ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

Note

As the engine assembly with transaxle is extremely heavy, the engine lifter may suddenly drop if the instructions listed in the repair manual are not followed. Therefore, always follow the instructions listed in the repair manual when performing this procedure.

Tech Tips

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

PROCEDURE


  1. INSTALL INNER OIL SEAL (w/ Stop And Start System)

    Click here

  2. INSTALL RING GEAR SUB-ASSEMBLY (w/ Stop And Start System)

    Click here

  3. REMOVE RING GEAR SNAP RING (w/ Stop And Start System)

    Click here

  4. INSTALL ERS ONE-WAY CLUTCH ASSEMBLY (w/ Stop And Start System)

    Click here

  5. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (w/ Stop And Start System)

    Click here

  6. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for CVT)

    Click here

  7. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)

    Click here

  8. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)

    Click here

  9. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)

    Click here

  10. INSTALL WATER HOSE SUB-ASSEMBLY B (for Manual Transaxle)


    1. Install the water hose sub-assembly B with the clamp.

  11. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY (for CVT)


    1. Install the No. 2 water by-pass pipe hose sub-assembly with the clamp.

  12. INSTALL WATER HOSE SUB-ASSEMBLY


    1. Install the water hose sub-assembly with the clamp.

  13. INSTALL ENGINE WIRE


    1. Install the engine wire to the cylinder head cover with the 2 nuts.

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

    2. Install the 2 ground wires to the cylinder head with the 2 bolts.

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

  14. REMOVE ENGINE HANGER


    1. Remove the 2 bolts and 2 engine hangers.

  15. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

    Click here

  16. INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY (for CVT)

    Click here

  17. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for CVT)

    Click here

  18. INSTALL STARTER ASSEMBLY (w/ Stop And Start System)

    Click here

  19. INSTALL STARTER ASSEMBLY (w/o Stop And Start System)

    Click here

  20. INSTALL FLYWHEEL HOUSING SIDE COVER (w/ Stop And Start System)

    Click here

  21. INSTALL FLYWHEEL HOUSING SIDE COVER (w/o Stop And Start System)

    Click here

  22. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


    1. Install the engine mounting insulator sub-assembly RH with the 3 bolts.

      Tech Tips

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

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

    2. Install the engine mounting insulator LH with the 5 bolts.

      Tech Tips

      Only perform this procedure when replacement of the engine mounting insulator LH is necessary.

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

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

    4. Operate the engine lifter and lift the engine assembly with transaxle into the position where the engine mounting insulators RH and LH can be installed.

      CAUTION:

      Do not raise the engine more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

      Note


      • Make sure that the engine is clear of all wiring and hoses.


      • While raising the engine into the vehicle, do not allow it to contact the vehicle.

    5. Install the engine mounting insulator LH with the through bolt and nut.

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

    6. Install the engine mounting insulator sub-assembly RH with the bolt and 2 nuts.

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

    7. Provisionally install the front suspension crossmember onto the body with the 6 bolts.

      A01VHZEE02
      Text in Illustration
      *a Datum Hole - -
      A01VL3H Front of the Vehicle - -

    8. By inserting SST into the datum holes in the front suspension crossmember RH and LH alternately, tighten bolts A, B and C on both sides to the specified torque, in several steps.

      SST
      09670-00010
      Torque:
      Bolt A
      87 N*m  { 887 kgf*cm, 64 ft.*lbf }
      Bolt B
      151 N*m  { 1540 kgf*cm, 111 ft.*lbf }
      Bolt C
      98 N*m  { 999 kgf*cm, 72 ft.*lbf }

      Note


      • Insert SST into the datum hole in a vertical orientation.

      • If SST cannot be inserted into the datum hole vertically, loosen all the bolts and then insert SST again.

    9. A01VLCO

      Tighten the bolt and install the engine moving control rod.

      Torque:
      120 N*m  { 1224 kgf*cm, 89 ft.*lbf }

  23. INSTALL WIRE HARNESS CLAMP BRACKET (for Manual Transaxle)


    1. Install wire harness clamp bracket with the bolt.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  24. INSTALL WIRE HARNESS CLAMP BRACKET (for CVT)


    1. Install wire harness clamp bracket with the bolt.

      Torque:
      61 N*m  { 622 kgf*cm, 45 ft.*lbf }

  25. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY


    1. Install the drive shaft heat insulator sub-assembly with the 2 bolts.

      Torque:
      24 N*m  { 240 kgf*cm, 17 ft.*lbf }

  26. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. A01VJJ8

      Using a vernier caliper, measure the free length of the compression springs.

      Minimum length
      41.5 mm (1.634 in.)

      If the length is not as specified, replace the compression spring.

    2. A01VIW9E05
      Text in Illustration
      *1 Gasket
      *2 Wooden Block
      *3 Plastic Hammer
      *4 Exhaust Manifold Converter Sub-assembly

      Using a plastic hammer and a wooden block, tap in a new gasket until its surface is flush with the exhaust manifold converter sub-assembly.

      Note


      • Install the gasket in the correct direction.

      • Do not reuse the gasket.

      • Do not damage the gasket by dropping it, etc.

      • Do not damage the outer surface of the gasket.

      • Do not push in the gasket with the exhaust pipe when connecting its.

    3. Hang the front exhaust pipe assembly with the 3 exhaust pipe supports.

    4. A01VJRBE01
      Text in Illustration
      *1 Exhaust Manifold Converter Sub-assembly
      *2 Front Exhaust Pipe Assembly
      *3 Gasket
      *a Space between flanges: 8.5 mm (0.335 in.)

      Install the front exhaust pipe sub-assembly to the exhaust manifold converter sub-assembly with the 2 compression springs and 2 bolts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

      Note

      After the installation, check that the gaps between the flanges of the exhaust manifold converter sub-assembly and front exhaust pipe assembly are consistent front-to-rear and left-to-right.

    5. Hang the tail exhaust pipe assembly with the exhaust pipe support.

    6. Install a new gasket onto the front exhaust pipe sub-assembly.

    7. Install the tail exhaust pipe assembly onto the front exhaust pipe sub-assembly with the 2 compression springs and 2 bolts.

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

    8. Connect the connector of the heated oxygen sensor.

    9. Engage the clamp and connect the heated oxygen sensor wire to the wire harness clamp bracket.

  27. INSTALL FRONT FLOOR CENTER BRACE

    Click here

  28. INSTALL FRONT DRIVE SHAFT ASSEMBLY

    Click here

  29. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  30. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY

    Click here

  31. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  32. CONNECT ENGINE WIRE (for Manual Transaxle)


    1. Connect the connector to the negative battery terminal.

    2. Connect the 2 connectors to the positive battery terminal.

    3. Install the ground wire to the body with the bolt.

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

    4. Engage the 3 clamps and connect the connector to the engine room relay block.

    5. Install the engine room relay block cover.

    6. Check that the engine wire is connected between the body and engine assembly with transaxle.

  33. CONNECT ENGINE WIRE (for CVT)


    1. Connect the connector to the negative battery terminal.

    2. Connect the 2 connectors to the positive battery terminal.

    3. Install the ground wire to the body with the bolt.

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

    4. Engage the 3 clamps and connect the 2 connectors to the engine room relay block.

    5. Install the engine room relay block cover.

    6. Check that the engine wire is connected between the body and engine assembly with transaxle.

  34. CONNECT ECM CONNECTOR (for LHD)


    1. A01VKWF

      Pull down the lever to engage the lock and connect the connector to the ECM.

      Note

      Make sure that the levers are securely locked.

    2. Engage the clamp and install the engine wire.

  35. CONNECT ECM CONNECTOR (for RHD)


    1. A01VGI0

      Pull down the lever to engage the lock and connect the connector to the ECM.

      Note

      Make sure that the levers are securely locked.

  36. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY (for TMC Made)

    Click here

  37. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY (for TMMF Made)

    Click here

  38. INSTALL CLUTCH HOSE (for Manual Transaxle)

    Click here

  39. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)

    Click here

  40. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for CVT)

    Click here

  41. CONNECT FUEL TUBE SUB-ASSEMBLY

    Click here

  42. INSTALL EFI FUEL PIPE CLAMP

    Click here

  43. CONNECT WATER HOSE SUB-ASSEMBLY (for TMC Made)

    Click here

  44. CONNECT WATER HOSE SUB-ASSEMBLY B (for TMC Made)

    Click here

  45. CONNECT WATER HOSE SUB-ASSEMBLY (for TMMF Made)

    Click here

  46. CONNECT WATER HOSE SUB-ASSEMBLY B (for TMMF Made)

    Click here

  47. CONNECT NO. 2 RADIATOR HOSE


    1. A01VM2EE02
      Text in Illustration
      *a View A
      *b Upper Side

      Connect the No. 2 radiator hose with the clamp.

  48. CONNECT NO. 1 RADIATOR HOSE


    1. A01VJ5JE01
      Text in Illustration
      *a View A
      *b Upper Side
      *c Rear Side

      Connect the No. 1 radiator hose with the clamp.

  49. CONNECT NO. 1 BREATHER PLUG (for CVT)


    1. Connect the No. 1 breather plug.

  50. CONNECT UNION TO CONNECTOR TUBE HOSE


    1. Connect the union to connector tube hose to the intake manifold.

  51. INSTALL AIR CLEANER AND HOSE ASSEMBLY


    1. Connect the air cleaner hose to the throttle body.

    2. Connect the No. 2 ventilation hose to the air cleaner hose.

    3. Connect the No. 1 fuel vapor feed hose and the No. 2 fuel vapor feed hose to the No. 1 vacuum switching valve assembly.

    4. Connect the No. 1 vacuum switching valve assembly connector and engage the clamp.

    5. Install the air cleaner case to the cylinder head cover with the 2 bolts.

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

    6. Connect the intake mass air flow meter connector and engage the clamp.

  52. INSTALL BATTERY CARRIER


    1. Install the battery carrier with the 5 bolts.

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

    2. Engage the 3 clamps and connect the wire harness to the battery carrier.

  53. INSTALL BATTERY TRAY


    1. Install the battery tray to the battery carrier.

  54. INSTALL BATTERY


    1. Install the battery to the battery tray.

    2. Install the battery carrier clamp with the nut.

      Torque:
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

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

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  55. INSTALL GENERATOR ASSEMBLY (for 80A Type)

    Click here

  56. INSTALL GENERATOR ASSEMBLY (for 100A Type)

    Click here

  57. INSTALL OUTER COWL TOP PANEL

    Click here

  58. INSTALL INNER COWL TOP TO COWL BRACE

    Click here

  59. INSTALL FRONT NO. 1 VENTILATOR SEAL

    Click here

  60. INSTALL FRONT AIR SHUTTER SEAL RH

    Click here

  61. INSTALL WINDSHIELD WIPER LINK ASSEMBLY

    Click here

  62. INSTALL FRONT WHEELS

    Torque:
    103 N*m  { 1050 kgf*cm, 76 ft.*lbf }

  63. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Torque:
    5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  64. INSPECT SHIFT LEVER POSITION (for CVT)

    Click here

  65. ADJUST SHIFT LEVER POSITION (for CVT)

    Click here

  66. INSTALL REAR CONSOLE BOX ASSEMBLY (for CVT)

    Click here

  67. ADD ENGINE OIL

    Click here

  68. ADD ENGINE COOLANT

    Click here

  69. ADD CONTINUOUSLY VARIABLE TRANSAXLE FLUID (for CVT)

    Click here

  70. ADD MANUAL TRANSAXLE OIL (for Manual Transaxle)

    Click here

  71. BLEED CLUTCH PIPE LINE (for Manual Transmission)

    Click here

  72. INSPECT CONTINUOUSLY VARIABLE TRANSAXLE FLUID (for CVT)

    Click here

  73. INSPECT FOR FUEL LEAK

    Click here

  74. INSPECT ENGINE OIL LEVEL

    Click here

  75. INSPECT FOR ENGINE OIL LEAK

  76. INSPECT FOR ENGINE COOLANT LEAK

    Click here

  77. INSPECT RESERVOIR TANK ENGINE COOLANT LEVEL

    Click here

  78. INSPECT CONTINUOUSLY VARIABLE TRANSAXLE FLUID LEAK (for CVT)

  79. INSPECT MANUAL TRANSAXLE OIL LEAK (for Manual Transaxle)

  80. INSPECT FOR CLUTCH FLUID LEAK (for Manual Transmission)

  81. INSPECT FOR EXHAUST GAS LEAK

    Tech Tips

    Perform "Inspection After Repairs" after repairing gas leaks in the exhaust system Click here.

  82. INSPECT IGNITION TIMING

    Click here

  83. INSPECT ENGINE IDLING SPEED

    Click here

  84. INSPECT CO/HC

    Click here

  85. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  86. INSTALL ENGINE UNDER COVER RH

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

  87. INSTALL ENGINE UNDER COVER LH

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

  88. CHECK ABS SENSOR SIGNAL (w/o VSC)

    Click here

  89. CHECK VSC SENSOR SIGNAL (w/ VSC)

    Tech Tips