ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:


  • The engine assembly with transaxle is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop or the engine assembly with transaxle may fall off the engine lifter.

  • To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

PROCEDURE


  1. INSTALL ENGINE MOUNTING INSULATOR LH

    Tech Tips

    Perform this procedure only when replacement of the engine mounting insulator LH is necessary.

    Click here

  2. INSTALL ENGINE MOUNTING BRACKET SUB-ASSEMBLY LH

    Tech Tips

    Perform this procedure only when replacement of the engine mounting bracket sub-assembly LH is necessary.


    1. B008476E01

      Temporarily tighten the bolt (A), and then fully tighten the 4 bolts in the order of (B), (C), (D) and (A).

      Torque:
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }

      Note

      Make sure that there is no gap between the engine mounting bracket sub-assembly LH and vehicle body before tightening the bolts.

  3. INSTALL ENGINE MOUNTING SPACER

    Tech Tips

    Perform this procedure only when replacement of the engine mounting spacer is necessary.


    1. B0088TEN01

      Install the engine mounting spacer to the vehicle body with the 2 bolts.

      Torque:
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }

      Note

      Temporarily tighten the bolt (A), and then fully tighten the 2 bolts in the order of (B) and (A).

  4. 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.


    1. B0087AJN01

      Install the engine mounting insulator sub-assembly RH with the 2 bolts and nut.

      Torque:
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }

      Note

      Temporarily tighten the bolt (A), and then fully tighten the 2 bolts and nut in the order of (B), (A) and (C).

    2. Engage the clamp.

    3. Connect the No. 1 bond cable to the engine mounting insulator sub-assembly RH with the bolt.

      Torque:
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }

    4. Connect the bracket to the engine mounting insulator sub-assembly RH with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    5. B0085I0C01
      *a Bolt
      *b Nut

      Install the radiator reserve tank assembly with the bolt and nut.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      Note

      Temporarily tighten the bolt, nut and then fully tighten the bolt and nut in the order of bolt and nut.

    6. Engage the clamp.

    7. Engage the No. 6 water by-pass hose.

  5. INSTALL ENGINE HANGERS

    Click here

  6. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND


    1. Remove the engine assembly from the engine stand.

  7. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine assembly.

  8. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  9. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

    Click here

  10. INSTALL INLET NO. 1 OIL COOLER HOSE (w/o Air Cooled Oil Cooler)

    Click here

  11. INSTALL OUTLET NO. 1 OIL COOLER HOSE (w/o Air Cooled Oil Cooler)

    Click here

  12. INSTALL TRANSMISSION OIL COOLER

    Click here

  13. CONNECT INLET NO. 1 OIL COOLER HOSE (w/o Air Cooled Oil Cooler)

    Click here

  14. CONNECT OUTLET NO. 1 OIL COOLER HOSE (w/o Air Cooled Oil Cooler)

    Click here

  15. INSTALL STARTER ASSEMBLY

    Click here

  16. INSTALL REAR ENGINE MOUNTING INSULATOR


    1. Install the rear engine mounting insulator to the rear engine mounting bracket with the bolt.

      Torque:
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }

  17. INSTALL FRONT ENGINE MOUNTING INSULATOR


    1. Install the front engine mounting insulator to the front engine mounting bracket with the bolt.

      Torque:
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }

  18. INSTALL FRONT FRAME ASSEMBLY


    1. Install the front frame assembly with the 7 nuts.

      Torque:
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }

  19. CONNECT WIRE HARNESS

    Click here

  20. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    Tech Tips

    Perform inspection after repair after replacing the engine assembly.

    Click here


    1. Set the engine assembly with transaxle on an engine lifter.

      Note


      • Using height adjustment attachments and plate lift attachments, keep the engine assembly with transaxle level.

      • 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 No. 2 oil pan sub-assembly from deforming, do not place any attachments under the No. 2 oil pan sub-assembly of the engine assembly with transaxle.

    2. Remove the 2 bolts, No. 1 engine hanger and No. 2 engine hanger.

    3. Operate the engine lifter and 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 wiring and hoses.

      • While raising the engine assembly with transaxle into the vehicle, do not allow it to contact the vehicle.

    4. B008596C02
      B00888T Bolt
      B0086HX Nut

      Install the front bumper extension sub-assembly RH and front bumper extension sub-assembly LH to the front frame assembly and vehicle body with the 8 bolts.

      Torque:
      Bolt (A)
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
      Bolt (B)
      12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }
      Bolt (C)
      135 N*m  { 1377 kgf*cm, 100 ft.*lbf }

    5. Install the front suspension member bracket sub-assembly RH and front suspension member bracket sub-assembly LH to the front frame assembly and vehicle body with the 4 bolts and 2 nuts.

      Torque:
      Bolt (D)
      17.5 N*m  { 178 kgf*cm, 13 ft.*lbf }
      Bolt (E)
      135 N*m  { 1377 kgf*cm, 100 ft.*lbf }
      Nut
      17.5 N*m  { 178 kgf*cm, 13 ft.*lbf }

    6. Install the engine mounting insulator LH to the engine mounting bracket sub-assembly LH with the bolt and nut.

      Torque:
      42 N*m  { 428 kgf*cm, 31 ft.*lbf }

      Note

      While holding the bolt in place, tighten the nut.

    7. Install the engine mounting insulator sub-assembly RH to the engine mounting bracket RH with the 2 bolts and nut.

      Torque:
      Bolt
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }
      Nut
      42 N*m  { 428 kgf*cm, 31 ft.*lbf }

    8. Engage the clamp.

  21. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

    Click here

  22. INSTALL FLYWHEEL HOUSING UNDER COVER


    1. Install the flywheel housing under cover to the cylinder block sub-assembly.

  23. INSTALL FRONT DRIVE SHAFT ASSEMBLY

    Click here

  24. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

    Click here

  25. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  26. CONNECT WIRE HARNESS


    1. Connect the wire harness to the vehicle body with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    2. Engage the claw to connect the wire harness to the engine room relay block and junction block assembly.

    3. Connect the 4 connectors.

    4. Install the nut.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    5. Install the relay block cover.

    6. Connect the wire harness with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  27. CONNECT OIL COOLER HOSE (w/ Air Cooled Oil Cooler)


    1. Connect the oil cooler hose and slide the clip to secure it.

    2. Connect the 3 oil cooler hoses and slide the 3 clips to secure them.

  28. CONNECT WATER HOSE


    1. Engage the 4 clamps.

    2. Connect the 4 water hoses and slide the 4 clips to secure them.

  29. CONNECT SUCTION HOSE SUB-ASSEMBLY

    Click here

  30. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE SUB-ASSEMBLY

    Click here

  31. CONNECT NO. 2 RADIATOR HOSE


    1. Connect the No. 2 radiator hose to the water inlet and slide the clip to secure it.

  32. CONNECT NO. 1 RADIATOR HOSE


    1. Connect the No. 1 radiator hose to the water outlet and slide the clip to secure it.

  33. CONNECT UNION TO CONNECTOR TUBE HOSE (for LHD)


    1. Connect the union to connector tube hose and slide the clip to secure it.

  34. CONNECT UNION TO CHECK VALVE HOSE (for RHD)


    1. Connect the union to check valve hose and slide the clip to secure it.

  35. CONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. Connect the No. 1 fuel vapor feed hose to the No. 1 vacuum switching valve assembly and slide the clip to secure it.

  36. CONNECT FUEL TUBE SUB-ASSEMBLY

    Click here

  37. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. Connect the transmission control cable assembly to the No. 1 transmission control cable bracket with a new clip.

    2. Connect the transmission control cable assembly to the transmission control shaft lever with the nut.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

      Note

      Before installing the transmission control cable assembly, check that the park/neutral position switch assembly and shift lever are in N.

  38. INSTALL BATTERY CLAMP SUB-ASSEMBLY


    1. Install the battery clamp sub-assembly with the 3 bolts.

      Torque:
      18.5 N*m  { 189 kgf*cm, 14 ft.*lbf }

    2. Engage the 5 clamps to the battery clamp sub-assembly.

  39. INSTALL BATTERY

    Click here

  40. CONNECT WIRE HARNESS


    1. Connect the wire harness to the positive (+) battery terminal with the nut.

      Torque:
      7.6 N*m  { 77 kgf*cm, 67 in.*lbf }

  41. INSTALL ECM

    Click here

  42. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE


    1. B0085JHC01
      *a Air Cleaner Support

      Insert the 3 pins of the air cleaner assembly into the 3 air cleaner supports as shown in the illustration.

      Note


      • Insert the 3 pins of the air cleaner assembly into the 3 air cleaner supports at the same time.

      • Check that the pins are securely inserted into air cleaner supports.

    2. Connect the air cleaner assembly with air cleaner hose to the throttle body with motor assembly and tighten the hose clamp.

    3. Engage the 2 clamps.

    4. Connect the ventilation hose to the cylinder head cover sub-assembly and slide the clip to secure it.

    5. Engage the 3 wire harness clamps.

    6. Connect the mass air flow meter sub-assembly connector.

  43. INSTALL INLET AIR CLEANER ASSEMBLY


    1. B00840BN01

      Install the inlet air cleaner assembly with the 2 bolts in the order shown in the illustration.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  44. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. Engage the 3 clips to install the No. 1 engine cover sub-assembly.

  45. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Click here

  46. ADD ENGINE OIL

    Click here

  47. ADD ENGINE COOLANT

    Click here

  48. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

  49. WARM UP ENGINE

    Click here

  50. INSPECT SHIFT LEVER POSITION

    Click here

  51. ADJUST SHIFT LEVER POSITION

    Click here

  52. INSPECT FOR ENGINE OIL LEAK

    Click here

  53. INSPECT FOR COOLANT LEAK

    Click here

  54. INSPECT FOR REFRIGERANT LEAK

    Click here

  55. INSPECT FOR FUEL LEAK

    Click here

  56. INSPECT FOR EXHAUST GAS LEAK

    Click here

  57. CHECK ENGINE OIL LEVEL

    Click here

  58. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR TANK

    Click here

  59. INSTALL FRONT LOWER BUMPER ABSORBER


    1. Engage the 2 claws to install the front lower bumper absorber.

    2. Install the 4 bolts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  60. INSTALL FRONT BUMPER COVER

    Click here

  61. INSTALL FRONT FENDER APRON SEAL LH


    1. Install the front fender apron seal LH with the 2 screws and clip.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  62. INSTALL FRONT FENDER APRON SEAL RH


    1. Install the front fender apron seal RH with the 2 screws and clip.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  63. INSTALL NO. 1 ENGINE UNDER COVER


    1. Install the No. 1 engine under cover with the bolt, 6 screws and 2 clips.

      Torque:
      Bolt
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  64. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH


    1. Install the front wheel opening extension pad LH with the 3 screws.

  65. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH


    1. Install the front wheel opening extension pad RH with the 3 screws.

  66. INSTALL FRONT WHEELS

    Click here

  67. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  68. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  69. PERFORM INITIALIZATION

    Click here

  70. INSPECT IGNITION TIMING

    Click here

  71. INSPECT ENGINE IDLE SPEED

    Click here

  72. INSPECT CO/HC

    Click here

  73. CHECK SPEED SENSOR SIGNAL

    Click here