ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:

The engine assembly with transmission is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop.

PROCEDURE


  1. INSTALL ENGINE HANGER

    Click here

  2. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND


    1. Remove the engine assembly from the engine stand.

  3. 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. B003VX8C01
      *a Claw
      B003WAF Front of Engine

      Install the rear No. 1 engine mounting insulator to the automatic transmission assembly with the 4 bolts.

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

      Tech Tips

      Make sure that the claw is facing towards the front of the vehicle.

  4. INSTALL REAR ENGINE MOUNTING MEMBER

    Tech Tips

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


    1. Install the rear engine mounting member to the rear No. 1 engine mounting insulator with the 4 nuts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  5. INSTALL FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. Install the 2 front engine mounting insulators to the front suspension crossmember sub-assembly with the 2 nuts.

      Torque:
      70 N*m  { 714 kgf*cm, 52 ft.*lbf }

  6. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. Install the front suspension crossmember sub-assembly to the engine assembly with the 2 bolts

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  7. INSTALL REAR END PLATE


    1. Install the rear end plate with the 2 bolts.

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

  8. CONNECT NO. 13 WATER BY-PASS HOSE


    1. Connect the No. 13 water by-pass hose to the No. 1 water by-pass pipe and slide the clip to secure it.

  9. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  10. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

    Click here

  11. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

    Click here

  12. INSTALL FLYWHEEL HOUSING SIDE COVER

    Click here

  13. INSTALL STARTER ASSEMBLY


  14. CONNECT WATER BY-PASS HOSE

    Click here

  15. CONNECT WIRE HARNESS

    Click here

  16. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (TWC: Front and Rear Catalyst)

    Click here

  17. INSTALL NO. 4 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  18. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  19. INSTALL NO. 2 AIR HOSE


    1. Install the No. 2 air hose and tighten the hose clamp.

      Torque:
      6.3 N*m  { 64 kgf*cm, 56 in.*lbf }

  20. INSTALL NO. 1 AIR HOSE


    1. Install the No. 1 air hose and tighten the hose clamp.

      Torque:
      6.3 N*m  { 64 kgf*cm, 56 in.*lbf }

  21. INSTALL AIR TUBE


    1. Temporarily install the air tube with the 2 bolts.

    2. Tighten the 2 hose clamps to secure the air tube.

      Torque:
      6.3 N*m  { 64 kgf*cm, 56 in.*lbf }

    3. Tighten the 2 bolts.

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

  22. INSTALL NO. 3 VENTILATION HOSE


    1. Engage the clamp to install the No. 3 ventilation hose.

    2. Connect the No. 3 ventilation hose to the cylinder head sub-assembly and air tube and slide the 2 clips to secure it.

  23. INSTALL ENGINE WIRE


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

  24. INSTALL ENGINE ASSEMBLY WITH TRANSMISSION

    Tech Tips

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



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

      Note


      • Using height adjustment attachments and plate lift attachments, place the engine assembly with transmission horizontally.

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

    2. Remove the 2 bolts, No. 1 engine hanger and No. 2 engine hanger.

    3. Operate the engine lifter and install the engine assembly with transmission to the vehicle.

      Note

      Make sure that the engine assembly with transmission is clear of all wiring, hoses and the steering sliding with shaft yoke sub-assembly.

    4. B003VAAC02
      B003WAF Bolt
      B003U82 Nut

      Install the strut bar bracket reinforcement LH, strut bar bracket reinforcement RH and front suspension crossmember sub-assembly with the 6 bolts and 2 nuts.

      Torque:
      Bolt (A)
      194 N*m  { 1978 kgf*cm, 143 ft.*lbf }
      Bolt (B)
      57 N*m  { 581 kgf*cm, 42 ft.*lbf }
      Nut
      151 N*m  { 1540 kgf*cm, 111 ft.*lbf }

    5. Install the front No. 2 stabilizer bracket LH and front No. 2 stabilizer bracket RH with the 4 bolts.

      Torque:
      Bolt (C)
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }

    6. Install the rear engine mounting member with the 4 bolts.

      Torque:
      34.7 N*m  { 354 kgf*cm, 26 ft.*lbf }

    7. Connect the No. 2 earth wire with the bolt.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  25. INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR


    1. Install the front lower suspension member protector to the front suspension crossmember sub-assembly with the 4 bolts.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  26. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY

    Click here

  27. CONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY

    Click here

  28. INSTALL FRONT UPPER NO. 2 SUSPENSION MEMBER


    1. Install the 2 front upper No. 2 suspension members with the 6 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  29. INSTALL SUSPENSION TOWER DAMPER

    Click here

  30. CONNECT FRONT LOWER BALL JOINT ASSEMBLY LH

    Click here

  31. CONNECT FRONT LOWER BALL JOINT ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  32. CONNECT FRONT SHOCK ABSORBER ASSEMBLY LH


    1. Connect the lower part of the front shock absorber assembly LH to the front lower suspension arm assembly with the bolt and nut.

      Torque:
      180 N*m  { 1835 kgf*cm, 133 ft.*lbf }

      Note


      • Insert the bolt from the rear of the vehicle.

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

  33. CONNECT FRONT SHOCK ABSORBER ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  34. CONNECT HEATER ACCESSORY ASSEMBLY


    1. Connect the heater accessory assembly to the vehicle body with the 2 bolts.

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

  35. INSTALL PROPELLER SHAFT ASSEMBLY WITH CENTER BEARING

    Click here

  36. CONNECT NO. 3 ENGINE WIRE (for LHD)


    1. B003VPJ

      Engage the 2 wire harness clamps and 3 wire harness connectors to the power steering link assembly.

      Tech Tips

      For the connector with lock lever, fully insert the connector and push down the lock lever to engage the lock.

  37. CONNECT NO. 3 ENGINE WIRE (for RHD)


    1. B003TFD

      Engage the 2 wire harness clamps and 3 wire harness connectors to the power steering link assembly.

      Tech Tips

      For the connector with lock lever, fully insert the connector and push down the lock lever to engage the lock.

  38. CONNECT ENGINE WIRE (for LHD)


    1. for LH side:


      1. Engage the No. 3 engine wire clamp to the engine wire bracket.

      2. Connect the No. 3 engine wire to the engine wire bracket with the bolt.

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

      3. Engage the 2 No. 4 engine wire clamps.

      4. Engage the 2 claws to connect the No. 4 engine wire to the No. 1 engine room relay block.

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

        Torque:
        10.5 N*m  { 107 kgf*cm, 8 ft.*lbf }

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

      7. Engage the clamp.

      8. Connect the No. 2 engine wire to the positive (+) battery terminal with the nut.

        Torque:
        7.6 N*m  { 77 kgf*cm, 67 in.*lbf }

    2. for RH side:


      1. Engage the claw to connect the engine wire.

      2. Connect the engine wire and install the nut.

        Torque:
        10.5 N*m  { 107 kgf*cm, 8 ft.*lbf }
      3. B003WMS

        Push down the lock lever to connect the ECM connector.

      4. Connect the 4 engine wire harness connectors.

  39. CONNECT ENGINE WIRE (for RHD)


    1. for LH side:


      1. Engage the No. 4 engine wire clamp.

      2. Engage the 2 claws to connect the No. 4 engine wire to the No. 1 engine room relay block.

      3. Install the nut to the No. 1 engine room relay block and No. 1 junction block assembly.

        Torque:
        10.5 N*m  { 107 kgf*cm, 8 ft.*lbf }

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

      5. Engage the claw to connect the engine wire.

      6. Connect the engine wire and install the nut.

        Torque:
        10.5 N*m  { 107 kgf*cm, 8 ft.*lbf }
      7. B003WMS

        Push down the lock lever to connect the ECM connector.

      8. Connect the 4 engine wire harness connectors.

      9. Engage the No. 2 engine wire clamp.

      10. Connect the No. 2 engine wire to the positive (+) battery terminal with the nut.

        Torque:
        7.6 N*m  { 77 kgf*cm, 67 in.*lbf }

    2. for RH side:


      1. Engage the No. 3 engine wire clamp to the engine wire bracket.

      2. Connect the No. 3 engine wire to the engine wire bracket with the bolt.

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

  40. INSTALL ENGINE ROOM ECU COVER

    Click here

  41. CONNECT SUCTION HOSE

    Click here

  42. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

  43. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. Connect the fuel tube sub-assembly to the fuel delivery pipe and fuel pump assembly.

      Click here

    2. Connect the fuel tube sub-assembly to the fuel pump assembly.

      Click here

    3. Install the No. 1 fuel tube clamp to the wire harness clamp bracket.

  44. CONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. Connect the No. 1 fuel vapor feed hose to the purge valve (purge VSV) and slide the clip to secure it.

  45. CONNECT OUTLET HEATER WATER HOSE A


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

    2. Install the water hose set to the outlet heater water hose A.

  46. CONNECT INLET HEATER WATER HOSE A


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

    2. Install the water hose set to the inlet heater water hose A.

  47. CONNECT UNION TO CHECK VALVE HOSE (for LHD)


    1. Install the union to check valve hose with the bolt.

    2. Connect the union to check valve hose to the vacuum pump assembly and slide the clip to secure it.

  48. CONNECT UNION TO CHECK VALVE HOSE (for RHD)


    1. Engage the clamp to connect the union to check valve hose to the vacuum hose clamp.

    2. Connect the union to check valve hose to the vacuum pump assembly and slide the clip to secure it.

  49. INSTALL V-RIBBED BELT

    Click here

  50. INSTALL INTERCOOLER RESERVE TANK ASSEMBLY

    Click here

  51. CONNECT NO. 2 RADIATOR HOSE SUB-ASSEMBLY


    1. Connect the No. 2 radiator hose sub-assembly to the water inlet and slide the clip to secure it.

  52. INSTALL RADIATOR HOSE SUB-ASSEMBLY

    Click here

  53. INSTALL AIR CLEANER ASSEMBLY WITH NO. 2 AIR CLEANER HOSE


    1. B003W6NC02
      *1 Air Cleaner Support
      *a Pin

      Connect the air cleaner assembly with No. 2 air cleaner hose to the compressor inlet elbow.

    2. Insert the pin of the air cleaner assembly with No. 2 air cleaner hose into the hole of the air cleaner support as shown in the illustration.

    3. Install the 3 bolts.

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

    4. Engage the 2 wire harness clamps to the air cleaner assembly with No. 2 air cleaner hose.

    5. Connect the mass air flow meter sub-assembly connector.

    6. Connect the No. 1 ventilation hose to the air cleaner hose assembly and slide the hose clamp to secure it.

  54. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Tech Tips

    Perform this procedure only when replacement of the air cleaner case sub-assembly is necessary.


    1. B003T58C01
      *1 Air Cleaner Support
      *a Pin

      Insert the pin of the air cleaner case sub-assembly into the hole of the air cleaner support as shown in the illustration.

    2. Install the 2 bolts.

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

    3. Engage the wire harness clamp to the air cleaner case sub-assembly.

  55. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Tech Tips

    Perform this procedure only when replacement of the air cleaner filter element sub-assembly is necessary.


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

  56. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY

    Tech Tips

    Perform this procedure only when replacement of the air cleaner filter element sub-assembly or air cleaner case sub-assembly is necessary.


    1. Engage the 4 clamps and tighten hose clamp to install the air cleaner cap sub-assembly with air cleaner hose assembly.

    2. Install the bolt.

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

    3. Connect the intake mass air flow meter sub-assembly connector.

    4. Engage the wire harness clamp to the air cleaner cap sub-assembly with air cleaner hose assembly.

    5. Connect the No. 1 ventilation hose to the air cleaner hose assembly and slide the hose clamp to secure it.

  57. ADD ENGINE OIL

    Click here

  58. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


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

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

      Note

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

      Click here

  59. ADD ENGINE COOLANT (for Intercooler)

    Click here

  60. ADD ENGINE COOLANT

    Click here

  61. ADD AUTOMATIC TRANSMISSION FLUID

    Click here

  62. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

  63. INSPECT SHIFT LEVER POSITION

    Click here

  64. ADJUST SHIFT LEVER POSITION

    Click here

  65. INSPECT FOR COOLANT LEAK (for Intercooler)

    Click here

  66. INSPECT FOR COOLANT LEAK

    Click here

  67. INSPECT FOR ENGINE OIL LEAK

    Click here

  68. INSPECT FOR FUEL LEAK

    Click here

  69. INSPECT FOR EXHAUST GAS LEAK

    Click here

  70. INSPECT FOR REFRIGERANT LEAK

    Click here

  71. INSTALL FRONT WHEELS

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

  72. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  73. INSPECT IGNITION TIMING

    Click here

  74. INSPECT ENGINE IDLE SPEED

    Click here

  75. INSPECT CO/HC

    Click here

  76. INSPECT ENGINE COOLANT LEVEL

    Click here

  77. CHECK ENGINE OIL LEVEL

    Click here

  78. INSTALL REAR ENGINE UNDER COVER LH


    1. Install the rear engine under cover LH with the screw.

  79. INSTALL REAR ENGINE UNDER COVER RH

    Tech Tips

    Use the same procedure as for the LH side.

  80. INSTALL NO. 2 ENGINE UNDER COVER


    1. Install the No. 2 engine under cover with the 4 screws.

  81. INSTALL FRONT SUSPENSION MEMBER BRACE


    1. Install the front suspension member brace with the 4 bolts and clip.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

  82. INSTALL ENGINE UNDER COVER


    1. Install the engine under cover with the 13 screws and 3 clips.

  83. INSTALL INLET NO. 1 AIR CLEANER


    1. Install the inlet No. 1 air cleaner with the bolt.

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

  84. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. B003V7TC01
      *a Clip

      Engage the 3 clips in the order shown in the illustration to install the No. 1 engine cover sub-assembly.

      Note


      • Securely engage the clips.

      • If the clips are forcibly engaged or struck with an object, they may be damaged.

  85. INSTALL COOL AIR INTAKE DUCT SEAL

    Click here