ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

Note

When the transaxle is removed, be sure to use a new clutch release with bearing cylinder and new installation bolts. Removal of the transaxle allows the compressed clutch release with bearing cylinder to return to its original position, and dust from the moving section could damage the seal of the clutch release with bearing cylinder, possibly causing clutch fluid leaks.

PROCEDURE


  1. INSTALL ENGINE HANGER

    Click here

  2. REMOVE ENGINE FROM ENGINE STAND


    1. Using a chain block and engine sling device, secure the engine assembly.

      Note


      • Adjust the angle of the sling device carefully to prevent the engine assembly or engine hangers from deforming or becoming damaged.

      • Servicing an engine assembly while it is hanging is dangerous. This can be done only when installing/removing the engine assembly to/from an engine stand.

    2. Remove the engine assembly from the engine stand.

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


    1. Gently place the engine assembly on wooden blocks or equivalent.

      CAUTION:

      This step should be done while hanging the engine assembly using the engine hangers and a chain block.

    2. Install the drive plate and ring gear sub-assembly.

      Click here

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


    1. Gently place the engine assembly on to wooden blocks or equivalent.

      CAUTION:

      This step should be done while hanging the engine assembly using the engine hangers and a chain block.

    2. Install the flywheel sub-assembly

      Click here

  5. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)

    Click here

  6. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)

    Click here

  7. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transaxle)

    Click here

  8. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY (for Manual Transaxle)

    Click here

  9. REMOVE CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Manual Transaxle)

    Click here

  10. INSPECT CLUTCH PIPE LINE (for Manual Transaxle)

    Click here

  11. INSTALL CLUTCH RELEASE BLEEDER SUB-ASSEMBLY (for Manual Transaxle)

    Click here

  12. INSTALL BLEEDER CLUTCH RELEASE TUBE (for Manual Transaxle)

    Click here

  13. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

    Click here

  14. INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY (for CVT)

    Click here

  15. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine assembly with transaxle.

  16. INSTALL STARTER ASSEMBLY

    Click here

  17. INSTALL FLYWHEEL HOUSING SIDE COVER

    A01M0BGC01
    *a Protruding Portion
    *b Claw

    1. Insert the protruding portion into the end of the cylinder block sub-assembly and while pushing it along the cylinder block sub-assembly, fit the claw into the stiffening crankcase assembly.

      Note


      • Make sure that the claw makes a click sound, indicating that it fits tightly.

      • Replace the claw with a new one if it does not fit tightly or is deformed.

  18. CONNECT NO. 5 WATER BY-PASS HOSE (for CVT)


    1. Connect the No. 5 water by-pass hose to the No. 1 water by-pass pipe and slide the clip to secure it.

  19. INSTALL HEATER WATER INLET HOSE A


    1. Install the heater water inlet hose A to the No. 1 water by-pass pipe and slide the clip to secure it.

  20. INSTALL HEATER WATER OUTLET HOSE A


    1. Install the heater water outlet hose A to the cylinder head sub-assembly and slide the clip to secure it.

  21. TEMPORARILY TIGHTEN 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 through bolt and nut.

  22. TEMPORARILY TIGHTEN 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 through bolt.

  23. 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 with the 4 bolts.

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

  24. 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 with the 3 bolts.

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

    2. 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 }

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

    4. Install the radiator reservoir tank with the 2 bolts.

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

  25. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


    1. Set the engine assembly with transaxle on an engine lifter.

    2. Operate the engine lifter and lift the engine assembly with transaxle to the position where the engine mounting insulators sub-assembly 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 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 with the through bolt and nut.

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

      Tech Tips

      When tightening the through bolt, keep the nut from rotating.

    4. A01M0HYN07

      Install the engine mounting insulator RH with the bolt and 2 nuts.

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

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

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

    6. Connect 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 }

  26. REMOVE ENGINE HANGER

    Click here

  27. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the wire harness clamp bracket with the bolt.

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

  28. CONNECT CLUTCH HOSE (for Manual Transaxle)


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

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

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

      Note

      Use the formula to calculate special torque values for situations where the union nut wrench is combined with a torque wrench.

      Click here

  29. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

    Click here

  30. INSTALL FRONT SUSPENSION MEMBER REAR BRACE LH

    Click here

  31. INSTALL FRONT SUSPENSION MEMBER REAR BRACE RH

    Tech Tips

    Perform the same procedure as for the LH side.

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

    Click here

  33. INSTALL FLYWHEEL HOUSING UNDER COVER (for CVT)


    1. Install the flywheel housing under cover.

  34. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH

    Click here

  35. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH

    Click here

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

    Click here

  37. FULLY TIGHTEN REAR ENGINE MOUNTING INSULATOR


    1. Tighten the rear engine mounting insulator to the engine mounting bracket with the through bolt.

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

  38. FULLY TIGHTEN FRONT ENGINE MOUNTING INSULATOR


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

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

      Tech Tips

      Because the nut its own stopper, do not turn the nut. Tighten the bolt with the nut secured

  39. INSTALL FRONT DRIVE SHAFT ASSEMBLY

    Click here

  40. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Front and Rear Catalyst)

    Click here

  41. INSTALL FRONT CENTER FLOOR BRACE SUB-ASSEMBLY

    Click here

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

    Click here

  43. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  44. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  45. CONNECT WIRE HARNESS


    1. for CVT:


      1. Install the No. 3 engine wire to the CVT with the bolt and clamp.

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

    2. for Manual Transaxle:


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

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

    3. Connect the 3 wire harness connectors and wire harness to the engine room junction block and engage the 2 claws.

    4. Install the 2 nuts to the engine room relay block and junction block assembly.

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

    5. Install the No. 1 engine room relay block cover to the engine room relay block and junction block assembly.

    6. Connect the wire harness clamp.

    7. Connect the ECM connector and lower the lever.

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

    Click here

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

    Click here

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

    Click here

  49. INSTALL GENERATOR ASSEMBLY

    Click here

  50. INSTALL V-RIBBED BELT

    Click here

  51. ADJUST V-RIBBED BELT

    Click here

  52. INSPECT V-RIBBED BELT

    Click here

  53. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. Connect the fuel tube connector and fuel pipe.

      CAUTION:

      Align the fuel tube connector with the fuel pipe, then push the fuel tube connector in until the retainer makes a "click" sound. If the connection is tight, apply a small amount of engine oil to the tip of the fuel pipe. After connecting, pull the fuel pipe and fuel tube connector to make sure that they are securely connected.

    2. Engage the claw and install the No. 1 fuel pipe clamp.

  54. CONNECT HEATER WATER INLET HOSE A

    Click here

  55. CONNECT HEATER WATER OUTLET HOSE A

    Click here

  56. CONNECT UNION TO VACUUM TUBE HOSE


    1. Connect the union to vacuum tube hose to the air tube and slide the clamp to secure it.

  57. CONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. Connect the No. 1 fuel vapor feed hose to the duty vacuum switching valve and slide the clamp to secure it.

  58. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for CVT)


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

    3. Install the transmission control cable assembly onto the control shaft lever with the nut.

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

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


    1. A01M02CN05

      Install the transmission control cable assembly to the rear engine mounting bracket with the bolt.

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

    2. Install the 2 transmission control cable assemblies to the control cable bracket with 2 new clips (A).

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

  60. CONNECT NO. 2 RADIATOR HOSE


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

  61. CONNECT NO. 1 RADIATOR HOSE (for CVT)


    1. Connect the No. 1 radiator hose to the cylinder head sub-assembly and slide the clamp to secure it.

    2. Connect the breather plug hose to the clamp.

  62. CONNECT NO. 1 RADIATOR HOSE (for Manual Transaxle)


    1. Connect the No. 1 radiator hose to the cylinder head sub-assembly and slide the clamp to secure it.

  63. INSTALL BATTERY CARRIER ASSEMBLY


    1. Install the battery carrier assembly with the 4 bolts.

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

    2. Connect the water pipe with the 2 bolts.

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

    3. Connect the 2 wire harness clamps.

    4. Install the battery tray.

  64. INSTALL BATTERY


    1. Install the battery.

    2. A01M326C01
      *a Bolt
      *b Nut

      Install the battery clamp sub-assembly with the bolt and nut.

      Torque:
      Bolt
      16.5 N*m  { 168 kgf*cm, 12 ft.*lbf }
      Nut
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

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

      Torque:
      5.4 N*m  { 55 kgf*cm, 4 ft.*lbf }

  65. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. Install the air cleaner case sub-assembly 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.

  66. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  67. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


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

      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

  68. BLEED CLUTCH LINE (for Manual Transaxle)

    Click here

  69. ADD ENGINE OIL

    Click here

  70. ADD MANUAL TRANSAXLE OIL (for Manual Transaxle)

    Click here

  71. ADD ENGINE COOLANT

    Click here

  72. ADD CONTINUOUSLY VARIABLE TRANSAXLE FLUID (for CVT)

    Click here

  73. CHECK ENGINE OIL LEVEL

    Click here

  74. INSPECT TRANSAXLE OIL (for Manual Transaxle)

    Click here

  75. ADJUST SHIFT LEVER POSITION (for Manual Transaxle)

    Click here

  76. INSPECT SHIFT LEVER POSITION (for CVT)

    Click here

  77. ADJUST SHIFT LEVER POSITION (for CVT)

    Click here

  78. INSPECT FOR FUEL LEAK

    Click here

  79. INSPECT FOR COOLANT LEAK

    Click here

  80. INSPECT FOR OIL LEAK

  81. INSPECT FOR EXHAUST GAS LEAK

  82. INSTALL FRONT NO. 3 ENGINE UNDER COVER (for Full Cover Type)


    1. Install the front No. 3 engine under cover with the 4 clips.

  83. 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.

  84. INSTALL NO. 1 ENGINE UNDER COVER (for Full Cover Type)


    1. Install the No. 1 engine under cover with the 2 bolts and 13 clips.

  85. INSTALL NO. 1 ENGINE UNDER COVER (for Half Cover Type)


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

  86. INSTALL REAR ENGINE UNDER COVER LH


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

  87. INSTALL REAR ENGINE UNDER COVER RH


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

  88. INSTALL FRONT LOWER BUMPER ABSORBER


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

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

    Click here

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

    Click here

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

    Click here

  92. INSTALL FRONT WHEELS

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

  93. INSPECT IGNITION TIMING

    Click here

  94. INSPECT ENGINE IDLE SPEED

    Click here

  95. INSPECT CO/HC

    Click here

  96. ADJUST FRONT WHEEL ALIGNMENT

    Click here

  97. INSTALL NO. 2 CYLINDER HEAD COVER


    1. Engage the 2 front clips, then the rear clip to install the No. 1 engine cover.

      Note


      • Be sure to engage the clips securely.

      • Do not apply excessive force or tap the No. 2 cylinder head cover to engage the clips. This may cause the No. 2 cylinder head cover to break.

  98. CHECK FOR SPEED SENSOR SIGNAL

    Click here