With Manual Transmission
Special Tools:
1. General note.
- The locations of the engine mountings and the engine support insulators are described looking from the transaxle to the engine.
2. Use the floor crane to bring the engine into installation position and lower it.
3. Position the jack under the oil pan and unhook the engine.
4. Install the special tool.
5. NOTE: Do not tighten the bolts.
Install the engine front support insulator.
6. NOTE: Do not tighten the nuts from transaxle.
Install the engine rear support insulator.
7. Raise and support the vehicle.
8. Install the special tool to the subframe.
- Install the center bolt into the special tool.
9. Lower the vehicle.
10. Tighten the engine front support insulator.
11. Tighten the engine rear support insulator.
12. Remove the special tool.
13. Raise and support the vehicle.
14. Install the right-hand engine support insulator bracket.
15. NOTE: The installed position of the engine support insulator must be to the center of the bracket, otherwise realignment of the engine/transaxle assembly will be required.
Install the left-hand engine support insulator.
- Remove the special tool.
1 Nuts
2 Center bolt
16. NOTE: The installed position of the engine support insulator must be to the center of the bracket, otherwise realignment of the engine/transaxle assembly will be required.
Install the right-hand engine support insulator center bolt.
Vehicles With Air Conditioning
17. Install the compressor.
- Connect the compressor electrical connector.
18. Install the compressor heat shield.
All Vehicles
19. Install the accessory drive belt.
1 Left-hand moving stop
2 Square ratchet wrench 3/8 inch.
- Using the square ratchet wrench press the belt tensioner to the left-hand moving stop and install the drive belt.
20. Install the coolant pipe.
21. Connect the left Heated Oxygen Sensor (H02S) electrical connector.
22. Install the fan.
23. Install the radiator.
Vehicles With Air Conditioning
24. Install the condenser core to the radiator.
- Cut the cable tie.
- One bolt on each side.
All Vehicles
CAUTION: To prevent damage to the halfshaft joints and boots, do not bend the inner halfshaft joints by more than 18 degrees, the outer one by not more than 45 degrees.
25. Install the left-hand halfshaft to the transaxle.
CAUTION: To prevent damage to the halfshaft joints and boots, do not bend the inner halfshaft joints by more than 18 degrees, the outer one by not more than 45 degrees.
26. Install the right-hand halfshaft to the transaxle.
CAUTION: Do not damage the boot and the wheel speed sensor ring.
27. Install the right-hand lower suspension arm (left-hand-side shown).
- Install the lower suspension arm ball joint to the wheel knuckle.
28. Install the right-hand splash shields (shown with wheel removed).
29. NOTE: Install a new gasket.
Install the dual converter Y-pipe.
30. Connect the shifter cables.
1 Install the shifter bracket.
2 Install the nuts.
3 Connect the shifter cables to the shifter lever.
31. Connect the radiator lower hose to the radiator.
32. Install the radiator splash shield.
- Install the coolant drain plug.
33. Install the lower engine cover (if equipped).
34. Lower the vehicle.
35. Connect two ground cables to the transaxle and install the electrical connector.
36. Using 4 mm rivets and a riveter, install the PCM cover plate.
CAUTION: Do not drop hydraulic oil onto the drive belt.
37. Connect the power steering lines.
1 Pressure line bracket and ground cable
2 Return line
3 Power Steering Pressure (PSP) switch
38. Install the power steering fluid reservoir.
39. Connect the heater control vacuum hoses.
40. Install the fan to the radiator.
- Install the fan wiring harness.
41. Install the fan to the radiator (continued).
42. Install the fan ground cable to the body.
43. Connect the two fan motor electrical connectors.
- Install the connectors and the wiring harness.
Vehicles With Air Conditioning
44. Connect the suction accumulator electrical connector.
All Vehicles
45. Tighten the right-hand suspension strut nut.
46. Tighten the right-hand suspension strut nut (continued).
47. Install the coolant hose.
48. Install the coolant hoses.
- To cylinder block
- To heater
- Connect the heater coolant hose.
- To thermostat housing
49. Install the radiator upper hose to the radiator.
50. Install the coolant expansion tank.
- Connect the coolant level indicator electrical connector.
51. Install the coolant expansion tank hoses.
52. Install the clutch slave cylinder hydraulic line.
53. Connect the fuel pipes and install the clips.
54. Connect the starter motor positive cable.
- Push the positive cable into the housing and close it.
55. Install the starter motor wiring.
56. Install the battery bracket.
57. Install the Central Junction Box (CJB).
58. Install the cable bracket.
59. Connect the Evaporative Emission (EVAP) hose.
60. Install the speed control cable.
61. Install and adjust the accelerator cable.
1 Insert the cable into the bracket and install the plastic clamp.
- Install the cable.
- Install the spring.
- Check if the throttle is fully opened by depressing the accelerator pedal. Adjust if necessary.
2 Adjust: Pull out the clamp, depress the accelerator cable pedal fully. Install the clamp.
62. Install the Air Cleaner (ACL).
63. Fill up the transaxle with Transmission fluid.
64. Install the water pump pulley shield.
- Install the coolant hose.
65. Fill and bleed the power steering system.
66. Fill the engine cooling system.
NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.
67. Install the battery.
68. Check the routing of the vacuum hoses and wiring and secure them with cable ties.
69. Check the fluid level after the road test and correct as necessary.