ENGINE ASSEMBLY INSTALLATION

PROCEDURE

INSTALL ENGINE HANGER

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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.
INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
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.
  
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INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY

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INSTALL STARTER ASSEMBLY

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INSTALL FLYWHEEL HOUSING SIDE COVER
*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 flywheel housing side cover with a new one if the claw does not fit tightly or is deformed.
INSTALL ENGINE WIRE
1. Install the engine wire to the engine assembly with transaxle.
CONNECT NO. 5 WATER BY-PASS HOSE
1. Connect the No. 5 water by-pass hose to the No. 1 water by-pass pipe.
REMOVE ENGINE HANGER
1. Remove the 2 bolts and No. 1 and No. 2 engine hangers.
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 }
2. Connect the clamp and wire harness to the wire harness clamp bracket.
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 }
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 }
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.
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.
INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
1. Set the engine assembly with transaxle on an engine lifter.
  
  Note
  
  Place height adjustment attachments and plate lift attachments under the engine assembly with transaxle.
2. Operate the engine lifter and lift the engine assembly with transaxle to the position where the engine mounting insulator sub-assembly RH and engine mounting insulator LH can be installed.
  
  CAUTION:
  
  Do not raise the engine assembly with transaxle more than necessary. If the engine assembly with transaxle 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
  
  Tighten the through bolt while holding the nut.
4. Install the engine mounting insulator sub-assembly 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 sub-assembly to the front crossmember sub-assembly with the 2 bolts.
  
  Torque:
  
  95 N*m { 969 kgf*cm, 70 ft.*lbf }
INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

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INSTALL FRONT SUSPENSION MEMBER REAR BRACE LH

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INSTALL FRONT SUSPENSION MEMBER REAR BRACE RH

Tech Tips

Perform the same procedure as for the LH side.
INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH

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INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH

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INSTALL FRONT ENGINE MOUNTING BRACKET LOWER REINFORCEMENT

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FULLY INSTALL REAR ENGINE MOUNTING INSULATOR
1. Fully install the rear engine mounting insulator with the through bolt.
  
  Torque:
  
  95 N*m { 969 kgf*cm, 70 ft.*lbf }
FULLY INSTALL FRONT ENGINE MOUNTING INSULATOR
1. Fully install the front engine mounting insulator with the nut and through bolt.
  
  Torque:
  
  85 N*m { 867 kgf*cm, 63 ft.*lbf }
  
  Tech Tips
  
  Tighten the through bolt while holding the nut.
INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

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INSTALL FLYWHEEL HOUSING UNDER COVER
1. Install the flywheel housing under cover.
INSTALL DRIVE SHAFT ASSEMBLY

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

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CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

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CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

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INSTALL COLUMN HOLE COVER SILENCER SHEET

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CONNECT WIRE HARNESS
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. Connect the 3 wire harness connectors and wire harness to the engine room junction block and engage the 2 claws.
3. 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 }
4. Install the No. 1 engine room relay block cover to the engine room relay block and junction block assembly.
5. Connect the wire harness clamp.
6. Connect the ECM connector and lower the lever.
INSTALL COMPRESSOR ASEEMBLY WITH PULLEY

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INSTALL SUCTION HOSE SUB-ASSEMBLY

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INSTALL DISCHARGE HOSE SUB-ASSEMBLY

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INSTALL GENERATOR ASSEMBLY

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INSTALL V-RIBBED BELT

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ADJUST V-RIBBED BELT

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INSPECT V-RIBBED BELT

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CONNECT FUEL TUBE SUB-ASSEMBLY
1. Connect the fuel tube connector and fuel pipe.
  
  Note
  
  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.
CONNECT INLET HEATER WATER HOSE
1. Connect the inlet heater water hose to the air conditioner unit assembly and slide the clip to secure it.
CONNECT OUTLET HEATER WATER HOSE
1. Connect the outlet heater water hose to the No. 1 water by-pass pipe and slide the clip to secure it.
2. Connect the outlet heater water hose to the air conditioner unit assembly and slide the clip to secure it.
CONNECT UNION TO VACUUM TUBE HOSE
1. Connect the union to vacuum tube hose to the air tube and slide the clip to secure it.
CONNECT NO. 1 FUEL VAPOR FEED HOSE
1. Connect the No. 1 fuel vapor feed hose to the vacuum switching valve assembly and slide the clip to secure it.
INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY
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 transmission control cable bracket with a new clip.
3. *a P Position
  
  *b N Position
  
  Turn the lever clockwise until it stops, then turn it counterclockwise 2 notches.
4. Install the transmission control cable assembly to the control shaft lever with the nut.
  
  Torque:
  
  12 N*m { 122 kgf*cm, 9 ft.*lbf }
CONNECT NO. 2 RADIATOR HOSE
1. Connect the No. 2 radiator hose to the water inlet and slide the clip to secure it.
CONNECT NO. 1 RADIATOR HOSE
1. Connect the No. 1 radiator hose to the cylinder head sub-assembly and slide the clip to secure it.
2. Connect breather plug hose to the clamp.
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 radiator pipe with the 2 bolts.
  
  Torque:
  
  18.5 N*m { 189 kgf*cm, 14 ft.*lbf }
3. Connect the 2 wire harness clamps.
INSTALL BATTERY
1. Install the battery tray.
2. Install the battery.
3. *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 }
4. Connect the cable to the positive (+) battery terminal.
  
  Torque:
  
  5.4 N*m { 55 kgf*cm, 48 in.*lbf }
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.
3. Install the air cleaner filter element sub-assembly.
INSTALL AIR CLEANER CAP SUB-ASSEMBLY

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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.
  
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ADD ENGINE OIL

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ADD ENGINE COOLANT

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ADD CONTINUOUSLY VARIABLE TRANSAXLE FLUID

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INSPECT ENGINE OIL LEVEL

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INSPECT SHIFT LEVER POSITION

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ADJUST SHIFT LEVER POSITION

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INSPECT FOR FUEL LEAK

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INSPECT FOR ENGINE COOLANT LEAK

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INSPECT FOR OIL LEAK
INSPECT FOR EXHAUST GAS LEAK
INSTALL REAR ENGINE UNDER COVER LH
1. Install the rear engine under cover LH with the 5 clips.
INSTALL REAR ENGINE UNDER COVER RH
1. Install the rear engine under cover RH with the 5 clips.
INSTALL NO. 2 ENGINE UNDER COVER
1. Install the No. 2 engine under cover with the 5 clips.
INSTALL NO. 1 ENGINE UNDER COVER
1. Install the No. 1 engine under cover with the 2 clips and 5 bolts.
INSTALL FRONT LOWER BUMPER ABSORBER
1. Install the front lower bumper absorber with the 4 screws and 8 bolts.
CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT (for HFC-134a(R134a))

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CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT (for HFO-1234yf(R1234yf))

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WARM UP ENGINE (for HFC-134a(R134a))

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WARM UP ENGINE (for HFO-1234yf(R1234yf))

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INSPECT FOR REFRIGERANT LEAK (for HFC-134a(R134a))

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INSPECT FOR REFRIGERANT LEAK (for HFO-1234yf(R1234yf))

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INSTALL FRONT WHEELS

Torque:

103 N*m { 1050 kgf*cm, 76 ft.*lbf }
INSPECT IGNITION TIMING

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INSPECT ENGINE IDLE SPEED

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INSPECT CO/HC

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ADJUST FRONT WHEEL ALIGNMENT

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INSTALL NO. 2 CYLINDER HEAD COVER
1. Engage the 4 clips to install the No. 2 cylinder head cover.
  Note
  - Be sure to engage the clips securely.
  - Do not apply excessive force or hit the No. 2 cylinder head cover to engage the clips. This may cause the No. 2 cylinder head cover to break.
INSPECT FOR SPEED SENSOR SIGNAL

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w/o VSC: Click here

*a	Protruding Portion
*b	Claw

*a	P Position
*b	N Position

*a	Bolt
*b	Nut