Installing an engine with a manual transmission

Special tool

	Engine Lifting Tool 303-122 (21068A)
	Radiator Hose Clamp Remover and Installer 303-397 (24-003)

General equipment:

• Technological plugs
• Assembly stand:
• Fixing clamp
• Repair zone crane

Installation

All cars

1. General notes:

• If necessary, use special tool 303-397 to install and remove coolant hoses and vent hoses.
• The location of the engine mounts in the description is indicated based on the view directed from the gearbox towards the engine.

2.

CAUTION: Make sure that two guide bushings are installed.

Connect the engine and gearbox.

3. Install the left flange bolts.



4. Install the right flange bolts. Connect the shift cable bracket.



5. Install the engine assembly with the gearbox on the assembly stand. Support the gearbox with wooden blocks and secure it with a clamp.


6. Disconnect the special tool.



7. Connect the vehicle speed sensor (VSS) connector.



8. Connect the reversing light switch connector.



9. Raise the vehicle. Refer to Section 100-02 for additional information.

10. Place the engine and gearbox assembly on the assembly stand under the vehicle.


11. Lower the vehicle and position the engine and gearbox assembly into the engine compartment.

12. Install the rear engine mount.

• Tighten the middle nut.
• Tighten the engine mount nuts.

13. Install the front engine mount.



14. Remove the retaining clamp.

15. Raise the vehicle. Refer to Section 100-02 for additional information. Remove the assembly stand from under the engine/transmission assembly.

16. Connect the clutch master cylinder line.



17.

CAUTION: The inner hinge should not be deflected at an angle exceeding 18 degrees. The outer hinge should not be deflected at an angle exceeding 45 degrees.

Install the left front axle shaft into the gearbox. Remove the service plugs from the gearbox holes.



18.

NOTE: Replace the clamp and nuts on the intermediate bearing.

NOTE: Insert the intermediate shaft into the gearbox so that the intermediate shaft bearing rests against the rib of the intermediate shaft bracket.

Install the front axle shaft with the intermediate shaft. Remove the technological plugs from the gearbox holes.



19. Install the engine roll limiter.



Cars with air conditioning system


20. Connect the power steering pump bracket to the drive belt tensioner.



All cars

21. Connect the ball joints of the lower suspension arms on both sides.



22. Install the gear shift cable and gear selector cable.



23. Connect the heated oxygen sensor (HO2S) connector.



24. Connect the plug connector of the crankshaft position sensor (CKP sensor).



25. Connect the oil pressure switch plug connector.



26. Connect the exhaust manifold to the exhaust pipe.

• Connect the exhaust manifold to the cylinder head.
• Use new gaskets.

27. Remove the temporary flexible exhaust pipe support.

28. Install the starter ground cable.



Cars without air conditioning

29. Connect the power steering pump to the support plate. Remove the clamp.



30. Connect the power steering hydraulic line bracket.



Cars with air conditioning system

31. Connect the air conditioning compressor.



32. Install the power steering high pressure line bracket.



All cars

33. Install the drive belt and tighten it.



34. Install the drive belt cover.



35. Lower the vehicle.

36. Install the coolant hose.



37. Connect the carbon filter vacuum line.



38. Connect the coolant and heating hoses.

• 1. Cooling system expansion tank hose
• 2.Heater hose
• 3.Coolant hose

Cars without air conditioning

39. Connect the plug connector and connect the wire.

• 1. Connect the electrical wiring to the generator.
• 2.Install the power steering pump connector.

Cars with air conditioning system

40. Connect the electrical wiring to the generator.



All cars

41. Connect the heater hose.



42. Connect the hoses and fit the plug connector.

• 1.Vacuum hose - fuel pressure control
• 2. Brake booster vacuum hose

43. Connect the engine wiring harness connector. Secure the gear shift cables.



44. Connect the plug connector.

• 1. Ignition coil (EI)
• 2. Capacitor

45.

NOTE: Use a new exhaust manifold gasket.

Connect the exhaust manifold (shown from below).



46. Connect the exhaust manifold heat shield and engine ground cable.

• 1.Heat shield for exhaust manifold
• 2.Engine ground cable

47. Connect the fuel lines.



48. Connect the engine wiring harness plug connector and the camshaft position (CMP) sensor plug connector.



49. Connect the accelerator cable.

• 1. Fix the clamp.
• 2. Secure the cable to the bracket.

50. Install the intake manifold.



51. Install the air filter with the air intake hose.

• 1.Air intake hose
• 2. Connect the mass air flow (MAF) sensor connector.
• Connect the PCV hose to the cylinder head.

52. Secure the power steering fluid reservoir.



53. Tighten the nuts of the upper supports of the left and right suspension struts.



54. Install the battery shelf.

• 1. Fix and connect the plug connector.
• 2. Tighten the bolts.
• 3. Secure the wiring harness.

55. Install a new oil filter.

56. Fill engine oil according to specification.

57. Standard finishing operations:

• Fill with coolant. Refer to Section 303-03 for additional information.
• Bleed the hydraulic clutch system. Refer to Section 308-00 for additional information.
• Check the engine oil level.
• Install the battery. For additional information, refer to Section 414-01.
• If necessary, secure the cable using cable ties.
• Check the fluid levels again and adjust them if necessary.