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.


    1. B005LCFN01

      Install the engine mounting insulator LH to the vehicle body with the 5 bolts.

      Torque:
      71 N*m  { 724 kgf*cm, 52 ft.*lbf }

      Note

      Temporarily tighten the bolt (A), then tighten the bolt (B) before tightening the order 4 bolts.

  2. INSTALL ENGINE MOUNTING SPACER

    Tech Tips

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


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

      Torque:
      71 N*m  { 724 kgf*cm, 52 ft.*lbf }

  3. 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. Install the engine mounting insulator sub-assembly RH to the engine mounting spacer and vehicle body with the nut and 2 bolts.

      Torque:
      71 N*m  { 724 kgf*cm, 52 ft.*lbf }

    2. Install the brake actuator with bracket to the engine mounting insulator sub-assembly RH with the bolt.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

    3. Install the cooler bracket to the engine mounting insulator sub-assembly RH with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    4. Engage the clamp to the engine mounting insulator sub-assembly RH.

  4. INSTALL REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. Install the rear engine mounting insulator to the front frame assembly with the 4 nuts.

      Torque:
      71 N*m  { 724 kgf*cm, 52 ft.*lbf }

    2. Install the 2 hole plugs to the front frame assembly.

  5. INSTALL FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. Install the front engine mounting insulator to the front frame assembly with the 3 nuts.

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

    2. Install the hole plug to the front frame assembly.

  6. INSTALL ENGINE HANGERS

    Click here

  7. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND


    1. Remove the engine assembly from the engine stand.

  8. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  9. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

    for U881E: Click here

    for U881F: Click here

  10. INSTALL TRANSFER STIFFENER PLATE RH (for AWD)

    Click here

  11. INSTALL STARTER ASSEMBLY

    Click here

  12. INSTALL FRONT ENGINE MOUNTING BRACKET

    for U881E: Click here

    for U881F: Click here

  13. INSTALL FRONT FRAME ASSEMBLY


    1. Temporarily install the front engine mounting insulator with front frame assembly to the front engine mounting bracket with the bolt.

    2. B005NDYC01
      *a Protrusion
      *b Rib

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

      Torque:
      71 N*m  { 724 kgf*cm, 52 ft.*lbf }

      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.

    3. Fully tighten the bolt of the front engine mounting insulator.

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

  14. INSTALL STEERING LINK ASSEMBLY

    Click here

  15. INSTALL FRONT NO. 1 STABILIZER BRACKET LH

    Click here

  16. INSTALL FRONT NO. 1 STABILIZER BRACKET RH

    Tech Tips

    Perform the same procedure as for the LH side.

  17. INSTALL NO. 2 VACUUM SWITCHING VALVE ASSEMBLY

    Click here

  18. INSTALL ENGINE WIRE


    1. Connect all connectors and clamps, and install the engine wire to the engine assembly with transaxle.

  19. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    Tech Tips

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

    Click here


    1. Using height adjustment attachments and plate lift attachments to keep the engine assembly with transaxle and front frame assembly level, set an engine lifter underneath the engine assembly with transaxle and front frame assembly.

      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.

    2. Remove the 4 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. B005OCZC02
      B005NIZ Bolt
      B005LWS Nut

      Install the frame side plate sub-assembly RH and frame side plate sub-assembly LH to the front frame assembly and vehicle body with the 6 bolts and 2 nuts.

      Torque:
      Bolt (A)
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }
      Bolt (B) and Nut (A)
      32 N*m  { 326 kgf*cm, 24 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 6 bolts and 2 nuts.

      Torque:
      Bolt (C)
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }
      Bolt (D) and Nut (B)
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }
    6. B005LO6N01

      Install the engine mounting insulator sub-assembly RH to the front No. 1 engine mounting bracket LH with the 2 bolts and 2 nuts.

      Torque:
      Bolt and Nut (A)
      71 N*m  { 724 kgf*cm, 52 ft.*lbf }
      Nut (B)
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

    7. Install the No. 2 engine mounting stay RH with the bolt and 2 nuts.

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

    8. Install the engine mounting insulator LH to the engine mounting bracket LH with the bolt and nut.

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

      Note

      Tighten the bolt while holding the nut in place.

  20. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

    for U881E: Click here

    for U881F: Click here

  21. INSTALL FLYWHEEL HOUSING UNDER COVER


    1. Install the flywheel housing under cover to the automatic transaxle case sub-assembly with the 2 bolts.

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

  22. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  23. INSTALL FRONT DRIVE SHAFT ASSEMBLY

    Click here

  24. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  25. INSTALL EXHAUST MANIFOLD

    Click here

  26. CONNECT SUCTION HOSE SUB-ASSEMBLY

    Click here

  27. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

    Click here

  28. CONNECT NO. 1 TRANSMISSION OIL COOLER HOSE ASSEMBLY


    1. for 2WD:


      1. Engage the clamp to connect the No. 1 transmission oil cooler hose assembly to the front No. 2 suspension member dynamic damper.

    2. for AWD:


      1. Connect the No. 1 transmission oil cooler hose assembly to the front frame assembly with the bolt.

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

  29. CONNECT NO. 1 TRANSMISSION OIL COOLER HOSE ASSEMBLY


    1. Connect the 2 No. 1 transmission oil cooler hose assemblies and slide the 2 clips to secure them.

  30. CONNECT UNION TO CHECK VALVE HOSE

    for LHD: Click here

    for RHD: Click here

  31. CONNECT OUTLET HEATER WATER HOSE


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

  32. CONNECT INLET HEATER WATER HOSE


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

    2. Engage the clamp.

  33. CONNECT NO. 2 RADIATOR HOSE


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

  34. CONNECT NO. 1 RADIATOR HOSE


    1. Install the No. 1 radiator hose to the radiator pipe clamp.

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

  35. CONNECT NO. 1 FUEL HOSE


    1. Connect the fuel tube sub-assembly (for Port Injection).


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

        Click here

    2. Connect the No. 2 fuel tube sub-assembly (for Direct Injection).


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

        Click here

    3. Install the No. 2 fuel pipe clamp to the fuel tube connector.

  36. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY


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

  37. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    for U881E: Click here

    for U881F: Click here

  38. CONNECT ENGINE WIRE


    1. Connect the No. 2 earth wire to the bracket with the bolt.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    2. Engage the clamp and connect the engine wire to the vehicle body.

    3. Engage the 2 claws to connect the engine room main wire to the engine wire.

    4. Install the engine room main wire with engine wire to the positive (+) battery terminal with the nut.

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

    5. Engage the clamp and connect the engine wire to the engine mounting insulator LH.

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

    7. Install the 2 nuts to the engine mounting insulator LH and vehicle body.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    8. Engage the clamp to the engine room relay block assembly.

    9. Connect the engine wire to the vehicle body with the bolt.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

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

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    11. Connect the 3 connectors to the engine room relay block assembly.

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

  39. INSTALL ECM

    Click here

  40. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. B005PF0N01

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

      Note


      • Securely engage the clips.

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

  41. INSTALL AIR CLEANER BRACKET


    1. Install the air cleaner bracket to the engine mounting insulator LH with the 2 bolts.

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

  42. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. Install the air cleaner case sub-assembly to the engine mounting insulator LH and air cleaner bracket with the 2 bolts.

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

  43. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


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

  44. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

    Click here

  45. INSTALL INLET AIR CLEANER ASSEMBLY

    Click here

  46. INSTALL COOL AIR INTAKE DUCT SEAL

    Click here

  47. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Click here

  48. ADD ENGINE OIL

    Click here

  49. ADD ENGINE COOLANT

    Click here

  50. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

  51. WARM UP ENGINE

    Click here

  52. INSPECT SHIFT LEVER POSITION

    for U881E: Click here

    for U881F: Click here

  53. ADJUST SHIFT LEVER POSITION

    for U881E: Click here

    for U881F: Click here

  54. INSPECT FOR ENGINE OIL LEAK

    Click here

  55. INSPECT FOR COOLANT LEAK

    Click here

  56. INSPECT FOR AUTOMATIC TRANSAXLE FLUID LEAK

  57. INSPECT FOR REFRIGERANT LEAK

    Click here

  58. INSPECT FOR FUEL LEAK

    Click here

  59. INSPECT FOR EXHAUST GAS LEAK

    Click here

  60. CHECK ENGINE OIL LEVEL

    Click here

  61. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR TANK

    Click here

  62. INSTALL FRONT FENDER APRON SEAL RH


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

  63. INSTALL FRONT FENDER APRON SEAL LH


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

  64. INSTALL FRONT FLOOR COVER LH

    Click here

  65. INSTALL NO. 2 ENGINE UNDER COVER


    1. Install the No. 2 engine under cover to the front frame assembly with the 2 bolts, 2 screws and clip.

  66. INSTALL FRONT LOWER BUMPER ABSORBER


    1. Engage the 2 claws and install the front lower bumper absorber to the vehicle body with the 4 screws and 2 clips.

  67. INSTALL NO. 1 ENGINE UNDER COVER


    1. Install the No. 1 engine under cover to the vehicle body with the 3 bolts, 2 screws and clip.

  68. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH


    1. Install the front wheel opening extension pad RH to the No. 1 engine under cover with the 2 screws.

  69. INSTALL NO. 3 ENGINE UNDER COVER


    1. Install the No. 3 engine under cover to the vehicle body with the 5 bolts, 2 screws and 2 clips.

  70. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH


    1. Install the front wheel opening extension pad LH to the No. 3 engine under cover with the 2 screws.

  71. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

    Click here

  72. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  73. PERFORM INITIALIZATION

    Click here

  74. INSPECT IGNITION TIMING

    Click here

  75. INSPECT ENGINE IDLE SPEED

    Click here

  76. INSPECT CO/HC

    Click here

  77. CHECK FOR SPEED SENSOR SIGNAL

    Click here