ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

Perform "Inspection After Repairs" after replacing the engine assembly, cylinder head sub-assembly, camshaft, No. 2 camshaft, camshaft timing gear assembly, camshaft timing exhaust gear assembly, piston sub-assembly or piston ring Click here.

PROCEDURE


  1. INSTALL NO. 1 ENGINE HANGER

    Click here

  2. REMOVE ENGINE FROM ENGINE STAND


    1. Attach an engine sling device and hang the engine assembly with a chain block.

      Note

      Pay attention to the angle of the sling device as the engine assembly or No. 1 engine hanger may be damaged or deformed if the angle is incorrect.

    2. Lift the engine assembly and remove it from the engine stand.

  3. INSTALL ENGINE ASSEMBLY

    Tech Tips

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


    1. Slowly lower the engine assembly into the engine compartment.

    2. Install the engine assembly with the 4 bolts and 4 nuts.

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

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

  4. INSTALL REAR END PLATE


    1. B001GMAE01

      Install the rear end plate with the 2 bolts.

      Torque:
      for bolt A
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
      for bolt B
      18 N*m  { 178 kgf*cm, 13 ft.*lbf }

    2. Attach the flywheel housing dust seal.

  5. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)

    Click here

  6. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission)

    Click here

  7. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission)

    Click here

  8. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transmission)

    Click here

  9. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission)

    Click here

  10. INSTALL REAR NO. 1 ENGINE MOUNTING INSULATOR

    Tech Tips

    Perform this procedure only when replacement of the rear No. 1 engine mounting insulator is necessary.


    1. Install the rear No. 1 engine mounting insulator.


  11. INSTALL MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission)

    Click here

  12. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

    Click here

  13. INSTALL STARTER ASSEMBLY


  14. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transmission)

    Click here

  15. INSTALL FRONT PROPELLER SHAFT ASSEMBLY

    Click here

  16. INSTALL PROPELLER SHAFT ASSEMBLY

    Click here

  17. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  18. CONNECT ENGINE WIRE


    1. Install the bracket to the engine mounting insulator LH with the bolt.

      Torque:
      13 N*m  { 131 kgf*cm, 9 ft.*lbf }
    2. B001EERE01
      Text in Illustration
      *a 45° or less

      Install the ground wire and engine wire with the 2 clamps and bolt.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }
    3. B001G4L

      Attach the 2 clamps to connect the wire harness to the engine room No. 1 relay block.

    4. Install the nut.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

    5. Connect the connector and attach the clamp.

    6. B001EQ8E08

      Connect the ECM connector.


      1. Attach the grommet to the wire harness support.

        Text in Illustration
        *1 Grommet
        *2 Wire Harness Support

      2. Pass the wire harness into the vehicle and install the wire harness support.

      3. B001FU4

        Attach the clamp.

      4. Connect the 9 connectors and attach the clamp.

      5. Install the glove compartment door Click here.

    7. Attach the 3 clamps and connect the engine wire to the vehicle RH side.

  19. INSTALL FRONT NO. 1 FENDER APRON TO FRAME SEAL LH

    Click here

  20. INSTALL FRONT NO. 1 FENDER APRON TO FRAME SEAL RH

    Click here

  21. CONNECT COOLER COMPRESSOR ASSEMBLY


    1. B001DCHE01

      Temporarily install the cooler compressor assembly with the 4 bolts.

    2. Tighten the bolts in the order shown in the illustration to connect the cooler compressor assembly.

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

    3. Connect the connector.

    4. Connect the suction hose with the bolt.

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

  22. CONNECT VANE PUMP ASSEMBLY


    1. Connect the vane pump assembly with the 2 bolts.

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

    2. Connect the 2 connectors.

    3. Install the pressure feed tube with the bolt.

      Torque:
      28 N*m  { 285 kgf*cm, 21 ft.*lbf }

  23. CONNECT HEATER HOSE


    1. for Single Air Conditioning System:

      Connect the 2 heater hoses to the heater core, and slide the 2 clips to secure the hoses.

    2. for Dual Air Conditioning System:

      Connect the 2 heater hoses to the water by-pass pipe and hose, and slide the 2 clips to secure the hoses.

  24. 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 the hose.

  25. CONNECT PURGE LINE HOSE


    1. Connect the purge line hose to the purge VSV, and slide the clip to secure the hose.

  26. INSTALL NO. 2 FUEL HOSE


    1. B001I34E05
      Text in Illustration
      *a Front
      *b Top
      *c LH Side

      Install the No. 2 fuel hose to the fuel pressure regulator and floor pipe, and slide the clip to secure the hose.

      Tech Tips

      The direction of each clip is indicated in the illustration.

    2. Attach the clamp.

  27. INSTALL FUEL HOSE


    1. Install the fuel hose Click here.

    2. Attach the 2 clamps.

  28. CONNECT NO. 1 OIL COOLER INLET HOSE AND NO. 1 OIL COOLER OUTLET HOSE (for Automatic Transmission)

  29. INSTALL FAN SHROUD

    Click here

  30. INSTALL NO. 2 RADIATOR HOSE


    1. B001FBFE06
      Text in Illustration
      *a Top
      *b RH Side
      *c Protrusion
      *d Paint Mark

      Install the No. 2 radiator hose so that its paint marks align with the radiator assembly and water inlet protrusion as shown in the illustration and slide the 2 clips to secure the hose.

      Tech Tips

      The direction of each clip is indicated in the illustration.

  31. INSTALL NO. 1 RADIATOR HOSE


    1. B001IDNE04
      Text in Illustration
      *a Top
      *b LH Side
      *c Protrusion
      *d Paint Mark

      Install the No. 1 radiator hose so that its paint marks align with the radiator assembly and cylinder head protrusions as shown in the illustration and slide the 2 clips to secure the hose.

      Tech Tips

      The direction of each clip is indicated in the illustration.

  32. INSTALL RADIATOR RESERVOIR

    Click here

  33. INSTALL NO. 1 AIR INJECTION SYSTEM HOSE


    1. Install the No. 1 air injection system hose to the air switching valve assembly and air pump assembly, and slide the 2 clips to secure the hose.

    2. Install a new hose clamp.

  34. INSTALL INTAKE AIR CONNECTOR

    Click here

  35. INSTALL AIR CLEANER CASE


    1. Install the air cleaner case with the 3 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    2. Install the air cleaner filter element sub-assembly.

  36. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. B001FPLE03
      Text in Illustration
      *a Upper Side
      *b Front
      *c Matchmark

      Install the air cleaner hose and align its matchmark with the matchmark of the intake air connector as shown in the illustration.

    2. Tighten the hose clamp.

      Note

      Check that the air cleaner hose is securely installed.

    3. Attach the 4 clamps.

    4. Connect the mass air flow meter connector and attach the 3 clamps.

  37. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  38. INSTALL HOOD SUB-ASSEMBLY


    1. B001CM8E03
      Text in Illustration
      *a Bolt A
      *b Bolt B

      Install the hood sub-assembly with the 8 bolts.

      Torque:
      for bolt A
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      for bolt B
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    2. Connect the washer nozzle hose.

  39. ADJUST HOOD SUB-ASSEMBLY

    Click here

  40. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  41. ADD AUTOMATIC TRANSMISSION FLUID (for Automatic Transmission)

    Click here

  42. ADD ENGINE OIL

    Click here

  43. ADD ENGINE COOLANT

    Click here

  44. INSPECT SHIFT LEVER POSITION

    Click here

  45. INSPECT FOR OIL LEAK

    Click here

  46. INSPECT ENGINE OIL LEVEL

    Click here

  47. INSPECT FOR COOLANT LEAK

    Click here

  48. INSPECT FOR FUEL LEAK

    Click here

  49. INSPECT FOR EXHAUST GAS LEAK

    Click here

  50. INSPECT IGNITION TIMING

    Click here

  51. INSPECT ENGINE IDLE SPEED

    Click here

  52. INSPECT CO/HC

    Click here

  53. INSTALL UPPER RADIATOR SUPPORT SEAL


    1. Install the upper radiator support seal with the 13 clips.

  54. INSTALL REAR ENGINE UNDER COVER ASSEMBLY


    1. Install the rear engine under cover with the 4 bolts.

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

  55. INSTALL TRANSMISSION UNDER COVER


    1. Install the transmission under cover with the 2 bolts.

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

  56. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. B001IJW

      Hook the No. 1 engine under cover sub-assembly to the vehicle body as shown in the illustration.

    2. Install the 4 bolts.

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

  57. INSTALL FRONT BUMPER COVER LOWER


    1. Install the front bumper cover lower with the 5 bolts and clip.

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

  58. INSPECT ENGINE COOLANT LEVEL

    Click here