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.

Tech Tips

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

Click here

PROCEDURE


  1. INSTALL ENGINE HANGERS

    Click here

  2. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND


    1. Remove the engine assembly from the engine stand.

  3. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY (w/o Air Conditioning System)


    1. Using an E8 "TORX" socket wrench, install the 2 stud bolts.

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

    2. Install the No. 1 idler pulley sub-assembly.

    3. Install the bolt and 2 nuts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  4. INSTALL NO. 1 IDLER PULLEY (w/o Air Conditioning System)

    Tech Tips

    Perform this procedure only when replacement of the No. 1 idler pulley is necessary.


    1. Install the No. 1 idler pulley and 2 idler pulley cover plate to the idler pulley bracket with the bolt.

      Torque:
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

  5. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY (w/ Air Conditioning System)

    Click here

  6. INSTALL GENERATOR ASSEMBLY

    Click here

  7. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. Install the V-ribbed belt tensioner assembly to the timing chain cover assembly with the 2 bolts.

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

  8. INSTALL V-RIBBED BELT

    Click here

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

    Click here

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

    Click here

  11. INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY (for CVT)

    Click here

  12. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)

    Click here

  13. INSTALL ENGINE WIRE


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

  14. INSTALL STARTER ASSEMBLY

    w/o Stop And Start System: Click here

    for Transaxle CVT with Stop and Start System: Click here

    for Transaxle M/T with Stop and Start System: Click here

  15. INSTALL FLYWHEEL HOUSING SIDE COVER

    w/o Stop And Start System: Click here

    for Transaxle CVT with Stop and Start System: Click here

    for Transaxle M/T with Stop and Start System: Click here

  16. INSTALL WATER HOSE (for CVT)


    1. Install the water hose to engine assembly with transaxle and slide the 5 clips to secure them.

    2. Engage the 4 clamps to the engine assembly with transaxle.

  17. INSTALL WATER HOSE (for Manual Transaxle)


    1. Install the water hose to engine assembly with transaxle and slide the 3 clips to secure them.

    2. Engage the 3 clamps to the engine assembly with transaxle.

  18. 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 vehicle body with the 3 bolts.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

    2. Connect the cooler pipe clamp to the engine mounting insulator sub-assembly RH.

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

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

    4. Install the intercooler reserve tank assembly to the vehicle body with the 2 bolts.

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

  19. INSTALL ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. Install the engine mounting insulator LH to the vehicle body with the 4 bolts.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

  20. TEMPORARILY INSTALL REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. Temporarily install the rear engine mounting insulator to the rear engine mounting bracket with the bolt.

  21. TEMPORARILY INSTALL FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. Temporarily install the front engine mounting insulator to the front engine mounting bracket with the bolt and nut.

  22. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


    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 horizontal.

      • 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 oil pan sub-assembly from deforming, do not place any attachments under the oil pan sub-assembly of the engine assembly with transaxle.

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

      Torque:
      56 N*m  { 571 kgf*cm, 41 ft.*lbf }

      Note

      While holding the bolt in place, tighten the nut.

    4. A01LVQRN01

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

      Torque:
      Bolt
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }
      Nut (A)
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }
      Nut (B)
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

    5. Install the front crossmember sub-assembly to the vehicle body with the 4 bolts.

      Torque:
      99 N*m  { 1010 kgf*cm, 73 ft.*lbf }

    6. Install the front engine mounting insulator to the front crossmember sub-assembly with the 2 bolts.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

  23. REMOVE ENGINE HANGERS

    Click here

  24. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the wire harness clamp bracket to the cylinder head sub-assembly with the bolt.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

    2. Engage the clamp with the wire harness clamp bracket.

    3. Connect the wire harness to the wire harness clamp bracket.

  25. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

  26. INSTALL FRONT SUSPENSION MEMBER REAR BRACE LH

    Click here

  27. INSTALL FRONT SUSPENSION MEMBER REAR BRACE RH

    Tech Tips

    Use the same procedure as for the LH side.

  28. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT (for CVT)

    Click here

  29. CONNECT CLUTCH HOSE (for Manual Transaxle)


    1. Install a new clip and connect the clutch hose to the clutch flexible hose bracket.

    2. A01M0CDC01
      *a 10 mm Union Nut Wrench
      *b Torque Wrench Fulcrum Length

      Using a 10 mm union nut wrench, connect the bleeder clutch release tube to the clutch hose.

      Torque:
      Specified tightening torque
      15.2 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using a 10 mm union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

  30. INSTALL FLYWHEEL HOUSING UNDER COVER


    1. Install the flywheel housing under cover to the stiffening crankcase assembly.

  31. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH

    Click here

  32. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Click here

  33. INSTALL FRONT ENGINE MOUNTING BRACKET LOWER REINFORCEMENT (w/ Reinforcement)

    Click here

  34. INSTALL REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. Tighten the bolt of the rear engine mounting insulator.

      Torque:
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

  35. INSTALL FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. Tighten the bolt and nut of the front engine mounting insulator.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }

      Note

      While holding the nut in place, tighten the bolt.

  36. INSTALL FRONT DRIVE SHAFT ASSEMBLY

    Click here

  37. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

    Click here

  38. INSTALL FRONT CENTER FLOOR BRACE SUB-ASSEMBLY

    Click here

  39. CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  40. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  41. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  42. CONNECT WIRE HARNESS


    1. Connect the 2 wire harness clamps to the battery carrier assembly.

    2. Connect the cable to the positive (+) battery terminal and tighten the nut.

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

    3. for CVT:


      1. Connect the No. 3 engine wire to the continuously variable transaxle assembly with the bolt.

        Torque:
        12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }

      2. Engage the clamp to the wire harness clamp bracket.

    4. for Manual Transaxle:


      1. Connect the No. 3 engine wire to the manual transaxle assembly with the bolt.

        Torque:
        12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }

    5. Engage the 2 claws and connect the wire harness to the engine room relay block assembly.

    6. Install the 2 nuts to the engine room relay block assembly.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

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

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

    9. Connect the ECM connector and lower the lever.

      Note


      • When connecting the ECM connector, make sure that the connecting parts of the ECM connector are free of dirt, water or other foreign matter.

      • Be sure to securely connect the ECM connector.

    10. Engage the wire harness clamp.

  43. CONNECT SUCTION HOSE SUB-ASSEMBLY (w/ Air Conditioning System)

    Click here

  44. CONNECT DISCHARGE HOSE SUB-ASSEMBLY (w/ Air Conditioning System)

    Click here

  45. CONNECT FUEL TUBE SUB-ASSEMBLY

    Click here

  46. CONNECT HEATER WATER INLET HOSE A

    Click here

  47. CONNECT HEATER WATER OUTLET HOSE A

    Click here

  48. CONNECT FUEL VAPOR FEED HOSE


    1. Connect the fuel vapor feed hose to the fuel vapor feed pipe and slide the clip to secure it.

  49. CONNECT UNION TO CONNECTOR TUBE HOSE

    Click here

  50. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for CVT)


    1. Connect the transmission control cable assembly to the rear engine mounting insulator with the bolt.

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

    2. Connect the transmission control cable assembly to the No. 1 transmission control cable bracket with a new clip.

    3. A01M3GHC01
      *a P Position
      *b N Position

      Turn the control shaft lever clockwise until it stops, then turn it counterclockwise 2 notches.

    4. Connect the transmission control cable assembly to the control shaft lever with the nut.

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

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


    1. Connect the transmission control cable assembly to the rear engine mounting insulator with the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    2. A01LY8HN01

      Connect the transmission control cable assembly to the control cable bracket assembly with 2 new clips (A).

    3. Connect the transmission control cable assembly to the manual transaxle assembly with the 2 clips (B).

  52. CONNECT NO. 4 TURBO WATER HOSE

    Click here

  53. CONNECT NO. 1 TURBO WATER HOSE

    Click here

  54. CONNECT NO. 2 RADIATOR HOSE

    Click here

  55. CONNECT NO. 1 RADIATOR HOSE

    Click here

  56. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. Install the air cleaner case sub-assembly to the engine mounting insulator LH with the 3 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

    2. Install the wire harness clamp to the air cleaner case sub-assembly.

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

  57. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

    Click here

  58. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


    1. Connect the cable to the negative (-) battery terminal with the nut.

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

      Note

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

      Click here

  59. BLEED CLUTCH LINE (for Manual Transaxle)

    Click here

  60. ADD ENGINE OIL

    Click here

  61. ADD ENGINE COOLANT

    Click here

  62. ADD COOLANT (for Intercooler)

    Click here

  63. ADD MANUAL TRANSAXLE OIL (for Manual Transaxle)

    Click here

  64. ADD CONTINUOUSLY VARIABLE TRANSAXLE FLUID

    Click here

  65. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT (w/ Air Conditioning System)

    Click here

  66. WARM UP ENGINE (w/ Air Conditioning System)

    Click here

  67. INSPECT TRANSAXLE OIL (for Manual Transaxle)

    Click here

  68. ADJUST SHIFT LEVER POSITION (for Manual Transaxle)

    Click here

  69. INSPECT SHIFT LEVER POSITION (for CVT)

    for TMMT Made: Click here

    for TMUK Made: Click here

  70. ADJUST SHIFT LEVER POSITION (for CVT)

    for TMMT Made: Click here

    for TMUK Made: Click here

  71. INSPECT FOR ENGINE OIL LEAK

    Click here

  72. INSPECT FOR COOLANT LEAK

    Click here

  73. INSPECT FOR COOLANT LEAK (for Intercooler)

    Click here

  74. INSPECT FOR CONTINUOUSLY VARIABLE TRANSAXLE FLUID LEAK

  75. INSPECT FOR REFRIGERANT LEAK (w/ Air Conditioning System)

    Click here

  76. INSPECT FOR FUEL LEAK

    Click here

  77. INSPECT FOR EXHAUST GAS LEAK

    Click here

  78. CHECK ENGINE OIL LEVEL

    Click here

  79. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR

    Click here

  80. INSTALL REAR ENGINE UNDER COVER RH


    1. Install the rear engine under cover RH with the 5 clips.

  81. INSTALL REAR ENGINE UNDER COVER LH


    1. Install the rear engine under cover LH with the 5 clips.

  82. INSTALL CENTER NO. 4 ENGINE UNDER COVER (w/ Cover)


    1. for Full Cover Type:


      1. Install the center No. 4 engine under cover with the 2 clips.

    2. for Half Cover Type:


      1. Install the center No. 4 engine under cover with the 5 clips.

  83. INSTALL NO. 1 ENGINE UNDER COVER


    1. for Full Cover Type:


      1. Install the No. 1 engine under cover with the 2 bolts and 11 clips.

    2. for Half Cover Type:


      1. Install the No. 1 engine under cover with the 2 bolts and 7 clips.

  84. INSTALL FRONT LOWER BUMPER ABSORBER


    1. Install the front lower bumper absorber with the 8 bolts and 4 screws.

  85. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. Engage the 2 rear retainers, then the front retainer to install the No. 1 engine cover sub-assembly.

      Note


      • Be sure to engage the retainers securely.

      • Do not apply excessive force or tap the No. 1 engine cover sub-assembly to engage the retainers. This may cause the No. 1 engine cover sub-assembly to break.

  86. INSTALL FRONT WHEELS

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

  87. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  88. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  89. PERFORM INITIALIZATION

    Click here

  90. INSPECT IGNITION TIMING

    Click here

  91. INSPECT ENGINE IDLE SPEED

    Click here

  92. INSPECT CO/HC

    Click here

  93. CHECK SPEED SENSOR SIGNAL

    Click here