ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

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

PROCEDURE


  1. REMOVE ENGINE STAND


    1. Remove the bolts and engine assembly from the engine stand.

  2. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  3. INSTALL DRIVE SHAFT BEARING BRACKET


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

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

  4. 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 }

  5. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

    Click here

  6. INSTALL ENGINE WIRE


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

  7. TEMPORARILY INSTALL FRONT ENGINE MOUNTING INSULATOR ASSEMBLY

    Tech Tips

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


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

  8. 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.

  9. 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.

  10. INSTALL FRONT FRAME ASSEMBLY


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

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

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

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

    3. Install the front engine mounting insulator assembly with the bolt.

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

    4. Connect the 2 wire clamps and vacuum switching valve connector.

    5. Connect the 2 wire clamps.

    6. Fully tighten the 9 temporarily installed nuts of the front engine mounting insulator assembly, engine mounting insulator LH and engine mounting insulator RH to the specified torque.

      Tech Tips

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

      B001OMWE21
      Text in Illustration
      *1 Front Engine Mounting Insulator Assembly Side *2 Engine Mounting Insulator RH Side
      *3 Engine Mounting Insulator LH Side - -
      Torque:
      A
      58 N*m  { 591 kgf*cm, 43 ft.*lbf }
      Torque:
      B
      99 N*m  { 1010 kgf*cm, 73 ft.*lbf }

    7. Install the 4 hole plugs.

      Tech Tips

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

      B001OEGE02
      Text in Illustration
      *1 Engine Mounting Insulator RH Side *2 Engine Mounting Insulator LH Side

  11. INSTALL TRANSMISSION OIL THERMOSTAT (w/ ATF Warmer)


    1. w/ Transmission Oil Thermostat:


      1. Connect the clamp and install the transmission oil thermostat with the bolt.

        Torque:
        20 N*m  { 199 kgf*cm, 14 ft.*lbf }

      2. Connect the inlet oil cooler hose to the transmission oil thermostat and slide the clip to secure it.

      3. Connect the outlet oil cooler hose to the transmission oil thermostat and slide the clip to secure it.

  12. INSTALL TRANSMISSION OIL COOLER (w/ ATF Warmer)

    Click here

  13. INSTALL COMPRESSOR AND MAGNETIC CLUTCH

    Click here

  14. INSTALL GENERATOR ASSEMBLY

    Click here

  15. INSTALL V-RIBBED BELT

    Click here

  16. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


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

      Note


      • Place the height adjustment and plate lift attachments under the engine assembly with transaxle.

      • Servicing an engine assembly with transaxle while it is hanging is dangerous. This can be done only when installing/removing the engine assembly with transaxle to/from an engine stand.

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

      • Make sure to support the engine assembly with transaxle securely to prevent it from falling.

    2. Remove the No. 1 engine hanger and No. 2 engine hanger Click here.

    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. B001O5AE04

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

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

    5. Install the front suspension member rear brace RH and front suspension member rear brace LH with the 4 bolts and 2 nuts.

      Torque:
      C
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }
      D
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

      Tech Tips

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

  17. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

    Click here

  18. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY


    1. Install the No. 1 exhaust pipe support bracket sub-assembly with the 2 bolts.

      Torque:
      7.8 N*m  { 80 kgf*cm, 69 in.*lbf }

  19. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET


    1. Install the No. 1 exhaust pipe support bracket with the bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  20. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH

    Click here

  21. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  22. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

    Click here

  23. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

    Click here

  24. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  25. CONNECT TIE ROD ASSEMBLY LH

    Click here

  26. CONNECT TIE ROD ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  27. INSTALL FRONT SPEED SENSOR LH

    Click here

  28. INSTALL FRONT SPEED SENSOR RH

    Tech Tips

    Perform the same procedure as for the LH side.

  29. INSTALL FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  30. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  31. INSTALL FRONT AXLE SHAFT NUT LH

    Click here

  32. INSTALL FRONT AXLE SHAFT NUT RH

    Tech Tips

    Perform the same procedure as for the LH side.

  33. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  34. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  35. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET

    Click here

  36. CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE

    Click here

  37. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

  38. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. B001O6R

      Push in the fuel tube connector to the fuel main tube until the fuel tube connector makes a "click" sound.

      Note


      • Check that there is no damage or foreign matter on the fuel tube connector.

      • After connecting, check that the fuel tube connector and the fuel tube sub-assembly are securely connected by pulling on them.

    2. B001O38

      Install the fuel pipe clamp.

      Tech Tips

      The half connection prevention connector prevents the fuel hose connector cover from being locked if the fuel tube sub-assembly is not securely connected.

  39. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    Click here

  40. INSTALL AIR CLEANER BRACKET


    1. Install the 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.

  41. CONNECT ENGINE WIRE


    1. B001O2A

      Connect the 2 wire clamps.

    2. Connect the connector to the ECM with the lock lever.

    3. Connect the engine wire to the engine room relay block.

    4. Connect the 4 connectors.

    5. B001O7V

      Connect the engine wire to the engine room relay block.

    6. Connect the 2 wire clamps and install the 2 nuts.

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

    7. Install the No. 1 relay block cover.

  42. INSTALL STARTER ASSEMBLY

    Click here

  43. CONNECT OUTLET HEATER WATER HOSE (w/o ATF Warmer)


    1. Connect the outlet heater water hose to the water outlet and slide the clip to secure it.

  44. CONNECT INLET HEATER WATER HOSE (w/o ATF Warmer)


    1. Connect the inlet heater water hose to the water outlet and slide the clip to secure it.

  45. CONNECT WATER HOSE SUB-ASSEMBLY (w/ ATF Warmer)


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

  46. CONNECT INLET HEATER WATER HOSE (w/ ATF Warmer)


    1. Connect the inlet heater water hose to the water outlet and slide the clip to secure it.

  47. CONNECT NO. 3 WATER BY-PASS HOSE (w/ ATF Warmer)


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

  48. CONNECT INLET NO. 1 OIL COOLER HOSE (w/o ATF Warmer)


    1. Connect the inlet No. 1 oil cooler hose to the automatic transaxle assembly and slide the clip to secure it.

  49. CONNECT OUTLET NO. 1 OIL COOLER HOSE (w/o ATF Warmer)


    1. Connect the outlet No. 1 oil cooler hose to the automatic transaxle assembly and slide the clip to secure it.

  50. CONNECT OIL COOLER TUBE SUB-ASSEMBLY (w/ ATF Warmer)


    1. w/ Transmission Oil Thermostat:


      1. Connect the 2 oil cooler tube sub-assemblies to the transmission oil thermostat and slide the 2 clips to secure them.

  51. CONNECT NO. 2 RADIATOR HOSE


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

  52. CONNECT NO. 1 RADIATOR HOSE


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

    2. Install the air fuel ratio sensor wire to the No. 1 radiator hose with the hose clamp.

  53. CONNECT UNION TO CHECK VALVE HOSE


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

  54. CONNECT NO. 1 FUEL VAPOR FEED HOSE


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

  55. CONNECT EARTH WIRE


    1. Install the earth wire with the 2 bolts.

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

  56. INSTALL NO. 3 ENGINE MOUNTING STAY RH

    Tech Tips

    Perform this procedure only when replacement of the engine moving control rod or No. 3 engine mounting stay RH is necessary.


    1. B001NZKE08
      Text in Illustration
      *1 Engine Moving Control Rod
      *2 No. 3 Engine Mounting Stay RH
      *3 Engine Moving Control Rod Bracket

      Temporarily install the No. 3 engine mounting stay RH and engine moving control rod to the engine moving control rod bracket with the 2 bolts.

    2. Tighten the bolt A.

      Torque:
      78 N*m  { 795 kgf*cm, 58 ft.*lbf }

  57. INSTALL ENGINE MOVING CONTROL ROD SUB-ASSEMBLY


    1. B001O6ZE04

      When replacing the engine moving control rod or No. 3 engine mounting stay RH.


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

      2. Tighten the bolt (E).

        Torque:
        52 N*m  { 530 kgf*cm, 38 ft.*lbf }
    2. B001OQBE04

      When not replacing the engine moving control rod or No. 3 engine mounting stay RH.


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

  58. INSTALL NO. 2 ENGINE MOUNTING STAY RH


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

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

    2. Tighten the 2 nuts.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

  59. INSTALL INTAKE AIR RESONATOR SUB-ASSEMBLY


    1. Install the intake air resonator sub-assembly with the 2 bolts.

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

    2. Connect the 2 vacuum hoses and engage the claw.

  60. INSTALL INLET NO. 1 AIR CLEANER


    1. B001OAG

      Install the inlet No. 1 air cleaner to the intake air resonator sub-assembly.

    2. Engage the pin to the radiator support.

  61. INSTALL BATTERY


    1. Install the battery and battery tray.

    2. 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 }

    3. Connect the positive (+) cable to the positive (+) battery terminal.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  62. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. B001NMAE04
      Text in Illustration
      *1 Air Cleaner Case Sub-assembly
      *2 Inlet No. 1 Air Cleaner
      *a Projection
      *b Hole

      Install the air cleaner case sub-assembly to the inlet No. 1 air cleaner.

    2. Insert the projection of the air cleaner case sub-assembly to the hole of the No. 2 air cleaner bracket as shown in the illustration.

    3. Tighten the 2 bolts.

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

    4. Connect the 3 wire harness clamps, connector, vacuum hose and No. 1 fuel vapor feed hose.

  63. 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 front.

  64. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  65. INSTALL INLET NO. 2 AIR CLEANER


    1. Install the inlet No. 2 air cleaner to the air cleaner case sub-assembly with the 2 bolts.

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

    2. Connect the 2 wire harness clamps and vacuum hose clamp.

  66. INSPECT VACUUM HOSES


    1. Inspect the vacuum hoses.

      B001OOO

  67. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


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

      Torque:
      6.9 N*m  { 70 kgf*cm, 61 in.*lbf }

      Note

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

  68. INSTALL FRONT WHEELS

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

  69. ADD ENGINE OIL

    Click here

  70. ADD ENGINE COOLANT

    Click here

  71. ADD AUTOMATIC TRANSAXLE FLUID

    Click here

  72. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

  73. WARM UP ENGINE

    Click here

  74. INSPECT FOR REFRIGERANT LEAK

    Click here

  75. INSPECT ENGINE OIL LEVEL

    Click here

  76. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR

    Click here

  77. INSPECT FOR FUEL LEAK

    Click here

  78. INSPECT FOR COOLANT LEAK

    Click here

  79. INSPECT FOR OIL LEAK

  80. INSPECT FOR EXHAUST GAS LEAK

  81. INSPECT IGNITION TIMING

    Click here

  82. INSPECT ENGINE IDLE SPEED

    Click here

  83. INSPECT CO/HC

    Click here

  84. CHECK FOR SPEED SENSOR SIGNAL

    Click here

  85. INSPECT SHIFT LEVER POSITION

    Click here

  86. ADJUST SHIFT LEVER POSITION

    Click here

  87. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  88. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. Fit the 3 retainers and install the V-bank cover sub-assembly.

  89. INSTALL COOL AIR INTAKE DUCT SEAL

    Click here

  90. INSTALL FRONT FENDER APRON SEAL LH


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

  91. INSTALL ENGINE UNDER COVER LH (w/ Front Lower Bumper Absorber)


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

  92. INSTALL ENGINE UNDER COVER LH (w/o Front Lower Bumper Absorber)


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

  93. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH


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

  94. INSTALL FRONT FENDER APRON SEAL RH


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

  95. INSTALL ENGINE UNDER COVER RH (w/ Front Lower Bumper Absorber)


    1. Install the engine under cover RH with the 3 clips.

  96. INSTALL ENGINE UNDER COVER RH (w/o Front Lower Bumper Absorber)


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

  97. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH


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

  98. INSTALL FRONT LOWER BUMPER ABSORBER (w/ Front Lower Bumper Absorber)


    1. Install the front lower bumper absorber with the 6 screws and 6 bolts.