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.

    Click here

  2. INSTALL ENGINE MOUNTING BRACKET SUB-ASSEMBLY LH

    Tech Tips

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


    1. B006Y1TN01

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

      Torque:
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }

      Note

      Make sure that there is no gap between the engine mounting bracket sub-assembly LH and vehicle body before tightening the bolts.

  3. INSTALL ENGINE MOUNTING SPACER

    Tech Tips

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


    1. B006YPYN01

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

      Torque:
      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).

  4. 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. B006XCHE01

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

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

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    4. B006XIYN01

      Install the radiator reserve tank assembly with the bolt and nut in the order shown in the illustration.

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

    5. Engage the clamp.

  5. INSTALL ENGINE HANGERS

    Click here

  6. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND


    1. Remove the engine assembly from the engine stand.

  7. INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE

    Click here

  8. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  9. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

    Click here

  10. INSTALL FRONT ENGINE MOUNTING BRACKET

    Click here

  11. INSTALL REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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

    Click here

  12. 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:
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }

  13. INSTALL FRONT FRAME ASSEMBLY


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

      Torque:
      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.

      Torque:
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }

  14. REMOVE ENGINE HANGERS

    Click here

  15. INSTALL ENGINE WIRE


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

  16. CONNECT WATER BY-PASS HOSE ASSEMBLY

    Click here

  17. CONNECT NO. 1 WATER BY-PASS HOSE

    Click here

  18. INSTALL BREATHER PLUG HOSE

    Click here

  19. INSTALL STARTER ASSEMBLY

    Click here

  20. CONNECT VACUUM HOSE

    Click here

  21. 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. 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.

    3. B0070VKC02
      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.

      Torque:
      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 }

    4. 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.

      Torque:
      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 }

    5. Install the engine mounting insulator LH to the engine mounting bracket sub-assembly LH with the bolt and nut.

      Torque:
      42 N*m  { 428 kgf*cm, 31 ft.*lbf }

    6. Install the engine mounting insulator sub-assembly RH to the front No. 1 engine mounting bracket LH with the 3 bolts and nut.

      Torque:
      Bolt
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }
      Nut
      42 N*m  { 428 kgf*cm, 31 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 }

  22. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

    Click here

  23. INSTALL FLYWHEEL HOUSING UNDER COVER


    1. Install the flywheel housing under cover with the 2 bolts.

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

  24. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Upper Side)


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

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

  25. INSTALL FRONT DRIVE SHAFT ASSEMBLY

    Click here

  26. INSTALL EXHAUST MANIFOLD

    Click here

  27. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  28. CONNECT EARTH WIRE


    1. Connect the earth wire to the vehicle body with the 2 bolts.

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

  29. CONNECT ENGINE WIRE


    1. Engage the 2 clamps and connect the engine wire to the vehicle body.

    2. Connect the engine wire with the bolt.

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

    3. Engage the 2 clamps.

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

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

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

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

    7. Install the No. 2 relay block cover to the engine room relay block and junction block assembly.

  30. CONNECT SUCTION HOSE SUB-ASSEMBLY

    Click here

  31. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE SUB-ASSEMBLY

    Click here

  32. CONNECT NO. 1 FUEL HOSE


    1. Connect the No. 1 fuel hose (for Port Injection).


      1. Connect the No. 1 fuel hose to the fuel pipe.

        Click here

    2. Connect the No. 1 fuel hose (for Direct Injection).


      1. Connect the No. 1 fuel hose to the fuel pipe.

        Click here

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

    4. Engage the 2 claws to install the No. 2 fuel pipe clamp.

  33. CONNECT OUTLET HEATER WATER HOSE


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

  34. 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.

  35. CONNECT RADIATOR HOSE SUB-ASSEMBLY


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

    2. Install the radiator hose sub-assembly to the engine assembly with the 2 bolts.

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

  36. CONNECT NO. 2 RADIATOR HOSE


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

  37. CONNECT UNION TO CHECK VALVE HOSE


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

  38. 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.

  39. 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. B006Y1HC01
      *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. INSTALL BATTERY CLAMP SUB-ASSEMBLY


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

      Torque:
      18.5 N*m  { 189 kgf*cm, 14 ft.*lbf }

    2. Engage the 5 clamps to the battery clamp sub-assembly.

  41. INSTALL BATTERY

    Click here

  42. CONNECT ENGINE ROOM MAIN WIRE


    1. Connect the engine wire with engine room main wire to the positive (+) battery terminal with the nut.

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

  43. INSTALL ECM

    Click here

  44. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE


    1. B006X5MC01
      *a Protrusion
      *b Cutout
      *c Hose Clamp End
      *d 2.0 mm (0.0787 in.)
      *e Paint Mark

      Install the air cleaner assembly with air cleaner hose to the throttle body with motor assembly.

      Note

      Align the cutout of the air cleaner hose assembly with the protrusion of the throttle body with motor assembly.

    2. Tighten the hose clamp in the position shown in the illustration.

      Note

      Make sure that the end of the hose clamp is positioned as shown in the illustration.

    3. B00712CC01
      *a Air Cleaner Support

      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.

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

    5. Engage the 3 wire harness clamps.

    6. Connect the mass air flow meter sub-assembly connector.

    7. B0070PRC01
      *1 No. 1 Fuel Vapor Feed Hose
      *2 No. 2 Ventilation Hose
      *a Top
      *b Paint Mark
      *c Rear of Vehicle
      *d 180° (Claw of Clip Location)

      Connect the No. 2 ventilation hose to the air cleaner hose and slide the clip to secure it.

      Note

      Make sure that the condition of the clip is as shown in the illustration.

    8. Engage the 2 clamps to connect the No. 1 fuel vapor feed hose to the air cleaner hose.

  45. INSTALL INLET AIR CLEANER ASSEMBLY


    1. B006XDBE01

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

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

  46. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. B006YZCN01

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

      Note


      • Make sure that the clips are engaged securely.

      • Do not subject the clips to shock or apply excessive force to the clips when engaging them or they may be damaged.

      • If the clips are not engaged in the order shown in the illustration, the V-bank cover sub-assembly may be damaged.

  47. INSPECT VACUUM HOSES


    1. Inspect the vacuum hoses.

      B006ZMW

  48. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  49. ADD ENGINE OIL

    Click here

  50. ADD ENGINE COOLANT

    Click here

  51. ADD AUTOMATIC TRANSAXLE FLUID

    Click here

  52. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

  53. WARM UP ENGINE

    Click here

  54. INSPECT SHIFT LEVER POSITION

    Click here

  55. ADJUST SHIFT LEVER POSITION

    Click here

  56. INSPECT FOR ENGINE OIL LEAK

    Click here

  57. INSPECT FOR COOLANT LEAK

    Click here

  58. INSPECT FOR REFRIGERANT LEAK

    Click here

  59. INSPECT FOR FUEL LEAK

    Click here

  60. INSPECT FOR EXHAUST GAS LEAK

    Click here

  61. CHECK ENGINE OIL LEVEL

    Click here

  62. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR TANK

    Click here

  63. INSTALL FRONT LOWER BUMPER ABSORBER


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

    2. Install the 4 bolts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  64. INSTALL FRONT BUMPER COVER

    Click here

  65. INSTALL FRONT FENDER APRON SEAL LH


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

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  66. INSTALL FRONT FENDER APRON SEAL RH


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

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  67. INSTALL NO. 1 ENGINE UNDER COVER


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

      Torque:
      Bolt
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  68. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH


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

  69. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH


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

  70. INSTALL FRONT WHEELS

    Click here

  71. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  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