ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:


  • B002EEYC22
    *a Heavy object exceeding the capacity of the engine lifter

    Because the weight of the engine with transmission assembly is extremely heavy, make sure to follow the work procedures described in the repair manual.

  • If work is not performed according to the procedures described in the repair manual, there is a danger that the engine lifter could drop and components could fall down.

Note

When the oil cooler assembly (for air cooled type) has been removed/installed or the oil cooler hose sub-assembly has been disconnected/reconnected, check the engine oil level after warming up the engine oil to between 100°C (212°F) and 120°C (248°F) to open the thermostat between the engine and oil cooler assembly (for air cooled type).

B002C8GC06
*1 Thermostat (Thermostat Housing Assembly) *2 Oil Cooler Hose Sub-assembly
*3 Oil Cooler Assembly (for Air Cooled Type) - -

Tech Tips

Enter the following menus: Powertrain / Engine / Data List / Engine Oil Temperature Sensor.


Powertrain > Engine > Data List
Tester Display
Engine Oil Temperature Sensor

PROCEDURE


  1. INSTALL NO. 1 ENGINE HANGER

    Click here

  2. REMOVE ENGINE FROM ENGINE STAND


    1. Remove the engine assembly from the engine stand.

  3. INSTALL FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. Install the 2 front engine mounting insulators to the front suspension crossmember sub-assembly with the 2 nuts.

      Torque:
      70 N*m  { 714 kgf*cm, 52 ft.*lbf }

    2. Install the 2 engine mounting spacers.

  4. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. Install the front suspension crossmember sub-assembly to the engine assembly with the 2 nuts.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  5. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  6. INSPECT DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  7. INSTALL NO. 1 ENGINE MOUNTING BRACKET


    1. Install the No. 1 engine mounting bracket to the automatic transmission assembly with the 4 bolts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  8. INSTALL REAR ENGINE MOUNTING HEAT INSULATOR


    1. Install the rear engine mounting heat insulator to the rear engine mounting insulator.

  9. INSTALL REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. B002DNYC02
      *a Claw
      B002DP3 Front Side of Vehicle

      Install the rear engine mounting insulator to the No. 1 engine mounting bracket with the 4 nuts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

      Tech Tips

      Make sure that the claw is facing towards the front of the vehicle.

  10. INSTALL REAR ENGINE MOUNTING MEMBER

    Tech Tips

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


    1. Install the rear engine mounting member to the rear engine mounting insulator with the 4 nuts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  11. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

    Click here

  12. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

    Click here

  13. INSTALL STARTER ASSEMBLY

    Click here

  14. INSTALL GENERATOR ASSEMBLY

    Click here

  15. INSTALL COMPRESSOR WITH PULLEY ASSEMBLY


    1. B002EAQE01

      Install the compressor with pulley assembly with the 2 bolts and 2 nuts.

      Torque:
      24.5 N*m  { 250 kgf*cm, 18 ft.*lbf }

      Tech Tips

      Tighten the bolts and nuts in the order shown in the illustration.

  16. INSTALL OIL COOLER TUBE


    1. B002C8AE02

      Install the oil cooler tube with the 3 bolts.

      Torque:
      Bolt (A)
      13.5 N*m  { 138 kgf*cm, 10 ft.*lbf }
      Bolt (B)
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

    2. Engage the clamp to the oil cooler tube.

  17. CONNECT WIRE HARNESS

    Click here

  18. INSTALL FAN AND GENERATOR V BELT

    Click here

  19. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  20. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH (TWC: Front Catalyst)

    Click here

  21. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  22. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH (TWC: Front Catalyst)

    Click here

  23. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  24. INSTALL ENGINE MOUNTING DAMPER


    1. Install the 2 engine mounting dampers with the 2 bolts.

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

  25. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY RH


    1. Engage the 2 clamps to install the engine under cover sub-assembly RH to the front suspension crossmember sub-assembly.

  26. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY LH


    1. Engage the 2 clamps to install the engine under cover sub-assembly LH to the front suspension crossmember sub-assembly.

  27. INSTALL OIL LEVEL DIPSTICK GUIDE

    Click here

  28. INSTALL OIL LEVEL DIPSTICK SUB-ASSEMBLY

    Click here

  29. INSTALL ENGINE WITH TRANSMISSION ASSEMBLY


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

      Note


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

      • Do not perform any procedure 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 oil pan from deforming, do not place any attachments under the oil pan of the engine with transmission assembly.

    2. Remove the 2 bolts and 2 No. 1 engine hangers.

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

      Note

      Make sure that the engine with transmission assembly is clear of all wiring, hoses and the steering sliding yoke sub-assembly.

    4. B002E4NC02
      *a Nut

      Install the strut bar bracket reinforcement LH, strut bar bracket reinforcement RH and front suspension crossmember sub-assembly with the 6 bolts and 2 nuts.

      Torque:
      Bolt (A)
      194 N*m  { 1978 kgf*cm, 143 ft.*lbf }
      Bolt (B)
      57 N*m  { 581 kgf*cm, 42 ft.*lbf }
      Nut
      151 N*m  { 1540 kgf*cm, 111 ft.*lbf }

    5. Connect the front No. 2 stabilizer bracket LH and front No. 2 stabilizer bracket RH with the 4 bolts.

      Torque:
      Bolt (C)
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

    6. Install the rear engine mounting member to the vehicle body with the 4 bolts.

      Torque:
      34.7 N*m  { 354 kgf*cm, 26 ft.*lbf }

    7. Install the 2 No. 2 frame crossmember assemblies with the 6 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    8. B002E27C01
      *a Bolt

      Install the 2 oil cooler brackets with the 8 nuts and 2 bolts.

      Torque:
      Bolt, Nut (A)
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Nut (B)
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  30. CONNECT WIRE HARNESS (for LHD)


    1. Engage the 2 wire harness clamps to the power steering link assembly.

    2. Connect the 3 power steering link assembly connectors.

      Tech Tips

      For the connector with lock lever, fully insert the connector and push down the lock lever to engage the lock.

  31. CONNECT WIRE HARNESS (for RHD)


    1. Engage the 2 wire harness clamps to the power steering link assembly.

    2. Connect the 3 power steering link assembly connectors.

      Tech Tips

      For the connector with lock lever, fully insert the connector and push down the lock lever to engage the lock.

  32. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY

    Click here

  33. CONNECT TIE ROD ASSEMBLY LH

    Click here

  34. CONNECT TIE ROD ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  35. INSTALL STEERING SLIDING YOKE WITH SHAFT SUB-ASSEMBLY

    Click here

  36. CONNECT FRONT LOWER BALL JOINT ASSEMBLY LH

    Click here

  37. CONNECT FRONT LOWER BALL JOINT ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  38. CONNECT FRONT SHOCK ABSORBER ASSEMBLY LH


    1. Connect the front shock absorber assembly LH to the front suspension lower arm assembly LH with the bolt and nut.

      Torque:
      108 N*m  { 1101 kgf*cm, 80 ft.*lbf }

      Note


      • Insert the bolt from the rear of the vehicle.

      • Because the nut has its own stopper, do not turn the nut. Tighten the bolt with the nut secured.

  39. CONNECT FRONT SHOCK ABSORBER ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  40. INSTALL FRONT SKID CONTROL SENSOR WIRE LH

    Click here

  41. INSTALL FRONT SKID CONTROL SENSOR WIRE RH

    Tech Tips

    Perform the same procedure as for the LH side.

  42. INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

    Click here

  43. INSTALL NO. 1 ENGINE ROOM RELAY BLOCK


  44. INSTALL BATTERY TRAY

    Click here

  45. INSTALL POWER STEERING ECU ASSEMBLY


  46. CONNECT WIRE HARNESS (for LHD)


    1. Connect the ground cable to the generator assembly with the bolt.

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

    2. Engage the clamp.

    3. Engine room LH side:


      1. Install the engine wire to the engine room ECU box.

        Click here

      2. Engage the engine wire clamp.

    4. Engine room RH side:


      1. Connect the No. 3 engine wire to the vehicle body with the bolt.

        Torque:
        8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

      2. Engage the 2 claws to connect the No. 4 engine wire to the No. 1 engine room relay block.

      3. Engage the No. 4 engine wire clamp.

      4. Install the nut to the No. 1 engine room relay block.

        Torque:
        10.5 N*m  { 107 kgf*cm, 8 ft.*lbf }

      5. Install the No. 1 engine room relay block cover to the No. 1 engine room relay block.

      6. Connect the No. 2 engine wire to the positive (+) battery terminal with the nut.

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

      7. Engage the No. 2 engine wire clamp.

  47. CONNECT WIRE HARNESS (for RHD)


    1. Connect the ground cable to the generator assembly with the bolt.

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

    2. Engage the clamp.

    3. Engine room LH side:


      1. Install the engine wire to the engine room ECU box.

        Click here

      2. Engage the engine wire clamp.

      3. Engage the 2 claws to connect the No. 4 engine wire to the No. 1 engine room relay block.

      4. Engage the No. 4 engine wire clamp.

      5. Install the nut to the No. 1 engine room relay block.

        Torque:
        10.5 N*m  { 107 kgf*cm, 8 ft.*lbf }

      6. Install the No. 1 engine room relay block cover to the No. 1 engine room relay block.

      7. Connect the No. 2 engine wire to the positive (+) battery terminal with the nut.

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

      8. Engage the No. 2 engine wire clamp.

    4. Engine room RH side:


      1. Connect the No. 3 engine wire to the vehicle body with the bolt.

        Torque:
        8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  48. INSTALL ENGINE ROOM ECU COVER

    Click here

  49. CONNECT SUCTION HOSE

    Click here

  50. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

  51. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. Connect the fuel tube sub-assembly to the fuel pipe.


      1. Align the fuel tube connector with the fuel pipe, then push the fuel tube connector in until the retainer makes a "click" sound. If it is difficult to push the fuel tube connector in, apply a small amount of clean engine oil to the tip of the fuel pipe. After connecting, pull the fuel pipe and fuel tube connector to make sure that they are securely connected.

    2. Install the fuel pipe clamp.

  52. CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY


    1. Connect the No. 2 fuel tube sub-assembly to the fuel pipe.


      1. Align the fuel tube connector with the fuel pipe, then push the fuel tube connector in until the retainer makes a "click" sound. If it is difficult to push the fuel tube connector in, apply a small amount of clean engine oil to the tip of the fuel pipe. After connecting, pull the fuel pipe and fuel tube connector to make sure that they are securely connected.

    2. Install the fuel pipe clamp.

  53. CONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. Connect the No. 1 fuel vapor feed hose to the purge valve (purge VSV) and slide the clip to secure it.

  54. CONNECT UNION TO CHECK VALVE HOSE (for LHD)


    1. Connect the union to check valve hose to the intake air surge tank assembly and slide the clip to secure it.

    2. Engage the union to check valve hose to the clamp.

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


    1. Connect the union to check valve hose to the intake air surge tank assembly and slide the clip to secure it.

    2. Engage the union to check valve hose to the clamp.

  56. CONNECT HEATER WATER OUTLET HOSE


    1. Connect the heater water outlet hose to the No. 3 water by-pass pipe and slide the clip to secure it.

  57. CONNECT HEATER WATER INLET HOSE


    1. Connect the heater water inlet hose to the No. 3 water by-pass pipe and slide the clip to secure it.

  58. CONNECT OIL COOLER HOSE SUB-ASSEMBLY


    1. Apply a small amount of engine oil to 2 new O-rings and install them to the oil cooler hose sub-assembly.

      Note

      Do not damage the O-rings.

    2. Connect the oil cooler hose sub-assembly with the 2 bolts.

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

  59. CONNECT NO. 2 OIL COOLER OUTLET HOSE


    1. Connect the No. 2 oil cooler outlet hose to the oil cooler assembly and slide the clip to secure it.

  60. CONNECT NO. 2 OIL COOLER INLET HOSE


    1. Connect the No. 2 oil cooler inlet hose to the oil cooler assembly and slide the clip to secure it.

  61. CONNECT NO. 2 RADIATOR HOSE


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

  62. CONNECT NO. 1 RADIATOR HOSE


    1. Connect the No. 1 radiator hose to the front water by-pass joint and slide the clip to secure it.

  63. INSTALL RADIATOR RESERVE TANK ASSEMBLY

    Click here

  64. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Tech Tips

    Perform this procedure only when replacement of the air cleaner case sub-assembly is necessary.


    1. Install the air cleaner case sub-assembly with the 2 bolts.

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

    2. Connect the vacuum switching valve connector and engage the clamp.

    3. Connect the vacuum hose assembly and engage the 2 clamps.

  65. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Click here

  66. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

    Click here

  67. CONNECT VENTILATION HOSE

    Click here

  68. INSTALL INLET NO. 1 AIR CLEANER

    Click here

  69. INSTALL ENGINE UNDER COVER AIR GUIDE BRACKET


    1. Install the engine under cover air guide bracket with the 2 bolts.

      Torque:
      25.5 N*m  { 260 kgf*cm, 19 ft.*lbf }

  70. INSTALL NO. 2 ENGINE UNDER COVER


    1. Install the No. 2 engine under cover with the 2 screws.

  71. INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR


    1. Install the front lower suspension member protector with the 4 bolts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  72. INSTALL FRONT SUSPENSION MEMBER BRACE SUB-ASSEMBLY


    1. Install the front suspension member brace sub-assembly with the 6 bolts and 4 nuts.

      Torque:
      Bolt
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }
      Nut
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  73. INSTALL FRONT FENDER LINER LH


    1. Install the front fender liner LH with the 5 screws.

  74. INSTALL FRONT FENDER LINER RH

    Tech Tips

    Perform the same procedure as for the LH side.

  75. INSTALL REAR ENGINE UNDER COVER LH


    1. Engage the claw and install the rear engine under cover LH to the vehicle.

    2. Install the screw.

  76. INSTALL REAR ENGINE UNDER COVER RH

    Tech Tips

    Perform the same procedure as for the LH side.

  77. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Click here

    Note

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

    Click here

  78. ADD ENGINE OIL

    Click here

  79. ADD ENGINE COOLANT

    Click here

  80. ADD AUTOMATIC TRANSMISSION FLUID

    Click here

  81. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT


  82. WARM UP ENGINE


  83. INSPECT SHIFT LEVER POSITION

    Click here

  84. ADJUST SHIFT LEVER POSITION

    Click here

  85. INSPECT FOR COOLANT LEAK

    Click here

  86. INSPECT FOR ENGINE OIL LEAK

    Click here

  87. INSPECT FOR FUEL LEAK

    Click here

  88. INSPECT FOR EXHAUST GAS LEAK

    Click here

  89. INSPECT FOR REFRIGERANT LEAK


  90. INSTALL FRONT WHEELS

    Click here

  91. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  92. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  93. PERFORM INITIALIZATION

    Click here

  94. INSPECT IGNITION TIMING

    Click here

  95. INSPECT ENGINE IDLE SPEED

    Click here

  96. INSPECT CO/HC

    Click here

  97. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR

    Click here

  98. CHECK ENGINE OIL LEVEL

    Click here

  99. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY


    1. Install the No. 1 engine under cover assembly with the 13 screws and 3 clips.

  100. INSTALL COOL AIR INTAKE DUCT SEAL

    Click here

  101. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. B002EW4C01
      *a Tip (Sphere)

      Attach the 4 clips in the order shown in the illustration to install the V-bank cover sub-assembly.

      Note


      • Securely attach the clips.

      • If the clips are forcibly attached or struck with an object, they may be damaged.

      • Do not apply any oil to the tips (sphere).