ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

Perform "Inspection After Repair" after replacing the engine assembly Click here.

PROCEDURE


  1. INSTALL ENGINE HANGERS

    Click here

  2. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND


    1. Remove the engine assembly from the engine stand.

  3. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  4. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

    Click here

  5. INSTALL FRONT ENGINE MOUNTING BRACKET

    Click here

  6. INSTALL WIRE HARNESS CLAMP BRACKET

    Click here

  7. INSTALL ENGINE MOUNTING BRACKET RH


    1. Install the engine mounting bracket RH with the 3 bolts.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

  8. INSTALL DRIVE SHAFT BEARING BRACKET


    1. Install the drive shaft bearing bracket with the 3 bolts.

      Torque:
      64 N*m  { 650 kgf*cm, 47 ft.*lbf }

      Note

      Make sure that the bolts and bolt holes are free of oil. Clean them if necessary.

  9. TEMPORARILY INSTALL FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. Temporarily install the front engine mounting insulator with the 3 nuts.

  10. TEMPORARILY INSTALL ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. Temporarily install the engine mounting insulator LH with the 3 nuts.

  11. TEMPORARILY INSTALL ENGINE MOUNTING INSULATOR RH

    Tech Tips

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


    1. Temporarily install the engine mounting insulator RH with the 3 nuts.

  12. INSTALL FRONT FRAME ASSEMBLY


    1. Install the engine mounting insulator LH with the nut.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

    2. Install the front engine mounting insulator with the bolt.

      Torque:
      87 N*m  { 887 kgf*cm, 64 ft.*lbf }

    3. Install the engine mounting insulator RH with the nut.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

    4. Fully tighten the 9 temporarily installed nuts of the engine mounting insulators.

      B001NQGE02
      Text in Illustration
      *1 Front Engine Mounting Insulator *2 Engine Mounting Insulator RH
      *3 Engine Mounting Insulator LH - -
      Torque:
      Nut (A)
      58 N*m  { 591 kgf*cm, 43 ft.*lbf }
      Nut (B)
      99 N*m  { 1010 kgf*cm, 73 ft.*lbf }

      Tech Tips

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

    5. Install the 4 hole plugs.

      B001OEGE12
      Text in Illustration
      *1 Engine Mounting Insulator RH *2 Engine Mounting Insulator LH

      Tech Tips

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

  13. INSTALL GENERATOR ASSEMBLY

    Click here

  14. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY

    Click here

  15. INSTALL V-RIBBED BELT

    Click here

  16. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine assembly with transaxle.

  17. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


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

      Note


      • Using height adjustment attachments and plate lift attachments, place the engine assembly with transaxle horizontally.

      • To prevent the oil pan sub-assembly from deforming, do not place any attachments under the oil pan sub-assembly of the engine assembly with transaxle.

      • 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.

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

    3. Install the engine assembly with transaxle to the vehicle.

      Note


      • Do not raise the engine assembly with transaxle more than necessary. If the engine assembly with transaxle is raised excessively, the vehicle may also be lifted up.

      • 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. B001ON8E02

      Install the frame side rail plate sub-assembly RH and frame side rail plate sub-assembly LH with the 4 bolts and 2 nuts.

      Text in Illustration
      B001O8N Bolt
      B001OAO Nut
      Torque:
      Bolt (A)
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }
      Bolt (B) and Nut
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

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

      Torque:
      Bolt (A)
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }
      Bolt (B) and Nut
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

      Tech Tips

      Perform "Inspection After Repair" after replacing the engine assembly.

  18. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

    Click here

  19. INSTALL FLYWHEEL HOUSING UNDER COVER


    1. Install the flywheel housing under cover.

  20. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  21. INSTALL FRONT DRIVE SHAFT ASSEMBLY

    Click here

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

    Click here

  23. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY


    1. Connect the fuel vapor feed hose assembly to the floor tube Click here.

    2. Install the EFI fuel pipe clamp.

  24. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. Connect the 2 fuel tube sub-assemblies to the 2 fuel tubes Click here.

    2. Install the 2 EFI fuel pipe clamps Click here.

  25. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE

    Click here

  26. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

  27. CONNECT UNION TO CHECK VALVE HOSE

    Click here

  28. INSTALL ENGINE MOVING CONTROL ROD

    Tech Tips

    Perform this procedure only when replacement of the engine moving control rod is necessary.


    1. Temporarily install the engine moving control rod and No. 3 engine mounting stay RH to the engine moving control rod bracket with the bolt.

  29. INSTALL ENGINE MOVING CONTROL ROD BRACKET


    1. When replacing the engine moving control rod.


      1. B001OP7E06

        Install the engine moving control rod bracket with engine moving control rod with the 4 bolts.

        Torque:
        38 N*m  { 387 kgf*cm, 28 ft.*lbf }

        Note

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

      2. B001OOSE02
        Text in Illustration
        *a Torque Wrench Fulcrum Length
        *b Union Nut Wrench

        Using SST and a union nut wrench (14 mm), tighten the bolt.

        SST
        09961-00950
        Torque:
        Specified Tightening Torque
        52 N*m  { 530 kgf*cm, 38 ft.*lbf }

        Tech Tips


        • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.

        • When using SST (fulcrum length of 150 mm (5.91 in.)) + torque wrench (fulcrum length of 260 mm (10.2 in.)): 33 N*m (337 kgf*cm, 24 ft.*lbf)

    2. When not replacing the engine moving control rod.


      1. B001OP7E06

        Install the engine moving control rod bracket with engine moving control rod with the 4 bolts.

        Torque:
        38 N*m  { 387 kgf*cm, 28 ft.*lbf }

        Note

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

  30. INSTALL NO. 2 ENGINE MOUNTING STAY RH


    1. Install the No. 2 engine mounting stay RH with the 2 bolts.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  31. INSTALL EARTH WIRE


    1. Install the earth wire with the 2 bolts.

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

  32. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    Click here

  33. INSTALL NO. 1 AIR CLEANER BRACKET


    1. Install the No. 1 air cleaner bracket to the battery carrier with the bolt.

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

    2. Connect the 2 wire clamps.

  34. CONNECT ENGINE WIRE


    1. B001NVQ

      Engage the 2 wire harness clamps.

    2. Push down the lock lever to connect the ECM connector.

      Note


      • When connecting the ECM connector, make sure that dirt, water or other foreign matter does not contact the connecting part of the ECM connector.

      • Be sure to securely connect the ECM connectors.

    3. Engage the claw to connect the engine wire to the engine room relay block assembly.

    4. Install the nut to the engine room relay block assembly.

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

    5. Connect the 4 connectors to the engine room relay block assembly.

    6. Engage the wire harness clamp.

    7. Install the engine wire with the bolt.

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

    8. Install the No. 1 relay block cover to the engine room relay block assembly.

  35. INSTALL STARTER ASSEMBLY

    Click here

  36. CONNECT NO. 3 WATER BY-PASS HOSE


    1. Connect the water hose sub-assembly to the EGR cooler assembly and slide the clip to secure it.

    2. Connect the No. 3 water by-pass hose to the transmission oil cooler and slide the clip to secure it.

    3. Engage the 2 clamps to connect the No. 3 water by-pass hose.

  37. CONNECT HEATER INLET WATER HOSE


    1. Connect the heater inlet water hose to the cylinder head sub-assembly and slide the clip to secure it.

    2. Engage the 2 clamps to connect the heater inlet water hose.

  38. CONNECT NO. 2 RADIATOR HOSE


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

  39. CONNECT NO. 1 RADIATOR HOSE


    1. Connect the No. 1 radiator hose to the cylinder head sub-assembly and slide the clip to secure it.

  40. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. B001OQCE02
      Text in Illustration
      *a Hole
      *b Projection

      Insert the projection of the air cleaner case sub-assembly into the hole of the No. 1 air cleaner bracket as shown in the illustration.

    2. Install the 2 bolts.

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

    3. Connect the wire harness clamp.

  41. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


    1. Install the air cleaner filter element sub-assembly to the air cleaner case sub-assembly.

      Note

      Install the air cleaner filter element sub-assembly with the printed side facing the vehicle left.

  42. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

    Click here

  43. INSTALL BATTERY


    1. Install the battery and battery tray.

    2. w/ battery insulator:


      1. Install the battery insulator to the battery.

    3. Install the battery clamp with the bolt and nut.

      Torque:
      Bolt
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
      Nut
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

    4. Connect the cable to the positive (+) battery terminal with the nut.

      Torque:
      6.9 N*m  { 70 kgf*cm, 60 in.*lbf }

  44. INSTALL INLET AIR CLEANER ASSEMBLY


    1. Install the inlet air cleaner assembly with the 2 bolts.

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

  45. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


    1. Connect the cable to the negative (-) battery terminal with the nut.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

      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. ADD AUTOMATIC TRANSAXLE FLUID

    Click here

  49. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

  50. WARM UP ENGINE

    Click here

  51. INSPECT FOR FUEL LEAK

    Click here

  52. INSPECT FOR OIL LEAK

    Click here

  53. INSPECT FOR COOLANT LEAK

    Click here

  54. INSPECT FOR EXHAUST GAS LEAK

    Click here

  55. INSPECT FOR REFRIGERANT LEAK

    Click here

  56. INSPECT IGNITION TIMING

    Click here

  57. INSPECT ENGINE IDLE SPEED

    Click here

  58. INSPECT CO/HC

    Click here

  59. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY


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

  60. INSTALL COOL AIR INTAKE DUCT SEAL

    Click here

  61. INSPECT SHIFT LEVER POSITION

    Click here

  62. INSTALL FRONT FENDER APRON SEAL LH


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

  63. INSTALL FRONT FENDER APRON SEAL RH


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

  64. INSTALL ENGINE UNDER COVER LH


    1. Install the engine under cover LH with the 2 screws and 2 clips.

  65. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH


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

  66. INSTALL ENGINE UNDER COVER RH


    1. Install the engine under cover RH with the 2 screws and 3 clips.

  67. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH


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

  68. INSTALL FRONT WHEELS

    Torque:
    103 N*m  { 1049 kgf*cm, 76 ft.*lbf }

  69. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  70. INSPECT SPEED SENSOR SIGNAL

    Click here