CAUTION / NOTICE / HINT
CAUTION:
The engine assembly with transmission is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop.
PROCEDURE
INSTALL ENGINE MOUNTING INSULATOR LH
Tech Tips
Perform this procedure only when replacement of the engine mounting insulator LH is necessary.
Install the engine mounting insulator LH with the 5 bolts.
Note
Temporarily tighten the bolt (A), and then fully tighten the 2 bolts in the order of (B) and (A).
INSTALL ENGINE MOUNTING SPACER
Tech Tips
Perform this procedure only when replacement of the engine mounting spacer is necessary.
Install the engine mounting spacer with the 2 bolts.
INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH
Tech Tips
Perform this procedure only when replacement of the engine mounting insulator sub-assembly RH is necessary.
Temporarily install the engine mounting insulator sub-assembly RH with the 2 bolts and nut.
Install the engine mounting insulator sub-assembly RH with the bolt (A) and nut.
*a | Torque Wrench Fulcrum Length |
Using SST, install the engine mounting insulator sub-assembly RH with the bolt (B).
Tech Tips
Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
When using SST (fulcrum length of 200 mm (7.87 in.)) + torque wrench (fulcrum length of 255 mm (10.04 in.)):
40 N*m (408 kgf*cm, 30 ft.*lbf)]
Connect the brake actuator with bracket with the bolt.
Connect the cooler compressor bracket with the bolt.
Connect the earth wire with the bolt.
INSTALL REAR ENGINE MOUNTING INSULATOR
Tech Tips
Perform this procedure only when replacement of the rear engine mounting insulator is necessary.
Install the rear engine mounting insulator with the 4 nuts.
Install the 2 hole plugs to the front frame assembly.
INSTALL FRONT ENGINE MOUNTING INSULATOR
Tech Tips
Perform this procedure only when replacement of the front engine mounting insulator is necessary.
Install the front engine mounting insulator with the 3 nuts.
Install the hole plug to the front frame assembly.
INSTALL ENGINE HANGERS
REMOVE ENGINE FROM ENGINE STAND
Remove the engine assembly from the engine stand.
INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
for 2WD: Click here
for AWD: Click here
INSTALL FRONT FRAME ASSEMBLY
Temporarily install the front engine mounting insulator with front frame assembly to the front engine mounting bracket with the bolt.
*a | Protrusion |
*b | Rib |
Install the rear engine mounting insulator assembly to the rear engine mounting bracket with the bolt.
Note
If tightening the bolt before installation of the front frame assembly, ensure that the edge of the protrusion of the bracket is within the width of the rib.
Fully tighten the bolt of the front engine mounting insulator.
Connect the vacuum hose to the vacuum switching valve assembly.
INSTALL TRANSFER STIFFENER PLATE RH (for AWD)
INSTALL STEERING LINK ASSEMBLY
INSTALL FRONT STABILIZER BAR
INSTALL FRONT NO. 1 STABILIZER BRACKET LH
INSTALL FRONT NO. 1 STABILIZER BRACKET RH
Tech Tips
Perform the same procedure as for the LH side.
CONNECT WIRE HARNESS
for 2WD: Click here
for AWD: Click here
INSTALL NO. 2 INTERCOOLER COOLING WATER PIPE
Install the No. 2 intercooler cooling water pipe to the engine assembly with the bolt.
Connect the No. 6 intercooler cooling water hose to the No. 2 water by-pass pipe and slide the clip to secure it.
INSTALL NO. 3 INTERCOOLER COOLING WATER PIPE
Install the No. 3 intercooler cooling water pipe to the engine assembly with the bolt.
Connect the No. 2 intercooler cooling water hose to the No. 1 turbo water pipe sub-assembly and slide the clip to secure it.
Connect the No. 5 intercooler cooling water hose to the No. 2 water by-pass pipe and slide the clip to secure it.
REMOVE ENGINE HANGER
INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
Using height adjustment attachments and plate lift attachments to keep the engine assembly with transaxle level, set an engine lifter underneath the engine assembly with transaxle.
Note
Do not perform any procedures while the engine assembly is suspended because doing so may cause the engine assembly to drop, resulting in injury. However, the engine assembly needs to be suspended when it is installed to or removed from an engine stand.
To prevent the engine assembly from unexpectedly moving, securely support the engine assembly until it is secured to an engine stand.
Operate the engine lifter to install the engine assembly with transaxle to the vehicle.
CAUTION:
Do not raise the engine assembly with transaxle more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.
Note
Make sure that the engine assembly with transaxle is clear of all wirings and hoses.
While lowering the engine assembly with transaxle from the vehicle, do not allow it to contact the vehicle.
Bolt | |
Nut |
Install the frame side rail plate sub-assembly RH and front suspension member bracket sub-assembly RH with the 6 bolts and 2 nuts.
Install the frame side rail plate sub-assembly LH and front suspension member bracket sub-assembly LH with the 6 bolts and 2 nuts.
*a | Nut (A) |
*b | Nut (B) |
*c | Bolt |
Type A:
Install the engine mounting insulator sub-assembly RH from the engine mounting bracket RH with the 2 bolts and 2 nuts.
*a | Nut (A) |
*b | Nut (B) |
*c | Bolt |
Type B:
Install the engine mounting insulator sub-assembly RH to the engine mounting bracket RH with the bolt and 3 nuts.
Connect the engine mounting insulator LH to the engine mounting bracket LH with the bolt and nut.
INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT
for 2WD: Click here
for AWD: Click here
INSTALL FLYWHEEL HOUSING UNDER COVER
Install the flywheel housing under cover to the engine assembly.
INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY (for AWD)
INSTALL FRONT DRIVE SHAFT ASSEMBLY
CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY
INSTALL FRONT EXHAUST PIPE ASSEMBLY
INSTALL CENTER EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)
CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY
Connect the transmission control cable assembly to the control shift lever with the nut.
Connect the transmission control cable assembly to the No. 1 transmission control cable bracket with a new clip.
INSTALL TRANSMISSION OIL THERMOSTAT
for 2WD: Click here
for AWD: Click here
CONNECT TRANSMISSION OIL COOLER
Temporarily install the transmission oil cooler to the front engine mounting bracket with the bolt (A).
Install the bolt (B).
Install the bolt (C).
Tighten the bolt (A).
Engage the clamp and connect the No. 1 breather plug (ATM) to the breather plug hose clamp.
CONNECT FUEL VAPOR FEED HOSE ASSEMBLY
Connect the fuel vapor feed hose assembly to the fuel pipe and slide the clip to secure it.
CONNECT NO. 1 FUEL HOSE
Connect the No. 1 fuel hose to the 2 fuel pipes.
Install the No. 2 fuel pipe clamp to the fuel tube connector.
CONNECT UNION TO CHECK VALVE HOSE (for LHD)
Connect the union to check valve hose to the vacuum switching valve hose assembly and slide the clip to secure it.
CONNECT UNION TO CONNECTOR TUBE HOSE (for RHD)
Connect the union to connector tube hose to the vacuum switching valve hose assembly and slide the clip to secure it.
INSTALL STARTER ASSEMBLY
CONNECT ENGINE WIRE
Connect the No. 2 earth wire to the compressor assembly with pulley with the bolt.
Connect the earth wire with the bolt.
Connect the battery state sensor assembly connector.
Engage the 2 claws to connect the engine wire to the No. 1 engine room relay block and No. 1 junction block assembly.
Connect the 3 connectors to the No. 1 engine room relay block and No. 1 junction block assembly.
Install the nut.
Connect the engine wire, engage the 2 engine wire clamps and install the nut.
Install the engine room relay block assembly.
CONNECT DISCHARGE HOSE SUB-ASSEMBLY
CONNECT SUCTION HOSE SUB-ASSEMBLY
CONNECT HEATER HOSE
Connect the outlet heater hose to the water hose sub-assembly and slide the clip to secure it.
Connect the inlet heater hose to the cylinder head sub-assembly and slide the clip to secure it.
CONNECT NO. 1 RADIATOR HOSE
Connect the No. 1 radiator hose to the cylinder head sub-assembly and slide the clip to secure it.
CONNECT NO. 2 RADIATOR HOSE
Connect the No. 2 radiator hose to the water inlet and slide the clip to secure it.
INSTALL NO. 3 INTERCOOLER COOLING WATER HOSE
Connect the No. 3 intercooler cooling water hose to the No. 3 intercooler cooling water pipe and slide the clip to secure it.
INSTALL NO. 1 AIR TUBE
*1 | No. 2 Fuel Vapor Feed Hose |
*2 | Fuel Tube Sub-assembly |
*3 | No. 2 Fuel Tube Sub-assembly |
*4 | No. 3 Ventilation Hose |
*5 | Vacuum Switching Valve Hose Assembly |
*6 | No. 1 Air Tube |
Connect the No. 1 air tube to the intercooler assembly and tighten the clamp to secure it.
Install the 2 bolts (B).
Connect the vacuum switching valve hose assembly to the No. 1 air tube with the bolt (A).
Connect the No. 3 ventilation hose to the No. 1 air tube and slide the clip to secure it.
Engage the 2 clamps to connect the fuel tube sub-assembly and No. 2 fuel tube sub-assembly to the No. 1 air tube.
Engage the 2 clamps to connect the No. 2 fuel vapor feed hose to the No. 1 air tube.
INSTALL INTAKE AIR RESONATOR
INSTALL OUTLET COMPRESSOR ELBOW
INSTALL NO. 5 EXHAUST MANIFOLD HEAT INSULATOR
INSTALL NO. 2 AIR CLEANER HOSE
INSTALL INTAKE AIR CONNECTOR
INSTALL INTERCOOLER RESERVE TANK ASSEMBLY
Connect the No. 1 intercooler cooling water hose to the intercooler reserve tank assembly and slide the clip to secure it.
Connect the No. 4 intercooler cooling water hose to the intercooler reserve tank assembly and slide the clip to secure it.
Connect the No. 1 turbo water hose to the intercooler reserve tank assembly and slide the clip to secure it.
Install the intercooler reserve tank assembly with the 2 bolts.
INSTALL ECM
INSTALL AIR CLEANER BRACKET
INSTALL AIR CLEANER CASE SUB-ASSEMBLY
INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE
INSTALL INLET AIR CLEANER ASSEMBLY
Install the inlet air cleaner assembly with the 2 bolts.
INSTALL BATTERY BRACKET REINFORCEMENT
Install the battery bracket reinforcement with the 2 bolts.
INSTALL BATTERY CARRIER SUB-ASSEMBLY
w/ NO. 3 Battery Clamp:
Install the battery carrier sub-assembly with the 4 bolts.
Install the NO. 3 battery clamp with the 2 bolts.
Engage the 3 clamps and connect the wire harness to battery carrier sub-assembly.
w/o NO. 3 Battery Clamp:
Install the battery carrier sub-assembly with the 6 bolts.
Engage the 3 clamps and connect the wire harness to battery carrier sub-assembly.
INSTALL BATTERY
CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Note
When disconnecting the cable, some systems need to be initialized after the cable is reconnected.
INSTALL FRONT WHEELS
ADD ENGINE OIL
ADD TRANSFER OIL (for AWD)
ADD ENGINE COOLANT
ADD COOLANT (for Intercooler)
CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT
for HFC-134a (R134a): Click here
for HFO-1234yf (R1234yf): Click here
ADD AUTOMATIC TRANSAXLE FLUID
for 2WD: Click here
for AWD: Click here
INSPECT FOR FUEL LEAK
INSPECT FOR ENGINE OIL LEAK
INSPECT FOR COOLANT LEAK (for Intercooler)
INSPECT FOR COOLANT LEAK
INSPECT AUTOMATIC TRANSAXLE FLUID LEAK
WARM UP ENGINE
for HFC-134a (R134a): Click here
for HFO-1234yf (R1234yf): Click here
CHECK ENGINE OIL LEVEL
INSPECT ENGINE COOLANT LEVEL
INSPECT FOR EXHAUST GAS LEAK
INSPECT FOR REFRIGERANT LEAK
for HFC-134a (R134a): Click here
for HFO-1234yf (R1234yf): Click here
INSPECT IGNITION TIMING
INSPECT ENGINE IDLE SPEED
INSPECT CO/HC
INSPECT TEST MODE (SPEED SENSOR CHECK)
INSPECT SHIFT LEVER POSITION
ADJUST SHIFT LEVER POSITION
INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
INSTALL FRONT FLOOR COVER LH
INSTALL NO. 2 ENGINE UNDER COVER
Install the No. 2 engine under cover with the 2 bolts, 2 screws and clip.
INSTALL FRONT FENDER APRON SEAL LH
Install the front fender apron seal LH with the 2 screws and clip.
INSTALL FRONT FENDER APRON SEAL RH
Install the front fender apron seal RH with the 2 screws and clip.
INSTALL FRONT LOWER BUMPER ABSORBER
Engage the 2 claws.
Install the front lower bumper absorber with the 4 screws and 2 clips.
INSTALL NO. 1 ENGINE UNDER COVER
Install the No. 1 engine under cover with the 3 bolts, 2 screws and clip.
INSTALL NO. 3 ENGINE UNDER COVER
Install the No. 3 engine under cover with the 5 bolts, 2 screws and 2 clips.
INSTALL FRONT WHEEL OPENING EXTENSION PAD LH
Install the front wheel opening extension pad LH with the 2 screws.
INSTALL FRONT WHEEL OPENING EXTENSION PAD RH
Install the front wheel opening extension pad RH with the 2 screws.
INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY
Engage the 3 clips to install the No. 1 engine cover sub-assembly.
INSTALL COOL AIR INTAKE DUCT SEAL