Suzuki Esteem, Swift 1994-02

Engine

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NOTE
Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer systems and may require the computer to undergo a relearning process, once the negative battery cable is reconnected.

Removal & Installation



1.3L Engine

CAUTION
The fuel injection system remains under pressure after the engine has been turned OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Battery and tray
     
    Windshield washer hose from the hood
     

  6.  
  7. Using a grease pencil or marker, mark the hood hinge to hood outline. With the aid of an assistant, remove the hood.
  8.  
  9. Drain the cooling system.
  10.  
  11. Remove or disconnect the following:

    Air cleaner assembly with the Mass Air Flow (MAF) sensor outlet hose
     
    Radiator and cooling fan
     

  12.  
  13. Disconnect the following electrical wires and release the wiring harness from the clamps:

    Ignition coil wire from the distributor cap, if equipped
     
    Distributor electrical wires, if equipped
     
    Ignition coil assembly, if equipped
     
    Exhaust Gas Recirculation (EGR) solenoid vacuum valve
     
    Radiator fan temperature switch
     
    Engine coolant temperature gauge sensor
     
    Engine Coolant Temperature (ECT) sensor
     
    Idle Air Control (IAC) actuator
     
    Ground wires from the intake manifold
     
    Throttle Position (TP) sensor
     
    Fuel injector
     
    Camshaft Position (CMP) sensor, if equipped
     
    Oxygen (O 2 S) sensor
     
    Oil pressure gauge sensor
     
    Alternator
     
    Starter
     
    Back-up light switch
     
    Negative battery cable from the transaxle
     
    Vehicle Speed Sensor (VSS)
     
    Noise filter ground wire
     
    Evaporative (EVAP) emission canister purge valve, if equipped
     

  14.  
  15. Disconnect the following vacuum hoses:

    Brake booster hose from the intake manifold
     
    Canister purge hose
     
    Air conditioning valve hose
     

  16.  
  17. Remove or disconnect the following:

    Fuel return hose and the fuel feed hose from the throttle body
     
    Heater inlet and outlet hoses
     

  18.  
  19. Disconnect the following cables:

    Accelerator cable from the throttle body
     
    Clutch cable from the transaxle, if equipped
     
    Speedometer cable from the transaxle, if equipped
     
    Shift switch, if equipped with an automatic transaxle
     
    VSS, if equipped
     

  20.  
  21. Remove or disconnect the following:

    EVAP canister from the vehicle
     
    Fender apron extensions
     
    Exhaust pipe from the exhaust manifold
     
    Control shaft and extension rod from the transaxle
     

  22.  
  23. Drain the engine and transaxle oil.
  24.  
  25. Remove or disconnect the following:
    NOTE
    For engine and transaxle removal, it is not necessary to remove the halfshafts from the steering knuckles.



    Left and right halfshafts
     

  26.  
  27. Remove or disconnect the following:
    NOTE
    Suspend the compressor where no damage will occur during engine removal and installation.



    Air conditioning compressor from its mounting bracket with the hoses still attached, if equipped with air conditioning
     

  28.  
  29. Remove or disconnect the following:
    NOTE
    Plug the power steering hose, pipe and pump ports to minimize fluid loss.



    Power steering hoses from the power steering pump, if equipped
     



    Rear torque rod bracket from the transaxle, if equipped with an automatic transaxle
     
    Rear mount from the body, if equipped with a manual transaxle
     

  30.  
  31. If equipped with an automatic transaxle, remove the rear mounting nut.
  32.  
  33. Install an engine lifting device.
  34.  
  35. Remove or disconnect the following:

    Rear mount from the body
     
    Left side engine mounting bracket bolts and bracket
     
    Right side engine mount from its bracket
     

  36.  
  37. Before lifting the engine and assembly check to be sure that all the hoses, electric wires and cables are disconnected.
  38.  
  39. Remove the engine with the transaxle from the vehicle.
  40.  

To install:

  1. Lower the engine and transaxle into the engine compartment but do not remove the lifting device.
  2.  
  3. Install or connect the following:

    Rear mount to the body
     
    Left side engine mounting bracket and bolts
     
    Right side engine mount to its bracket
     
    Rear mounting nut, if equipped with an automatic transaxle
     

  4.  
  5. Tighten the engine mounting nuts and bolts to specification.

    Lifting device
     
    A/C compressor on its mounting bracket, if equipped. Tighten the mounting bolts to 13-20 ft. lbs. (18-28 Nm).
     
    Power steering hose and pipe to the power steering pump, if equipped
     
    Left and right halfshafts
     
    Control shaft and the extension rod to the transaxle. Tighten the control shaft nuts and bolts to 11-14 ft. lbs. (15-20 Nm) and tighten the extension rod nut to 19-29 ft. lbs. (25-40 Nm).
     
    Exhaust pipe to the exhaust manifold. Tighten the bolts to 29-36 ft. lbs. (40-50 Nm)
     

  6.  
  7. Fill the transaxle with gear oil.
  8.  
  9. Install the remaining components in the reverse order of removal.
  10.  
  11. Adjust the clutch pedal free-play.
  12.  
  13. Adjust the accelerator cable free-play.
  14.  
  15. Fill the engine with engine oil and the cooling system with coolant.
  16.  
  17. Fill the power steering reservoir and bleed the power steering system.
  18.  
  19. Run the engine and verify that there are no fuel, coolant, transmission or exhaust leaks.
  20.  


CAUTION
The fuel injection system remains under pressure after the engine has been turned OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Battery and tray
     
    Windshield washer hose from the hood
     

  6.  
  7. Using a grease pencil or marker, mark the hood hinge to hood outline. With the aid of an assistant, remove the hood.
  8.  
  9. Drain the cooling system.
  10.  
  11. Remove or disconnect the following:

    Air cleaner assembly with the Mass Air Flow (MAF) sensor outlet hose
     
    Radiator and cooling fan
     

  12.  
  13. Disconnect the following electrical wires and release the wiring harness from the clamps:

    Ignition coil wire from the distributor cap, if equipped
     
    Distributor electrical wires, if equipped
     
    Ignition coil assembly, if equipped
     
    Exhaust Gas Recirculation (EGR) solenoid vacuum valve
     
    Radiator fan temperature switch
     
    Engine coolant temperature gauge sensor
     
    Engine Coolant Temperature (ECT) sensor
     
    Idle Air Control (IAC) actuator
     
    Ground wires from the intake manifold
     
    Throttle Position (TP) sensor
     
    Fuel injector
     
    Camshaft Position (CMP) sensor, if equipped
     
    Oxygen (O 2 S) sensor
     
    Oil pressure gauge sensor
     
    Alternator
     
    Starter
     
    Back-up light switch
     
    Negative battery cable from the transaxle
     
    Vehicle Speed Sensor (VSS)
     
    Noise filter ground wire
     
    Evaporative (EVAP) emission canister purge valve, if equipped
     

  14.  
  15. Disconnect the following vacuum hoses:

    Brake booster hose from the intake manifold
     
    Canister purge hose
     
    Air conditioning valve hose
     

  16.  
  17. Remove or disconnect the following:

    Fuel return hose and the fuel feed hose from the throttle body
     
    Heater inlet and outlet hoses
     

  18.  
  19. Disconnect the following cables:

    Accelerator cable from the throttle body
     
    Clutch cable from the transaxle, if equipped
     
    Speedometer cable from the transaxle, if equipped
     
    Shift switch, if equipped with an automatic transaxle
     
    VSS, if equipped
     

  20.  
  21. Remove or disconnect the following:

    EVAP canister from the vehicle
     
    Fender apron extensions
     
    Exhaust pipe from the exhaust manifold
     
    Control shaft and extension rod from the transaxle
     

  22.  
  23. Drain the engine and transaxle oil.
  24.  
  25. Remove or disconnect the following:
    NOTE
    For engine and transaxle removal, it is not necessary to remove the halfshafts from the steering knuckles.



    Left and right halfshafts
     

  26.  
  27. Remove or disconnect the following:
    NOTE
    Suspend the compressor where no damage will occur during engine removal and installation.



    Air conditioning compressor from its mounting bracket with the hoses still attached, if equipped with air conditioning
     

  28.  
  29. Remove or disconnect the following:
    NOTE
    Plug the power steering hose, pipe and pump ports to minimize fluid loss.



    Power steering hoses from the power steering pump, if equipped
     



    Rear torque rod bracket from the transaxle, if equipped with an automatic transaxle
     
    Rear mount from the body, if equipped with a manual transaxle
     

  30.  
  31. If equipped with an automatic transaxle, remove the rear mounting nut.
  32.  
  33. Install an engine lifting device.
  34.  
  35. Remove or disconnect the following:

    Rear mount from the body
     
    Left side engine mounting bracket bolts and bracket
     
    Right side engine mount from its bracket
     

  36.  
  37. Before lifting the engine and assembly check to be sure that all the hoses, electric wires and cables are disconnected.
  38.  
  39. Remove the engine with the transaxle from the vehicle.
  40.  

To install:

  1. Lower the engine and transaxle into the engine compartment but do not remove the lifting device.
  2.  
  3. Install or connect the following:

    Rear mount to the body
     
    Left side engine mounting bracket and bolts
     
    Right side engine mount to its bracket
     
    Rear mounting nut, if equipped with an automatic transaxle
     

  4.  
  5. Tighten the engine mounting nuts and bolts to specification.

    Lifting device
     
    A/C compressor on its mounting bracket, if equipped. Tighten the mounting bolts to 13-20 ft. lbs. (18-28 Nm).
     
    Power steering hose and pipe to the power steering pump, if equipped
     
    Left and right halfshafts
     
    Control shaft and the extension rod to the transaxle. Tighten the control shaft nuts and bolts to 11-14 ft. lbs. (15-20 Nm) and tighten the extension rod nut to 19-29 ft. lbs. (25-40 Nm).
     
    Exhaust pipe to the exhaust manifold. Tighten the bolts to 29-36 ft. lbs. (40-50 Nm)
     

  6.  
  7. Fill the transaxle with gear oil.
  8.  
  9. Install the remaining components in the reverse order of removal.
  10.  
  11. Adjust the clutch pedal free-play.
  12.  
  13. Adjust the accelerator cable free-play.
  14.  
  15. Fill the engine with engine oil and the cooling system with coolant.
  16.  
  17. Fill the power steering reservoir and bleed the power steering system.
  18.  
  19. Run the engine and verify that there are no fuel, coolant, transmission or exhaust leaks.
  20.  

1.6L Engine

CAUTION
The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in personal injury.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Mark the position of the hood on the hinges for installation reference, then remove the hood with the aid of an assistant.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Radiator and cooling fan
     
    Air cleaner outlet hose
     
    Air cleaner case bolts and case
     

  10.  
  11. Disconnect the following cables:

    Accelerator cable from the throttle body
     
    Clutch cable from the transaxle, if equipped with manual transmission
     
    Gear select cable from the transaxle, if equipped with automatic transmission
     

  12.  
  13. Disconnect the following vacuum hoses:

    Brake booster hose from the intake manifold
     
    Canister purge hose from the Evaporative (EVAP) emission canister purge valve
     
    Manifold Absolute Pressure (MAP) sensor hose from the intake manifold
     

  14.  
  15. Disconnect the following electrical connectors:

    Distributor coil wire, if equipped
     
    Ignition coils, if equipped
     
    Camshaft Position (CKP) sensor
     
    Engine oil pressure switch
     
    Exhaust Gas Recirculation (EGR) solenoid vacuum valve
     
    EVAP canister purge valve
     
    Engine Coolant Temperature (ECT) sensor
     
    Fuel injectors
     
    Power steering pressure switch
     
    Heated Oxygen Sensor (HO 2 S)
     
    Back-up light switch, manual transmission
     
    Shift switch, automatic transmission
     
    Forward clutch revolution sensor, automatic transmission
     
    Automatic transmission Vehicle Speed Sensor (VSS)
     
    Alternator
     
    Starter
     
    Battery negative cable from the transaxle
     
    Throttle Position (TP) sensor
     
    Idle Air Control (IAC) valve
     
    Manifold Absolute Pressure (MAP) sensor
     
    Crankshaft Position (CKP) sensor, if equipped
     
    All engine wires from the engine
     

  16.  
  17. Remove or disconnect the following:

    Fuel feed hose from the feed pipe
     
    Return hose from the fuel pressure regulator
     
    Heater inlet and outlet hoses
     
    Right and left engine undercovers
     
    Front exhaust pipe from the exhaust manifold and center exhaust pipe
     
    Gear shift control shaft from the transaxle and the extension rod, if equipped with a manual transaxle
     

  18.  
  19. Drain the engine and transaxle oil.
  20.  
  21. Remove or disconnect the following:

    Left and right halfshafts
     
    A/C compressor from the compressor bracket with the hoses still attached, if equipped. Position the air conditioning out of the way from the engine.
     

  22.  
  23. If equipped with power steering, drain the power steering pump of fluid.
  24.  
  25. Remove or disconnect the following:

    Power steering hose from the power steering pump, if equipped
     

  26.  
  27. Install a lifting device on the engine.
  28.  
  29. Remove or disconnect the following:

    Center member from the vehicle by unfastening the 7 nuts and 4 bolts
     
    Left engine mount
     
    Right engine mount and bracket
     

  30.  
  31. Check to be sure all cooling hoses, vacuum hoses and electrical wires are disconnected from the engine.
  32.  
  33. Lower the engine with the transaxle from the vehicle.
  34.  

To install:

  1. Raise the engine and transaxle into the engine compartment.
  2.  
  3. Install or connect the following:

    Right engine mount with the bolts and nuts. Tighten the bolts and nuts to 40 ft. lbs. (55 Nm).
     
    Left engine mount and install the bolts and nuts. Tighten the bolts and nuts to 40 ft. lbs. (55 Nm).
     

  4.  
  5. Install the center member using the 7 nuts and 4 bolts. Tighten the bolts and nuts as follows:


    1. Center member to the radiator support: 33 ft. lbs. (45 Nm).
    2.  
    3. Center member to crossmember: 33 ft. lbs. (45 Nm).
    4.  
    5. Engine mounts to center member nuts: 40 ft. lbs. (55 Nm).
    6.  

  6.  
  7. Remove the lifting device.
  8.  
  9. Install or connect the following:

    Power steering hose to the power steering pump, if equipped
     
    A/C compressor on the air conditioning bracket on the engine, if equipped
     
    Left and right halfshafts
     
    Gear shift control shaft on the transaxle and the extension rod, if equipped with a manual transaxle
     
    Front exhaust pipe on the center exhaust pipe and exhaust manifold
     
    Remaining components in the reverse order of removal
     

  10.  
  11. Fill the cooling system, engine, transaxle and power steering pump.
  12.  
  13. Adjust all cables and check all connections.
  14.  
  15. Connect the negative battery cable to the battery.
  16.  
  17. Start the vehicle and check for leaks.
  18.  


CAUTION
The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in personal injury.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Mark the position of the hood on the hinges for installation reference, then remove the hood with the aid of an assistant.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Radiator and cooling fan
     
    Air cleaner outlet hose
     
    Air cleaner case bolts and case
     

  10.  
  11. Disconnect the following cables:

    Accelerator cable from the throttle body
     
    Clutch cable from the transaxle, if equipped with manual transmission
     
    Gear select cable from the transaxle, if equipped with automatic transmission
     

  12.  
  13. Disconnect the following vacuum hoses:

    Brake booster hose from the intake manifold
     
    Canister purge hose from the Evaporative (EVAP) emission canister purge valve
     
    Manifold Absolute Pressure (MAP) sensor hose from the intake manifold
     

  14.  
  15. Disconnect the following electrical connectors:

    Distributor coil wire, if equipped
     
    Ignition coils, if equipped
     
    Camshaft Position (CKP) sensor
     
    Engine oil pressure switch
     
    Exhaust Gas Recirculation (EGR) solenoid vacuum valve
     
    EVAP canister purge valve
     
    Engine Coolant Temperature (ECT) sensor
     
    Fuel injectors
     
    Power steering pressure switch
     
    Heated Oxygen Sensor (HO 2 S)
     
    Back-up light switch, manual transmission
     
    Shift switch, automatic transmission
     
    Forward clutch revolution sensor, automatic transmission
     
    Automatic transmission Vehicle Speed Sensor (VSS)
     
    Alternator
     
    Starter
     
    Battery negative cable from the transaxle
     
    Throttle Position (TP) sensor
     
    Idle Air Control (IAC) valve
     
    Manifold Absolute Pressure (MAP) sensor
     
    Crankshaft Position (CKP) sensor, if equipped
     
    All engine wires from the engine
     

  16.  
  17. Remove or disconnect the following:

    Fuel feed hose from the feed pipe
     
    Return hose from the fuel pressure regulator
     
    Heater inlet and outlet hoses
     
    Right and left engine undercovers
     
    Front exhaust pipe from the exhaust manifold and center exhaust pipe
     
    Gear shift control shaft from the transaxle and the extension rod, if equipped with a manual transaxle
     

  18.  
  19. Drain the engine and transaxle oil.
  20.  
  21. Remove or disconnect the following:

    Left and right halfshafts
     
    A/C compressor from the compressor bracket with the hoses still attached, if equipped. Position the air conditioning out of the way from the engine.
     

  22.  
  23. If equipped with power steering, drain the power steering pump of fluid.
  24.  
  25. Remove or disconnect the following:

    Power steering hose from the power steering pump, if equipped
     

  26.  
  27. Install a lifting device on the engine.
  28.  
  29. Remove or disconnect the following:

    Center member from the vehicle by unfastening the 7 nuts and 4 bolts
     
    Left engine mount
     
    Right engine mount and bracket
     

  30.  
  31. Check to be sure all cooling hoses, vacuum hoses and electrical wires are disconnected from the engine.
  32.  
  33. Lower the engine with the transaxle from the vehicle.
  34.  

To install:

  1. Raise the engine and transaxle into the engine compartment.
  2.  
  3. Install or connect the following:

    Right engine mount with the bolts and nuts. Tighten the bolts and nuts to 40 ft. lbs. (55 Nm).
     
    Left engine mount and install the bolts and nuts. Tighten the bolts and nuts to 40 ft. lbs. (55 Nm).
     

  4.  
  5. Install the center member using the 7 nuts and 4 bolts. Tighten the bolts and nuts as follows:


    1. Center member to the radiator support: 33 ft. lbs. (45 Nm).
    2.  
    3. Center member to crossmember: 33 ft. lbs. (45 Nm).
    4.  
    5. Engine mounts to center member nuts: 40 ft. lbs. (55 Nm).
    6.  

  6.  
  7. Remove the lifting device.
  8.  
  9. Install or connect the following:

    Power steering hose to the power steering pump, if equipped
     
    A/C compressor on the air conditioning bracket on the engine, if equipped
     
    Left and right halfshafts
     
    Gear shift control shaft on the transaxle and the extension rod, if equipped with a manual transaxle
     
    Front exhaust pipe on the center exhaust pipe and exhaust manifold
     
    Remaining components in the reverse order of removal
     

  10.  
  11. Fill the cooling system, engine, transaxle and power steering pump.
  12.  
  13. Adjust all cables and check all connections.
  14.  
  15. Connect the negative battery cable to the battery.
  16.  
  17. Start the vehicle and check for leaks.
  18.  

1.8L Engine

CAUTION
The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in personal injury.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Mark the position of the hood on the hinges for installation reference, then remove the hood with the aid of an assistant.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove radiator with cooling fan.
  10.  
  11. Remove air cleaner outlet hose.
  12.  
  13. Remove air cleaner case by removing its fastening bolts.
  14.  
  15. Disconnect the following cables:

    Accelerator cable from throttle body
     
    Shift and select cable from transaxle (M/T)
     
    Clutch cable from transaxle (M/T)
     
    Gear select cable from transaxle (A/T)
     

  16.  
  17. Remove accelerator cable from bracket.
  18.  
  19. Disconnect the following hoses:

    Brake booster hose from intake manifold
     
    Coolant hoses from throttle body
     
    Fuel feed hose from delivery pipe
     
    Fuel return hose from return pipe
     
    Heater hose from water outlet cap
     
    Radiator inlet hose from water outlet cap
     
    Vacuum hose from EVAP canister purge valve
     

  20.  
  21. Disconnect the following electric wires:

    Injector wire
     
    CMP sensor connector
     
    Ignition coil wire
     
    TP sensor connector
     
    MAF sensor connector
     
    IAC valve connector
     
    MDP sensor connector
     
    Crankshaft position sensor connector
     
    Ground terminals from cylinder head and intake manifold
     
    EVAP canister purge valve connector
     
    EGR valve connector
     
    Heated oxygen sensor-1 wire
     
    Heated oxygen sensor-2 wire
     
    ECT sensor connector
     
    Alternator wires
     
    Starter wires
     
    Oil pressure switch wire
     
    Power steering pressure switch connector
     
    A/C magnetic switch wire
     
    Back-up light switch (M/T)
     
    Vehicle speed sensor
     
    Battery negative cable from transaxle
     
    Transmission range switch (A/T)
     
    Forward clutch revolution sensor (A/T)
     

  22.  
  23. Release above wire harness from clamps.
  24.  
  25. Remove clutch operating cylinder (slave cylinder) from transaxle with hose still attached (M/T). Suspend removed clutch operating cylinder at a place free from any possible damage during removal and installation of engine assembly.
  26.  
  27. Remove right and left engine under covers.
  28.  
  29. Remove exhaust No.1 pipe.
  30.  
  31. Drain engine and transmission oil.
  32.  
  33. Remove halfshafts. For engine and transmission removal, it is not necessary to remove drive shafts from steering knuckle.
  34.  
  35. Remove A/C compressor from compressor bracket with hoses still attached. Suspend removed compressor at a place free from any possible damage during removal and installation of engine assembly.
  36.  
  37. Install lifting device.
  38.  
  39. Remove mounting member from front member and suspension frame.
  40.  
  41. Remove engine left mounting from body.
  42.  
  43. Remove engine right mounting from right mounting bracket.
  44.  
  45. Remove P/S pump from bracket. Suspend removed P/S pump at a place free from any possible damage during removal and installation of engine assembly.
  46.  
  47. Before removing engine with transmission from body, recheck to make sure all hoses, electric wires and cables are disconnected from engine and transmission.
  48.  
  49. Lower engine with transaxle from body.
    NOTE
    Before lowering engine, to avoid damage to A/C compressor, raise it through clearance made on engine crankshaft pulley side. At this time, use care so that no excessive force is applied to hoses.

  50.  
  51. Disconnect transaxle from the engine.
  52.  
  53. Remove clutch cover and clutch disc.
  54.  

To install:

  1. Install clutch cover and clutch disc.
  2.  
  3. Connect transaxle assembly to engine.
  4.  
  5. Lift engine with transaxle into engine compartment, but do not remove lifting device.
  6.  
  7. Install engine right mounting to right mounting bracket and stiffener.
  8.  
  9. Install engine left mounting to body.
  10.  
  11. Install mounting member to front member and suspension frame.

    Click image to see an enlarged view

    Fig. 1.8L engine mounting members-Esteem

  12.  
  13. Tighten bolts and nuts of all parts installed in the previous three steps to specified torque:

    Mounting member, mounting and bracket bolt and nut (a)-40 ft. lbs. (55 Nm)
     
    Mounting and torque bush nut (b)-33 ft. lbs. (45 Nm)
     

  14.  
  15. Remove lifting device.
  16.  
  17. Reverse removal procedures for installation of remainder.
  18.  
  19. Install the halfshaft assemblies.
  20.  
  21. Clamp electric wires securely.
  22.  
  23. For M/T model, adjust gear shift cable as follows:


    1. With shift lever in NEUTRAL position, adjust shift cable adjusting nut so that distance between edge of instrument panel and center of shift knob measures 5.4 inches (137mm).
    2.  
    3. After shift cable adjustment, tighten lock nut securely to 4.5 ft. lbs. (6 Nm).
    4.  
    5. Make sure that boots are installed correctly.

      Click image to see an enlarged view

      Fig. Adjusting shift select cable (for M/T models)-1.8L engine

    6.  

  24.  
  25. For M/T model, adjust shift select cable as follows:


    1. With shift lever in NEUTRAL position, adjust select cable adjusting nut so that front side end surface (A) of select arm and rear side line of rib (B) are aligned.
    2.  
    3. After select cable adjustment, tighten lock nut securely to 4.5 ft. lbs. (6 Nm).
    4.  

  26.  
  27. Refill transaxle with gear oil (M/T), or Automatic Transmission Fluid-ATF (A/T).
  28.  
  29. Refill engine with engine oil.
  30.  
  31. Refill cooling system.
  32.  
  33. Upon completion of installation, Check to make sure that there is no fuel leakage, coolant leakage, transmission oil leakage or exhaust gas leakage at each connection.
  34.  
  35. Inspect and adjust ignition timing.
  36.  

 
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