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 NO. 1 ENGINE HANGER

    Click here

  2. REMOVE ENGINE FROM ENGINE STAND


    1. Remove the engine assembly from the engine stand.

  3. INSTALL REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. Install the rear engine mounting insulator to the rear engine mounting bracket with the 4 nuts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    2. B003VDWC04
      *a Claw
      B003WAF Vehicle Front

      Install the rear 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 engine mounting insulator is necessary.


    1. Install the rear engine mounting member to the rear 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 DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  8. INSPECT DRIVE PLATE

    Click here

  9. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

    Click here

  10. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

    Click here

  11. INSTALL FLYWHEEL HOUSING SIDE COVER

    Click here

  12. INSTALL STARTER ASSEMBLY

    Click here

  13. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH (TWC: Front Catalyst)

    Click here

  14. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH (TWC: Front Catalyst)

    Click here

  15. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Install a new O-ring to the engine oil level dipstick guide.

      Tech Tips

      Apply a light coat of engine oil to the O-ring.

    2. Install the engine oil level dipstick guide with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    3. Connect the wire harness clamp to the engine oil level dipstick guide.

  16. INSTALL ENGINE ASSEMBLY WITH TRANSMISSION


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

      Note


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

      • Do not perform any procedure 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 4 bolts and 2 No. 1 engine hangers.

    3. 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 steering sliding with shaft yoke sub-assembly.

    4. B003VRNC03
      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 to the body with the 4 bolts.

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

    7. Install the No. 2 earth wire to the body with the nut.

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

  17. 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 }

  18. 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 }

  19. INSTALL SUSPENSION TOWER DAMPER

    Click here

  20. INSTALL FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY

    Click here

  21. CONNECT WIRE HARNESS


    1. B003TG6

      Connect the 2 wire harness clamps to the power steering link assembly.

    2. Connect the 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.

  22. CONNECT FRONT LOWER BALL JOINT ASSEMBLY LH

    Click here

  23. CONNECT FRONT LOWER BALL JOINT ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  24. CONNECT FRONT SHOCK ABSORBER ASSEMBLY LH


    1. Connect the front shock absorber assembly LH to the front suspension lower arm assembly LH 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.

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

  25. CONNECT FRONT SHOCK ABSORBER ASSEMBLY RH

    Tech Tips

    Perform the same procedure as for the LH side.

  26. INSTALL STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY

    Click here

  27. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY

    Click here

  28. INSTALL ENGINE UNDER BRACE SUB-ASSEMBLY


    1. Install the engine under brace sub-assembly to the body with the 4 bolts.

      Torque:
      7.4 N*m  { 75 kgf*cm, 65 in.*lbf }

  29. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  30. CONNECT NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  31. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. Connect the fuel tube sub-assembly to the fuel pipe and slide the clip to secure it.

      Click here

    2. Install the fuel pipe clamp.

  32. CONNECT NO. 3 FUEL HOSE


    1. Connect the No. 3 fuel hose to the No. 1 fuel pipe and slide the clip to secure it.

  33. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. Connect the fuel tube sub-assembly to the fuel pipe and slide the clip to secure it.

      Click here

    2. Install the fuel pipe clamp.

  34. CONNECT WIRE HARNESS (for LHD)


    1. Engine room LH side:


      1. Connect the engine wire to the engine room ECU box.

        Click here

      2. Connect the engine wire clamp.

    2. Engine room RH side:


      1. Connect the No. 3 engine wire to the body with the bolt.

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

      2. Connect the No. 3 engine wire clamp.

      3. Engage the 2 claws and connect the No. 4 engine wire to the No. 1 engine room relay block and No. 1 junction block assembly.

      4. 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 }

      5. Connect the 2 No. 4 engine wire clamps.

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

      7. 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 }

      8. Connect the No. 2 engine wire clamp.

  35. CONNECT WIRE HARNESS (for RHD)


    1. Engine room LH side:


      1. Connect the engine wire to the engine room ECU box.

        Click here

      2. Connect the engine wire clamp.

      3. Engage the 2 claws and connect the No. 4 engine wire to the No. 1 engine room relay block and No. 1 junction block assembly.

      4. 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 }

      5. Connect the No. 4 engine wire clamp.

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

      7. 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 }

      8. Connect the No. 2 engine wire clamp.

    2. Engine room RH side:


      1. Connect the No. 3 engine wire to the body with the bolt.

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

      2. Connect the No. 3 engine wire clamp.

  36. INSTALL ENGINE ROOM ECU COVER

    Click here

  37. CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

  38. CONNECT SUCTION HOSE

    Click here

  39. CONNECT HEATER OUTLET WATER HOSE


    1. Connect the heater outlet water hose to the No. 3 water by-pass pipe and slide the clip to secure it.

  40. CONNECT HEATER INLET WATER HOSE


    1. Connect the heater inlet water hose to the No. 3 water by-pass pipe and slide the clip to secure it.

  41. CONNECT NO. 2 RADIATOR HOSE

    Click here

  42. INSTALL NO. 1 RADIATOR HOSE

    Click here

  43. CONNECT RADIATOR RESERVE TANK HOSE


    1. Connect the radiator reserve tank hose to the water inlet sub-assembly and slide the clip to secure it.

  44. CONNECT NO. 2 FUEL VAPOR FEED HOSE


    1. Connect the No. 2 fuel vapor feed hose to the purge valve (purge VSV) and slide the clip to secure it.

  45. CONNECT UNION TO CHECK VALVE HOSE


    1. Connect the union to check valve hose to the intake air surge tank assembly and slide the clip to secure it.

  46. INSTALL AIR CLEANER ASSEMBLY WITH AIR CLEANER HOSE


    1. B003W0YC02
      *1 Air Cleaner Support
      *a Pin
      *b Protrusion

      Connect the air cleaner assembly with air cleaner hose to the throttle body with motor assembly.

    2. Fit the pin of the air cleaner assembly with air cleaner hose into the air cleaner support as shown in the illustration.

    3. Install the 2 bolts.

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

    4. Tighten the hose clamp.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

      Note

      Fit the protrusion on the air cleaner hose into the hole of the hose clamp on the throttle body with motor assembly side.

    5. Connect the union to check valve hose to the air cleaner cap with air cleaner hose (for RHD).

    6. Connect the No. 2 fuel vapor feed hose clamp to the air cleaner assembly with air cleaner hose.

    7. Connect the 2 wire harness clamps to the air cleaner assembly with air cleaner hose.

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

  47. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Tech Tips

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


    1. B003VPBC05
      *1 Air Cleaner Support
      *a Pin

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

    2. Install the air cleaner case sub-assembly with the 2 bolts.

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

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

  48. 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.

  49. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

    Tech Tips

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

    Click here

  50. CONNECT NO. 2 VENTILATION HOSE

    Click here

  51. 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 }

  52. ADD ENGINE OIL

    Click here

  53. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


    1. Connect the cable to negative (-) battery 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

  54. ADD ENGINE COOLANT

    Click here

  55. ADD AUTOMATIC TRANSMISSION FLUID

    Click here

  56. INSPECT FOR REFRIGERANT

    Click here

  57. INSPECT SHIFT LEVER POSITION

    Click here

  58. ADJUST SHIFT LEVER POSITION

    Click here

  59. INSPECT FOR COOLANT LEAK

    Click here

  60. INSPECT FOR OIL LEAK

    Click here

  61. INSPECT FOR FUEL LEAK

    Click here

  62. INSPECT FOR EXHAUST GAS LEAK

    Click here

  63. INSPECT FOR REFRIGERANT LEAK

    Click here

  64. INSTALL FRONT WHEELS

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

  65. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  66. CHECK AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  67. PERFORM INITIALIZATION

    Click here

  68. INSPECT THROTTLE BODY WITH MOTOR ASSEMBLY

    Click here

  69. INSPECT IGNITION TIMING

    Click here

  70. INSPECT ENGINE IDLE SPEED

    Click here

  71. INSPECT CO/HC

    Click here

  72. INSPECT COOLANT LEVEL IN RESERVOIR

    Click here

  73. INSPECT ENGINE OIL LEVEL

    Click here

  74. INSTALL NO. 2 ENGINE UNDER COVER


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

  75. INSTALL FRONT SUSPENSION MEMBER BRACE


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

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

  76. INSTALL REAR ENGINE UNDER COVER LH


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

  77. INSTALL REAR ENGINE UNDER COVER RH

    Tech Tips

    Perform the same procedure as for the LH side.

  78. INSTALL ENGINE UNDER COVER


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

  79. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. B003X1JC02
      *a Tip (Round Portion)

      Attach the 3 clips in the order shown in the illustration to install the V-bank cover sub-assembly.

      Note


      • Securely attach the clips.

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

      • Do not apply any oil to the tips (round portions).

  80. INSTALL COOL AIR INTAKE DUCT SEAL

    Click here