26. INSTALL STEERING KNUCKLE WITH AXLE HUB LH

(a) Align the matchmarks and connect the front drive shaft assembly to the front axle assembly LH.





27. INSTALL STEERING KNUCKLE WITH AXLE HUB RH

HINT
Perform the same procedure for the LH side.

28. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH Installation

29. INSTALL FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

HINT
Perform the same procedure for the LH side.

30. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation

31. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT
Perform the same procedure for the LH side.

32. CONNECT TIE ROD END SUB-ASSEMBLY LH Installation

33. CONNECT TIE ROD END SUB-ASSEMBLY RH

HINT
Perform the same procedure for the LH side.

34. INSTALL FRONT SPEED SENSOR LH Installation

35. INSTALL FRONT SPEED SENSOR RH

HINT
Perform the same procedure for the LH side.

36. INSTALL FRONT AXLE SHAFT LH NUT Installation

37. INSTALL FRONT AXLE SHAFT RH NUT

HINT
Perform the same procedure for the LH side.

38. INSTALL FRONT EXHAUST PIPE ASSEMBLY Installation

39. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY Installation

40. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY Installation

41. INSTALL COLUMN HOLE COVER SILENCER SHEET Installation

42. INSTALL WIRE HARNESS

(a) Install the earth wire to the engine compartment with the bolt and clamp (for Manual Transaxle).





Torque : 13 Nm (130 kgf-cm, 10 ft-lbf)

(b) Install the earth wire to the engine compartment with the bolt and clamp (for Automatic Transaxle).





Torque : 26 Nm (260 kgf-cm, 19 ft-lbf)

(c) Install the wire harness with the 2 nuts.





Torque : 8.4 Nm (85 kgf-cm, 74 in-lbf)

(d) Connect the 3 connectors and 2 wire harness clamps to the engine room junction block.

(e) Connect the connector to the ECU with the lock lever and connect the clamp.





43. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle)

(a) Install the clutch release cylinder assembly with the 4 bolts and clutch tube bracket.





Bolt A - Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

Bolt B - Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

Bolt C - Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)

44. INSTALL COMPRESSOR WITH PULLEY ASSEMBLY (w/ Air Conditioning System) Installation

45. INSTALL FAN BELT ADJUSTING BAR

(a) Install the bolt and fan belt adjusting bar.

Torque : 19 Nm (194 kgf-cm, 14 ft-lbf)

46. INSTALL GENERATOR ASSEMBLY Installation

47. INSTALL V-RIBBED BELT Installation

48. ADJUST V-RIBBED BELT Installation

49. INSPECT V-RIBBED BELT Testing and Inspection

50. CONNECT FUEL TUBE SUB-ASSEMBLY

(a) Connect the fuel tube connector and fuel pipe.

CAUTION:
Align the fuel tube connector with the pipe, then push the fuel tube connector in until the retainer makes a "click" sound. If the connection is tight, apply a small amount of engine oil to the tip of the pipe. After connecting, pull on the pipe and connector to make sure that they are securely connected.

(b) Engage the claw and install the No. 1 fuel pipe clamp.





51. CONNECT INLET HEATER WATER HOSE

(a) Connect the inlet heater water hose with the clamp.





52. CONNECT OUTLET HEATER WATER HOSE

(a) Connect the outlet heater water hose with the clamp.





53. CONNECT OIL COOLER HOSE (for Automatic Transaxle)

(a) Connect the 2 oil cooler hoses with the clamps.





54. CONNECT UNION TO CONNECTOR TUBE HOSE

(a) Connect the union to connector tube hose.





55. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY

(a) Connect the fuel vapor feed hose assembly.





56. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)

(a) Install the transmission control cable to the control cable bracket with 2 new clips.





(b) Install the transmission control cable to the transaxle with the 2 clips.

57. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)

(a) Secure the control cable onto the control cable bracket with a new clip.





(b) Connect the control cable onto the control shaft lever with the nut.

Torque : 12 Nm (122 kgf-cm, 9 ft-lbf)

(c) Connect the control cable to the cable support.

(d) Connect the clamp of the control cable with the bolt.

Torque : 5.0 Nm (51 kgf-cm, 44 in-lbf)

58. CONNECT NO. 2 RADIATOR HOSE

(a) Connect the No. 2 radiator hose with the clamp.





59. CONNECT NO. 1 RADIATOR HOSE

(a) Connect the No. 1 radiator hose with the clamp.





(b) Connect the clamp.

60. INSTALL BATTERY CARRIER

(a) Install the battery carrier with the 4 bolts.

Torque : 13 Nm (130 kgf-cm, 9 ft-lbf)

(b) Connect the radiator pipe with the 2 bolts.





Torque : 8.8 Nm (90 kgf-cm, 78 in-lbf)

(c) Connect the 2 wire harness clamps.





61. INSTALL BATTERY

(a) Install the battery clamp with the bolt and nut.

for bolt - Torque : 6.5 Nm (66 kgf-cm, 58 in-lbf)

for nut - Torque : 3.5 Nm (36 kgf-cm, 31 in-lbf)

(b) Connect the battery cables.

Torque : 5.4 Nm (55 kgf-cm, 48 in-lbf)

62. INSTALL AIR CLEANER CASE

(a) Install the air cleaner case with the 3 bolts.





Torque : 7.0 Nm (71 kgf-cm, 62 in-lbf)

(b) Install the wire harness clamp to the air cleaner case.

(c) Install the air cleaner filter element.

63. INSTALL AIR CLEANER CAP SUB-ASSEMBLY Installation

64. ADD TRANSAXLE OIL (for Manual Transaxle)

HINT
Service and Repair for C59.

65. INSPECT AND ADJUST TRANSAXLE OIL (for Manual Transaxle)

HINT
Service and Repair for C59.

66. ADD AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle)

67. INSPECT TRANSAXLE FLUID LEVEL (for Automatic Transaxle)

HINT
Procedures for U341E.

68. INSPECT FOR AUTOMATIC TRANSAXLE FLUID LEAK (for Automatic Transaxle)

69. INSPECT SHIFT LEVER POSITION (for Automatic Transaxle)

HINT
Adjustments for U341E.

70. ADJUST SHIFT LEVER POSITION (for Automatic Transaxle)

HINT
Adjustments for U341E.

71. ADD ENGINE COOLANT Service and Repair

72. ADD ENGINE OIL Replacement

73. INSPECT ENGINE OIL LEVEL Testing and Inspection

74. INSPECT FOR FUEL LEAK Testing and Inspection

75. INSPECT FOR ENGINE COOLANT LEAK Testing and Inspection

76. INSPECT FOR OIL LEAK

77. INSPECT FOR EXHAUST GAS LEAK

78. INSTALL ENGINE UNDER COVER LH

79. INSTALL ENGINE UNDER COVER RH

80. INSTALL FRONT WHEELS

Torque : 103 Nm (1050 kgf-cm, 76 ft-lbf)

81. INSPECT IGNITION TIMING Engine

82. INSPECT ENGINE IDLE SPEED Engine

83. INSPECT CO/HC Engine

84. ADJUST FRONT WHEEL ALIGNMENT

HINT
Service and Repair.

85. INSTALL NO. 2 CYLINDER HEAD COVER

(a) Engage the 4 clips to install the No. 2 cylinder head cover.





NOTICE:
* Be sure to engage the clips securely.
* Do not apply excessive force or do not hit the cover to engage the clips. This may cause the cover to break.
86. CHECK SPEED SENSOR SIGNAL

HINT
Test Mode Procedure w/o VSC.

Test Mode Procedure w/ VSC.
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