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ENGINE ASSEMBLY INSTALLATION

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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.

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PROCEDURE


  1. Click here

    INSTALL ENGINE MOUNTING INSULATOR LH

    Tip:

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

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  2. Click here

    INSTALL ENGINE MOUNTING SPACER

    Tip:

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


    1. B006XGLN01

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

      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).

  3. Click here

    INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    Tip:

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


    1. B00713ZN01

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

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

      8.0 N*m 82 kgf*cm 71 in.*lbf

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

      5.0 N*m 51 kgf*cm 44 in.*lbf

    5. Engage the clamp.

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

  4. Click here

    INSTALL ENGINE HANGERS

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  5. Click here

    REMOVE ENGINE ASSEMBLY FROM ENGINE STAND


    1. Remove the engine assembly from the engine stand.

  6. Click here

    INSTALL ENGINE WIRE


    1. Install the engine wire to the engine assembly.

  7. Click here

    INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

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  8. Click here

    INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

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  9. Click here

    INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

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  10. Click here

    INSTALL FRONT ENGINE MOUNTING BRACKET

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  11. Click here

    INSTALL REAR ENGINE MOUNTING INSULATOR

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  12. Click here

    INSTALL FRONT ENGINE MOUNTING INSULATOR


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

      72 N*m 734 kgf*cm 53 ft.*lbf
  13. Click here

    INSTALL FRONT FRAME ASSEMBLY


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

      72 N*m 734 kgf*cm 53 ft.*lbf

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

      72 N*m 734 kgf*cm 53 ft.*lbf
  14. Click here

    INSTALL STARTER ASSEMBLY

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  15. Click here

    INSTALL FLYWHEEL HOUSING SIDE COVER

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  16. Click here

    CONNECT WIRE HARNESS

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  17. Click here

    INSTALL STEERING GEAR HEAT INSULATOR

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  18. Click here

    INSTALL BREATHER PLUG HOSE

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  19. Click here

    CONNECT WATER BY-PASS HOSE ASSEMBLY

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  20. Click here

    INSTALL FLOW SHUTTING VALVE (NO. 1 WATER BY-PASS HOSE)

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  21. Click here

    CONNECT VACUUM HOSE

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  22. Click here

    INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

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  23. Click here

    INSTALL FLYWHEEL HOUSING UNDER COVER


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

  24. Click here

    INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    Tip:

    Perform inspection after repair after replacing the engine assembly.



    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.

    2. Remove the 4 bolts, No. 1 engine hanger and No. 2 engine hanger.

    3. Install the fuel delivery guard to the engine mounting bracket RH with the bolt.

      40 N*m 408 kgf*cm 30 ft.*lbf

    4. 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.

    5. B0071MPC01
      B006Z38 Bolt
      B006ZY0 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.

      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

    6. 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.

      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

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

      42 N*m 428 kgf*cm 31 ft.*lbf
      Note:

      While holding the bolt in place, tighten the nut.

    8. Install the engine mounting insulator sub-assembly RH to the engine mounting bracket RH with the 3 bolts and nut.

      Bolt
      72 N*m 734 kgf*cm 53 ft.*lbf
      Nut
      42 N*m 428 kgf*cm 31 ft.*lbf

    9. Install the body mounting plate with the 6 bolts.

      17.5 N*m 178 kgf*cm 13 ft.*lbf

    10. Engage the clamp.

  25. Click here

    INSTALL FRONT DRIVE SHAFT ASSEMBLY

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  26. Click here

    INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

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  27. Click here

    CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY

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  28. Click here

    CONNECT NO. 5 WATER BY-PASS HOSE


    1. Engage the clamp.

    2. Connect the No. 5 water by-pass hose to the No. 3 water by-pass pipe and slide the clip to secure it.

  29. Click here

    CONNECT WIRE HARNESS


    1. B0070CJN01

      Connect the wire harness to the body with the bolt.

      Bolt (A)
      8.0 N*m 82 kgf*cm 71 in.*lbf

    2. Connect the earth wire to the automatic transaxle assembly with the bolt.

      Bolt (B)
      20 N*m 204 kgf*cm 15 ft.*lbf

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

      Nut (C)
      7.6 N*m 77 kgf*cm 67 in.*lbf

    4. Engage the 3 clamps.

    5. Engage the claw to install the wire harness to the engine room relay block and junction block assembly.

    6. Connect the 4 connectors to the engine room relay block and junction block assembly.

    7. Install the nut to the engine room relay block and junction block assembly.

      8.0 N*m 82 kgf*cm 71 in.*lbf

    8. Install the relay block cover to the engine room relay block and junction block assembly.

  30. Click here

    CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE SUB-ASSEMBLY

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  31. Click here

    CONNECT SUCTION HOSE SUB-ASSEMBLY

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  32. Click here

    CONNECT NO. 2 RADIATOR HOSE


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

  33. Click here

    CONNECT NO. 1 RADIATOR HOSE


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

    2. Connect the No. 1 radiator hose to the No. 1 radiator bracket with the clamp.

  34. Click here

    CONNECT FUEL TUBE SUB-ASSEMBLY


    1. Connect the fuel tube sub-assembly.


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

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    2. Install the No. 1 fuel pipe clamp to the fuel tube connector.

  35. Click here

    CONNECT INLET HEATER HOSE


    1. B006ZQ3C02
      *a Protrusion
      *b Cutout

      Align the protrusions of the inlet heater hose connector with the cutouts in the flow shutting valve (water by-pass hose assembly) and push them together until the inlet heater hose connector makes a "click" sound.

    2. B006YYMC03
      *a Retainer
      B006Z38 Push
      B006ZY0 Push in

      Push in the retainer.

    3. Check that the flow shutting valve (water by-pass hose assembly) and inlet heater hose connector are securely connected by pulling on them.

  36. Click here

    CONNECT OUTLET HEATER HOSE


    1. B006WWCC02
      *a Protrusion
      *b Cutout

      Align the protrusion of the No. 2 water by-pass pipe sub-assembly with the cutout in the outlet heater hose connector and push them together until the outlet heater hose makes a "click" sound.

    2. B006X5FC02
      *a Retainer
      B006Z38 Push
      B006ZY0 Push in

      Push in the retainer.

    3. Check that the No. 2 water by-pass pipe sub-assembly and outlet heater hose connector are securely connected by pulling on them.

  37. Click here

    CONNECT UNION TO CHECK VALVE HOSE


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

  38. Click here

    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.

  39. Click here

    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. B006WXOC02
      *a Correct
      *b Incorrect

      Connect the transmission control cable assembly to the transmission control shaft lever as shown in the illustration.

      Note:

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

  40. Click here

    INSTALL BATTERY CLAMP SUB-ASSEMBLY


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

      18.5 N*m 189 kgf*cm 14 ft.*lbf

    2. Engage the 4 clamps to the battery clamp sub-assembly.

  41. Click here

    INSTALL BATTERY

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  42. Click here

    INSTALL ECM

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  43. Click here

    INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE


    1. B006Z31C01
      *a Air Cleaner Support

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

    2. 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.

    3. Engage the vacuum hose to the air cleaner hose.

    4. Connect the No. 2 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.

  44. Click here

    INSTALL INLET AIR CLEANER ASSEMBLY


    1. B006X25N01

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

      8.0 N*m 82 kgf*cm 71 in.*lbf
  45. Click here

    INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. B00718U

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

  46. Click here

    INSPECT VACUUM HOSES


    1. B006YR3

      Inspect the vacuum hoses.

  47. Click here

    CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

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

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  48. Click here

    ADD ENGINE OIL

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  49. Click here

    ADD ENGINE COOLANT

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  50. Click here

    ADD AUTOMATIC TRANSAXLE FLUID

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  51. Click here

    CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

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  52. Click here

    WARM UP ENGINE

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  53. Click here

    INSPECT SHIFT LEVER POSITION

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  54. Click here

    ADJUST SHIFT LEVER POSITION

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  55. Click here

    INSPECT FOR ENGINE OIL LEAK

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  56. Click here

    INSPECT FOR COOLANT LEAK

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  57. Click here

    INSPECT FOR REFRIGERANT LEAK

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  58. Click here

    INSPECT FOR FUEL LEAK

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  59. Click here

    INSPECT FOR EXHAUST GAS LEAK

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  60. Click here

    CHECK ENGINE OIL LEVEL

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  61. Click here

    INSPECT ENGINE COOLANT LEVEL IN RESERVOIR

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  62. Click here

    INSTALL FRONT LOWER BUMPER ABSORBER


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

    2. Install the 4 bolts.

      7.5 N*m 76 kgf*cm 66 in.*lbf
  63. Click here

    INSTALL FRONT BUMPER COVER

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  64. Click here

    INSTALL FRONT FENDER APRON SEAL LH


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

      7.5 N*m 76 kgf*cm 66 in.*lbf
  65. Click here

    INSTALL FRONT FENDER APRON SEAL RH


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

      7.5 N*m 76 kgf*cm 66 in.*lbf
  66. Click here

    INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY


    1. Install the No. 2 engine under cover assembly with the 4 screws and 6 clips.

      7.5 N*m 76 kgf*cm 66 in.*lbf
  67. Click here

    INSTALL NO. 1 ENGINE UNDER COVER


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

      Bolt
      7.5 N*m 76 kgf*cm 66 in.*lbf
  68. Click here

    INSTALL FRONT WHEEL OPENING EXTENSION PAD LH


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

  69. Click here

    INSTALL FRONT WHEEL OPENING EXTENSION PAD RH


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

  70. Click here

    INSTALL FRONT WHEELS

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  71. Click here

    ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  72. Click here

    INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

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  73. Click here

    PERFORM INITIALIZATION

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  74. Click here

    INSPECT IGNITION TIMING

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  75. Click here

    INSPECT ENGINE IDLE SPEED

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  76. Click here

    INSPECT CO/HC

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  77. Click here

    CHECK SPEED SENSOR SIGNAL

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