ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:

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.

Note

for Manual Transaxle:

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 could damage the seal of the clutch release with bearing cylinder, possibly causing clutch fluid leaks.

Tech Tips

Perform "Inspection After Repairs" after replacing the engine assembly, cylinder head sub-assembly, camshaft housing sub-assembly, camshaft timing gear assembly, camshaft timing exhaust gear assembly, piston sub-assembly or piston ring.

Click here

PROCEDURE


  1. INSTALL ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. A01KB2TN01

      Temporarily install the engine mounting insulator LH with the 4 bolts.

    2. Tighten the 4 bolts in the sequence shown in the illustration.

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

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

      Torque:
      7.7 N*m  { 79 kgf*cm, 68 in.*lbf }

  2. 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. A01KBJSN01

      Temporarily install the engine mounting insulator sub-assembly RH with the 3 bolts.

    2. Tighten the 3 bolts in the sequence shown in the illustration.

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

    3. Install the radiator reservoir bracket with the bolt.

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

  3. INSTALL REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. A01KCDFC02
      *A for Manual Transaxle
      *B for CVT

      Temporarily install the rear engine mounting insulator with the 2 bolts and 2 nuts.

    2. Tighten the 2 bolts and 2 nuts in the sequence shown in the illustration.

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

  4. INSTALL DRIVE SHAFT BEARING BRACKET


    1. Install the drive shaft bearing bracket with the 3 bolts.

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

  5. INSTALL ENGINE HANGER

    Click here

  6. REMOVE ENGINE FROM ENGINE STAND

    Note


    • Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.

    • With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.


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

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

  7. FIX ENGINE ASSEMBLY

    Click here

  8. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine.

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

    Click here

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

    Click here

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

    Click here

  12. INSPECT CLUTCH PIPE LINE (for Manual Transaxle)

    Click here

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

    Click here

  14. INSTALL CLUTCH TUBE (for Manual Transaxle)

    Click here

  15. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)

    Click here

  16. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)

    Click here

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

    Click here

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

    Click here

  19. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

    Click here

  20. INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY (for CVT)

    Click here

  21. INSTALL TRANSFER ASSEMBLY

    Click here

  22. INSTALL FLYWHEEL HOUSING SIDE COVER

    Click here

  23. INSTALL STARTER ASSEMBLY

    Click here

  24. INSTALL STEERING GEAR HEAT INSULATOR (for RHD)

    Click here

  25. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


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

    2. A01KC2IC01
      *1 Alignment Mark
      *2 Protrusion

      Temporarily install the front suspension crossmember with the through bolt.

      Tech Tips

      When installing the suspension crossmember, align the protrusion of the engine mounting bracket with the alignment mark of the engine mounting insulator.

    3. Place the engine on an engine lifter.

      Tech Tips

      Place the engine on wooden blocks or equivalent so that the engine is level.

    4. Operate the engine lifter and install the engine to the vehicle.

      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. Temporarily install the front suspension crossmember sub-assembly with 2 bolts.

    6. Temporarily install the front suspension member rear brace RH and LH with the 6 bolts.

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

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

      Note

      While holding the bolt in place, tighten the nut.

    8. A01KAK4N01

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

      Torque:
      for bolt and nut A
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }
      for nut B
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

    9. Tighten the 2 front suspension crossmember bolts.

      Torque:
      137 N*m  { 1397 kgf*cm, 101 ft.*lbf }
    10. A01KDIKN01

      Tighten the 6 front suspension member rear brace bolts.

      Torque:
      for bolt A
      137 N*m  { 1397 kgf*cm, 101 ft.*lbf }
      for bolt B
      93 N*m  { 948 kgf*cm, 69 ft.*lbf }

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

    12. Install the air fuel ratio sensor bracket with the bolt. Then connect the air fuel ratio sensor connector.

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

    13. Attach the fuel tube clamp.

    14. A01KBMWN01

      Install the front crossmember sub-assembly with the 6 bolts.

      Torque:
      for bolt A
      99 N*m  { 1010 kgf*cm, 73 ft.*lbf }
      for bolt B
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

    15. Tighten the rear engine mounting insulator bolt.

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

      Tech Tips

      Check that the protrusion of the engine mounting bracket is aligned with the alignment mark of the engine mounting insulator.

    16. Tighten the front engine mounting insulator bolt and nut.

      Torque:
      145 N*m  { 1479 kgf*cm, 107 ft.*lbf }

      Note

      While holding the bolt in place, tighten the nut.

  26. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH


    1. Install the front suspension member reinforcement LH with the 4 bolts.

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

  27. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH


    1. Install the front suspension member reinforcement RH with the 4 bolts.

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

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

    Click here

  29. TEMPORARILY INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  30. TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  31. CONNECT HEATED OXYGEN SENSOR (for Bank 1 Sensor 2)

    Click here

  32. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  33. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH

  34. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  35. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

    Click here

  36. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

    Click here

  37. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  38. CONNECT TIE ROD END SUB-ASSEMBLY LH

    Click here

  39. CONNECT TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  40. CONNECT FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  41. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  42. CONNECT FRONT SPEED SENSOR LH

    Click here

  43. CONNECT FRONT SPEED SENSOR RH

    Tech Tips

    Use the same procedure described for the LH side.

  44. INSTALL FRONT AXLE SHAFT NUT LH

    Click here

  45. INSTALL FRONT AXLE SHAFT NUT RH

    Tech Tips

    Use the same procedure described for the LH side.

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

    Click here

  47. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  48. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  49. CONNECT CLUTCH HOSE (for Manual Transaxle)


    1. Connect the clutch hose and install the clip to the clutch hose.

      Note

      Install the clip as far as it will go.

    2. Using a 10 mm union nut wrench, connect the clutch hose to the accumulator to flexible hose tube while holding the clutch hose.

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

      Note


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

        Click here

      • Do not kink or damage the clutch hose.

      • Do not allow any foreign matter such as dirt or dust to enter the clutch hose from the clip or bracket.

      • This torque value is effective when the union nut wrench is parallel to the torque wrench.

  50. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for CVT)


    1. Connect the clamp of the transmission control cable assembly with the bolt.

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

    2. Connect the transmission control cable assembly to the transmission control cable support.

    3. Connect the transmission control cable assembly to the transmission control cable bracket with a new clip.

    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 control cable to the control cable bracket, and install 2 new clips.

    2. Connect the control cable to the transaxle, and install the 2 washers and 2 clips.

  52. CONNECT WIRE HARNESS AND HOSE


    1. Connect the heater water outlet hose and heater water inlet hose to the heater core and slide the 2 clamps to secure the hoses.

    2. Connect the connector tube hose to the air tube and slide the clamp to secure the hose.

    3. for Manual Transaxle:

      Attach the clamp and connect the engine wire to the manual transaxle with the bolt.

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

    4. for CVT:

      Attach the clamp and connect the engine wire to the CVT with the bolt.

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

    5. Connect the starter wire to terminal B with the nut.

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

    6. Attach the wire harness clamp and connect the terminal cap.

    7. Connect the wire harness and attach the 2 wire harness claws.

    8. Connect the 2 engine room junction block connectors and install the nut.

      Torque:
      12.8 N*m  { 131 kgf*cm, 9 ft.*lbf }

    9. Install the bolt and attach the 2 wire harness clamps.

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

  53. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. Connect the fuel tube sub-assembly to the fuel pipe.

      Click here

  54. CONNECT NO. 1 RADIATOR HOSE


    1. for CVT:

      Connect the breather plug hose to the clamp.

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

  55. INSTALL ECM

    Click here

  56. INSTALL BATTERY BRACKET REINFORCEMENT

    Click here

  57. INSTALL FRONT BATTERY BRACKET

    Click here

  58. INSTALL RADIATOR HOSE SUB-ASSEMBLY

    Click here

  59. INSTALL BATTERY TRAY

  60. INSTALL BATTERY

  61. INSTALL BATTERY CLAMP SUB-ASSEMBLY

    Click here

  62. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  63. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  64. CONNECT COMPRESSOR ASSEMBLY WITH PULLEY


    1. Using an E8 "TORX" socket wrench, connect the compressor with pulley assembly with the 2 stud bolts.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    2. A01KB79N01

      Install the 2 bolts and 2 nuts.

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

      Tech Tips

      Tighten the bolts and the nuts in the order shown in the illustration.

    3. Connect the connector and attach the wire harness clamp.

  65. CONNECT NO. 2 RADIATOR HOSE

    Click here

  66. INSTALL GENERATOR ASSEMBLY

    Click here

  67. INSTALL V-RIBBED BELT

    Click here

  68. ADJUST V-RIBBED BELT

    Click here

  69. INSTALL RADIATOR RESERVOIR ASSEMBLY


    1. Install the radiator reservoir assembly with the 2 bolts.

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

    2. Connect the No. 1 and No. 2 water by-pass hoses to the radiator reservoir assembly, and slide the 2 hose clamps to secure the No. 1 and No. 2 water by-pass hose.

  70. CONNECT CABLE TO POSITIVE BATTERY TERMINAL

  71. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  72. ADD TRANSFER OIL

    Click here

  73. ADD MANUAL TRANSAXLE OIL (for Manual Transaxle)

    Click here

  74. ADD ENGINE OIL

    Click here

  75. ADD ENGINE COOLANT

    Click here

  76. ADD CONTINUOUSLY VARIABLE TRANSAXLE FLUID (for CVT)

    Click here

  77. INSPECT 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

    Click here

  81. INSPECT FOR EXHAUST GAS LEAK

    Click here

  82. INSPECT IGNITION TIMING

    Click here

  83. INSPECT ENGINE IDLE SPEED

    Click here

  84. INSPECT CO/HC

    Click here

  85. ADJUST FRONT WHEEL ALIGNMENT

    Click here

  86. INSTALL FRONT FLOOR COVER

    Click here

  87. INSTALL REAR ENGINE UNDER COVER RH


    1. Install the rear engine under cover RH with the 3 clips.

  88. INSTALL REAR ENGINE UNDER COVER LH


    1. Install the rear engine under cover LH with the 2 clips.

  89. INSTALL NO. 1 ENGINE UNDER COVER

    Click here

  90. INSTALL NO. 2 CYLINDER HEAD COVER

    Click here

  91. RESET MEMORY (for CVT)

    Click here