Special tool
 | Clamp remover/installer 303-397 (24-003) |
General equipment:
- Crafting table
- Fixing clamp
| Name | Specification |
| Extreme pressure lubricant | SAM-1C9107-A |
All cars
1.
WARNING: Do not smoke or walk with a lit cigarette or any type of open flame while working on or near fuel related items. In such situations, there are always highly flammable mixtures that can ignite. Failure to follow these instructions may result in injury.
Install the gearbox in the block with the drive axle on the engine.
2. Raise and support the vehicle. Refer to Section 100-02 for more information.
3.
WARNING: Install the engine/gearbox assembly in the drive axle assembly on blocks of wood. Failure to follow this instruction may result in injury.
CAUTION: Support the engine under the oil sump flange.
Using suitable clamps, secure the engine/gearbox assembly to the drive axle assembly on a workbench and position the unit under the vehicle.
4. Install the rear engine mount.
Vehicles manufactured up to 04.2001
5. Install the front engine mount.
Vehicles manufactured since 04.2001
6. Install the front engine mount.
All cars
7. Connect starter harness bracket and engine ground cable to transaxle case.
8. Connect the high pressure pipe to the clutch slave cylinder.
- 1.Install the clip.
- 2.Connect the bracket with rubber sealing rings.
9.
CAUTION: Secure the axle shaft to prevent damage to the CV joints. The internal constant velocity joint should not be deflected by more than 18 degrees. External hinge - at an angle exceeding 45 degrees.
CAUTION: Check that the shaft seal is not damaged.
Connect the left axle shaft to the gearbox in the block with the drive axle.
10.
CAUTION: Secure the axle shaft to prevent damage to the CV joints. The internal constant velocity joint should not be deflected by more than 18 degrees. External hinge - at an angle exceeding 45 degrees.
CAUTION: Check that the shaft seal is not damaged.
NOTE: Install a new intermediate bearing bearing cap and locknut.
Connect the right axle shaft to the transaxle, and install the bearing cover.
11. Install the engine mount.
12.
NOTE: Use new nuts.
Connect the flexible connector to the exhaust system. Apply anti-seize lubricant to the studs.
13. Remove the support bar from the flexible connector.
14. Connect the shift cables to the gearbox in the block with the drive axle.
- 1. Release the support sleeve by turning it counterclockwise and install the selector cable into the bracket.
- 2. Connect the selector cable to the selector lever.
- 3. Loosen the support sleeve by turning it counterclockwise and install the shift cable.
- 4. Connect the shift cable to the shift lever.
- 5.Install the adjustment mechanism by pressing on the appropriate tabs.
15. Install the radiator support bracket and radiator (left side shown).
16. Connect the starter connector and connect the power cable.
17.
NOTE: Use a new nut.
Connect the left tie rod end.
18.
CAUTION: Using a soft cloth, cover the ball joint seal.
Connect the lower control arms to the steering knuckles (left side shown).
19. Connect the vehicle's anti-roll bar on the left side.
20. Install the left front wheel and tire assembly. Refer to Section 204-04 for more information.
21. Using the special tool, connect the return hose to the power steering pump.
22. Using the special tool, connect the coolant hose to the oil cooler.
Vehicles with air conditioning
23. Connect the air conditioning compressor (four bolts).
24. Connect the air conditioning compressor connector and connect it to the air conditioning compressor.
All cars
25. Connect the horn connector and horn wiring harness.
26. Install accessory drive belt. Refer to Section 303-05 for more information.
27. Lower the car.
Vehicles equipped with an air conditioning system
28. Disconnect the air conditioning heat exchanger.
All cars
29. Connect the cooling fan connector and connect the cooling fan harness to the cooling fan shroud.
30. Install the expansion tank of the cooling system.
31. Using the special tool, connect the lower coolant hose to the coolant expansion tank.
32. Connect the fuel supply and return fuel quick couplers. Refer to Section 310-00 for more information.
33. Connect the supply and return fuel lines to the appropriate bracket.
34. Fix a tank of a working liquid of the amplifier of a steering.
35. Connect the power steering high pressure line to the bracket.
36. Connect the power steering high pressure pipe bracket to the lift lug.
37. Connect the power steering high pressure pipe bracket to the timing belt cover stud.
38. Connect the power steering high pressure line to the power steering pump.
Vehicles without Common Rail Fuel Injection
39. Disconnect the high pressure fuel pump connector.
40. Connect the vacuum hoses to the EGR valve (EGR) and connect the appropriate plug connector.
Vehicles with EGR cooler
41. Using the special tool, connect the upper coolant hose to the EGR cooler.
Vehicles with Common Rail Fuel Injection
42. Connect the electronic vacuum control valve support bracket to the intake manifold.
43. Connect the EGR vacuum hose.
44. Connect the EGR vacuum hose to the EGR valve.
45. Connect the plug connector of the injector control module.
All cars
46. Connect the engine wiring harness.
47. Connect the vacuum hose to the vacuum diaphragm unit.
48. Connect the generator plug and connect the generator power cable.
49. Establish a cover of an electric socket of the generator.
50. Using the special tool, connect the coolant hoses to the thermostat housing and to the coolant distribution pipe.
Vehicles with Common Rail Fuel Injection
51. Connect the high fuel pressure sensor connector.
All cars
52.
NOTE: Use a new gasket.
Install the thermostat housing.
53. Using the special tool, connect the upper coolant hose to the thermostat housing.
54. Connect the vacuum pipeline to the vacuum pump of the vacuum amplifier of brakes.
55. Connect the dipstick of the oil level indicator.
56. Connect the glow plug wire terminal block.
57. Connect the glow plug power wire to the glow plug wire terminal block.
58. Install air intake piping.
59. Install the air filter outlet pipe.
60. Install the charge air cooler.
61. Connect the plug connector of the air intake temperature sensor (IAT).
62. Install the charge air cooler duct.
63. Install the charge air cooler inlet and outlet pipes.
64. Install the engine top cover.
65. Tighten the nuts of the upper support of the rack assembly with the spring (at both sides).
66. Install the air filter. See Section 303-12 for more information.
67. Fill in coolant in the cooling system and remove air from the system. See Section 303-03 for more information.
68. Add working fluid to the power steering system and remove air from the system. See Section 211-00 for more information.
69. Adjust shift cables. See Section 308-00 for more information.
70. Install the battery shelf and connect the battery. See Section 414-01 for more information.
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