Installation

1NZ-FE ENGINE MECHANICAL: ENGINE ASSEMBLY:

INSTALLATION

1. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

(a) Install the drive shaft heat insulator sub-assembly with the bolt and nut.
Torque: 18 Nm (183 kgf-cm, 13 ft-lbf)
2. INSTALL EXHAUST MANIFOLD

(a) Tighten the exhaust manifold nuts and bolts, in the order shown in the illustration, through a new gasket.
Torque: 27 Nm (275 kgf-cm, 20 ft-lbf)
3. INSTALL MANIFOLD SUPPORT BRACKET
(a) Install the manifold bracket with the 3 bolts.
Torque: 44 Nm (449 kgf-cm, 33 ft-lbf)
4. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
(a) Install the exhaust manifold insulator with the 4 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 in-lbf)
5. INSTALL WIRE HARNESS CLAMP BRACKET

(a) Install the 2 wire harness clamp brackets with the 2 bolts.
Torque: 10 Nm (102 kgf-cm, 89 in-lbf)
6. INSTALL ENGINE WIRE
(a) Connect all the sensor connectors and wire harness clamps to the engine assembly and install the engine wire harness.
7. INSTALL BOOSTER VACUUM TUBE

(a) Install the booster vacuum tube with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
8. INSTALL WATER BY-PASS PIPE NO. 1

(a) Install water by-pass pipe No. 1 through a new gasket with the 2 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
9. INSTALL INTAKE MANIFOLD
(a) Install a new gasket onto the intake manifold.

(b) Provisionally tighten the intake manifold nuts and bolts in the order shown in the illustration, and then tighten them to the specified torque.
Torque: 30 Nm (306 kgf-cm, 22 ft-lbf)
(c) Connect the engine wire to the intake manifold.

(d) Connect the water by-pass hose to water bypass pipe No. 1.

(e) Connect the water by-pass hose to the cylinder head.
(f) Connect the union to connector tube hose to the booster vacuum tube.
(g) Connect the throttle with motor body assembly connector.
10. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY
11. INSTALL GENERATOR ASSEMBLY

12. INSTALL IGNITION COIL NO.1 Installation

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

(a) Hold the crankshaft with SST.
SST: 09960-10010
09962-01000
09963-01000
(b) Clean the 6 bolts and their holes.

(c) Apply adhesive to the end 2 or 3 threads of the bolts.
Adhesive:
Part No. 08833-0070, three bond 1324 or the equivalent.
(d) Install the drive plate spacer RR, drive plate and ring gear sub-assembly and drive plate spacer FR.

(e) Install and uniformly tighten the 6 bolts in several steps, in the sequence shown in the illustration.
Torque: 88 Nm (900 kgf-cm, 65 ft-lbf)
NOTICE: Do not start the engine for at least 1 hour after performing the installation.

14. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle)

(a) Make sure that the knock pin is installed on the engine side.
(b) Install the automatic transaxle with torque converter with the 7 bolts.
Torque: 30 Nm (301 kgf-cm, 22 ft-lbf)
CAUTION: Make sure that the torque converter rotates.

15. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)

(a) Hold the crankshaft with SST.
SST: 09960-10010
09962-01000
09963-01000
(b) Clean the 6 bolts and their holes.

(c) Apply adhesive to the end 2 or 3 threads of new bolts.
Adhesive:
Part No. 08833-0070, three bond 1324 or the equivalent.

(d) Install the flywheel with the 6 bolts in the order shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 38 ft-lbf)
(e) Mark a paint mark on each bolt head on the engine upper side.

(f) Tighten the bolts 90° in the sequence shown in the illustration.
NOTICE: Do not start the engine for at least 1 hour after performing the installation.

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

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

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

19. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle) Installation

20. INSTALL CONTROL CABLE BRACKET (for Manual Transaxle) Installation

21. INSTALL STARTER ASSEMBLY

22. INSTALL FLYWHEEL HOUSING SIDE COVER

23. CONNECT HEATER WATER INLET HOSE A
(a) Connect heater water inlet hose A to the cylinder head.
24. INSTALL WATER FILLER SUB-ASSEMBLY
(a) Connect radiator hose No. 1 to the cylinder head.
(b) Install the water filler sub-assembly with the 2 nuts.
Torque: 7.5 Nm (76 kgf-cm, 66 in-lbf)
(c) Connect radiator hose No. 1 to the water filler.
25. INSTALL FUEL TUBE SUB-ASSEMBLY

(a) Connect the fuel tube connector and pipe and install fuel pipe clamp No. 2.
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 the tip of the pipe. After connecting, pull the pipe and connector to make sure that they are securely connected.

26. INSTALL VENTILATION HOSE NO. 2
(a) Install ventilation hose No. 2 with the clip.
27. INSTALL VENTILATION HOSE
(a) Install the ventilation hose with the clip.
28. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
(a) Install the engine moving control rod with the through bolt.
Torque: 120 Nm (1,224 kgf-cm, 89 ft-lbf)
(b) Remove the 2 bolts and remove the 2 engine hangers.
(c) Install the oxygen sensor wiring bracket with the bolt.
Torque: 60 Nm (612 kgf-cm, 44 ft-lbf)
(d) Install the radio setting condenser with the bolt.
Torque: 40 Nm (408 kgf-cm, 30 ft-lbf)
29. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE (for Hatchback)

(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.

(d) Install the engine mounting insulator RH with the 5 bolts and nut.
Torque: 45 Nm (459 kgf-cm, 33 ft-lbf)
Torque: 52 Nm (530 kgf-cm, 38 ft-lbf)
Torque: 52 Nm (530 kgf-cm, 38 ft-lbf)
(e) Operate the engine lifter and provisionally install the front suspension crossmember onto the vehicle with the 6 bolts.
(f) Insert SST into the datum holes in the front suspension crossmembers RH and LH alternately and tighten bolts A, B and C on both sides in several sequences.

SST: 09670-00010
Torque: 70 Nm (714 kgf-cm, 52 ft-lbf)
Torque: 160 Nm (1,631 kgf-cm, 118 ft-lbf)
Torque: 95 Nm (969 kgf-cm, 70 ft-lbf)
CAUTION:
- Insert SST into the datum hole vertically.
- If impossible to insert SST vertically, loosen all the bolts and then insert SST again.

30. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE (for Sedan)

(d) Install the engine mounting insulator RH with the 5 bolts and nut.
Torque: 52 Nm (530 kgf-cm, 38 ft-lbf)

(e) Operate the engine lifter and provisionally install the engine assembly with transaxle and front suspension crossmember onto the vehicle with the 6 bolts.
(f) Insert SST into the datum holes of the front suspension crossmembers RH and LH alternately and tighten bolts A, B and C on both sides in several sequences.
SST: 09670-00010
Torque: 70 Nm (714 kgf-cm, 52 ft-lbf)
Torque: 160 Nm (1,631 kgf-cm, 118 ft-lbf)
Torque: 95 Nm (969 kgf-cm, 70 ft-lbf)
CAUTION:
- Insert SST into the datum hole vertically.
- If impossible to insert SST vertically, loosen all the bolts and then insert SST again.

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

(a) Tighten the 6 torque converter set bolts.
Torque: 27 Nm (275 kgf-cm, 20 ft-lbf)
32. INSTALL FLYWHEEL HOUSING UNDER COVER
33. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH Installation

34. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH Installation

35. INSTALL FRONT AXLE ASSEMBLY LH Installation

36. INSTALL FRONT AXLE ASSEMBLY RH Installation

37. INSTALL FRONT STABILIZER LINK ASSEMBLY LH Installation

38. INSTALL FRONT STABILIZER LINK ASSEMBLY RH Installation

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

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

41. INSTALL TIE ROD END SUB-ASSEMBLY LH Installation

42. INSTALL TIE ROD END SUB-ASSEMBLY RH Installation

43. INSTALL SPEED SENSOR FRONT LH (w/ ABS) Installation

44. INSTALL SPEED SENSOR FRONT RH (w/ ABS) Installation

45. INSTALL FRONT AXLE SHAFT LH NUT Installation

46. INSTALL FRONT AXLE SHAFT RH NUT Installation

47. INSTALL EXHAUST PIPE ASSEMBLY FRONT Installation

48. INSTALL HEATED OXYGEN SENSOR Installation

49. INSTALL CONSOLE BOX ASSEMBLY REAR

50. INSTALL CONSOLE BOX REAR COVER (for Hatchback)

51. INSTALL SHIFTING HOLE COVER SUB-ASSEMBLY (for Manual Transaxle)

52. INSTALL CONSOLE BOX CARPET (for Sedan)

53. INSTALL CONSOLE UPPER REAR PANEL SUB-ASSEMBLY (for Sedan)

54. INSTALL UPPER CONSOLE PANEL SUB-ASSEMBLY (for Sedan)

55. INSTALL INSTRUMENT PAD LOWER LH (for Sedan)

56. INSTALL INSTRUMENT PANEL FINISH PANEL END LH (for Sedan)

57. INSTALL INSTRUMENT PANEL FINISH PANEL LOWER CENTER (for Sedan)

58. INSTALL SHIFT LEVER KNOB SUB-ASSEMBLY (for Manual Transaxle)
59. INSTALL STEERING COLUMN HOLE COVER SUB-ASSEMBLY NO. 1

60. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY

61. INSTALL COLUMN HOLE COVER SILENCER SHEET

62. CONNECT ENGINE WIRE

(a) Install the earth wire of the engine room wire harness with the bolt.

(b) Connect the 2 engine wire harness connectors and wire harness clamp to the engine room junction block.

(c) Connect the engine wire harness connector to the ECM.
63. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle) Installation

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

65. INSTALL FAN AND GENERATOR V BELT Installation

66. ADJUST FAN AND GENERATOR V BELT Installation

67. CONNECT FUEL TUBE SUB-ASSEMBLY

(a) Connect the fuel tube connector and fuel pipe, and install fuel pipe clamp No. 1.
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 the tip of the pipe. After connecting, pull the pipe and connector to make sure that they are securely connected.

68. CONNECT HEATER WATER INLET HOSE A

(a) Connect heater water inlet hose A to the heater unit.
69. CONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)

(a) Connect heater water outlet hose A to the heater unit.
70. CONNECT UNION TO CHECK VALVE HOSE
(a) Connect the union to check valve hose to the booster vacuum tube.
71. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)

72. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle) Installation

73. INSTALL CYLINDER HEAD COVER NO. 2 Installation

74. CONNECT OIL COOLER INLET HOSE (for Automatic Transaxle)

(a) Connect the oil cooler inlet hose with the clip.
75. CONNECT OIL COOLER OUTLET HOSE (for Automatic Transaxle)

(a) Connect the oil cooler outlet hose with the clip.
76. CONNECT RADIATOR HOSE NO. 2

(a) Connect radiator hose No. 2 to the water inlet.
77. CONNECT RADIATOR RESERVOIR TANK HOSE

(a) Connect the radiator reservoir tank hose to the water filler.
78. CONNECT RADIATOR HOSE NO. 3

(a) Connect radiator hose No. 3 to the water filler.
79. INSTALL BATTERY CARRIER

(a) Install the battery carrier with the 5 bolts.
Torque: 17 Nm (173 kgf-cm, 13 ft-lbf)
(b) Install the clamp.
80. INSTALL AIR CLEANER BRACKET

(a) Install the air cleaner bracket with the 2 bolts.
Torque: 19 Nm (194 kgf-cm, 14 ft-lbf)
(b) Connect the wire harness clamp to the air cleaner bracket.
81. INSTALL AIR CLEANER ASSEMBLY

(a) Install the air cleaner case with air cleaner inlet No. 1 with the 2 bolts.
Torque: 7.8 Nm (80 kgf-cm, 69 in-lbf)
(b) Connect the wire harness to the air cleaner case.
(c) Install the air cleaner element.

(d) Install and lock the air cleaner cap and the air cleaner hose and then tighten the air cleaner hose clamp.
Torque: 4.0 Nm (41 kgf-cm, 35 in-lbf)
(e) Connect the ventilation hose to the air cleaner hose.
(f) Connect the vacuum switching valve connector and the wire harness clamp.
(g) Connect the fuel vapor feed hose and fuel vapor feed hose No. 1 to the vacuum switching valve assembly.
(h) Connect the intake air flow meter connector and the wire harness clamp.
82. INSTALL COWL TOP PANEL OUTER (for Hatchback)

(a) Install the cowl top panel with the 9 bolts.
Torque: 6.5 Nm (66 kgf-cm, 58 in-lbf)

(b) Connect the wire harness clamp.
83. INSTALL COWL TOP PANEL OUTER (for Sedan)

(a) Install the cowl top panel outer with the 8 bolts.
Torque: 6.5 Nm (66 kgf-cm, 58 in-lbf)

(b) Install the cowl top to cowl inner brace with the 2 bolts.
Torque: 6.5 Nm (66 kgf-cm, 58 in-lbf)

(a) Engage the claw and install cowl to register duct No. 2.
85. INSTALL FRONT AIR SHUTTER SEAL RH (for Sedan)

(a) Engage the 3 claws to install the front air shutter seal RH.
86. INSTALL FRONT WIPER MOTOR AND LINK

87. INSTALL COWL TOP VENTILATOR LOUVER LH (for Hatchback)

88. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for Hatchback)

89. INSTALL HOOD TO COWL TOP SEAL (for Hatchback)

90. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY (for Sedan)

91. INSTALL COWL SIDE VENTILATOR SUB-ASSEMBLY LH (for Sedan)

92. INSTALL COWL SIDE VENTILATOR SUB-ASSEMBLY RH (for Sedan)

93. INSTALL FRONT WIPER ARM LH

94. INSTALL FRONT WIPER ARM RH

95. INSTALL FRONT WIPER ARM HEAD CAP

96. INSTALL BATTERY TRAY
97. INSTALL BATTERY
(a) Install the battery onto the vehicle with the battery clamp.
Torque: 3.5 Nm (36 kgf-cm, 31 in-lbf)
(b) Connect the cable to the battery terminal.
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
98. ADD ENGINE COOLANT Service and Repair

99. ADD AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) Installation

100. INSPECT AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle) Procedures

101. ADD MANUAL TRANSAXLE OIL (for Manual Transaxle)
102. INSPECT MANUAL TRANSAXLE OIL (for Manual Transaxle) Testing and Inspection

103. INSPECT FAN AND GENERATOR V BELT Installation

104. CHECK FOR FUEL LEAKAGE Testing and Inspection

105. CHECK FOR ENGINE OIL LEAKAGE
106. CHECK FOR EXHAUST GAS LEAKAGE
107. CHECK FOR ENGINE COOLANT LEAKAGE Testing and Inspection

108. INSTALL ENGINE UNDER COVER RH
109. INSTALL ENGINE UNDER COVER LH
110. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76 ft-lbf)
111. INSPECT IGNITION TIMING Engine

112. INSPECT ENGINE IDLING SPEED Engine

113. INSPECT CO/HC Engine

114. INSPECT FRONT WHEEL ALIGNMENT
115. INSPECT ABS SENSOR SIGNAL (w/ ABS)