ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

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

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PROCEDURE


  1. INSTALL ENGINE HANGERS

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  2. REMOVE ENGINE FROM ENGINE STAND


    1. Using an engine sling device and engine lift, 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.

      • 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.

    2. Remove the engine assembly from the engine stand.

  3. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

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  4. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

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  5. INSTALL ENGINE MOUNTING BRACKET RH


    1. Install the engine mounting bracket RH with the 3 bolts.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

  6. 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 }

  7. TEMPORARILY INSTALL 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 with the 3 nuts.

  8. TEMPORARILY INSTALL ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. Temporarily install the engine mounting insulator LH with the 3 nuts.

  9. TEMPORARILY INSTALL ENGINE MOUNTING INSULATOR RH

    Tech Tips

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


    1. Temporarily install the engine mounting insulator RH with the 3 nuts.

  10. INSTALL FRONT FRAME ASSEMBLY


    1. Install the engine mounting insulator LH with the nut.

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

    2. Install the engine mounting insulator RH with the nut.

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

    3. Install the front engine mounting insulator with the bolt.

      Torque:
      87 N*m  { 887 kgf*cm, 64 ft.*lbf }

    4. Fully tighten the 9 temporarily installed nuts of the engine mounting insulators.

      A002AWXC13
      *1 Front Engine Mounting Insulator *2 Engine Mounting Insulator RH
      *3 Engine Mounting Insulator LH - -

      Tech Tips

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

      Torque:
      Nut (A)
      58 N*m  { 591 kgf*cm, 43 ft.*lbf }
      Nut (B)
      99 N*m  { 1010 kgf*cm, 73 ft.*lbf }

    5. Install the 5 hole plugs.

      A002CI2C02
      *1 Front Engine Mounting Insulator *2 Engine Mounting Insulator RH
      *3 Engine Mounting Insulator LH - -

      Tech Tips

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

  11. INSTALL GENERATOR ASSEMBLY

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  12. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY

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  13. INSTALL V-RIBBED BELT

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  14. INSTALL ENGINE WIRE


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

  15. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


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

      Note


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

      • Do not place any height adjustment attachments or plate lift attachments under the front frame assembly.

      • To prevent the oil pan sub-assembly from deforming, do not place any attachments under the oil pan sub-assembly of the engine assembly with transaxle.

      • 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 hangers.

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    3. Install the engine assembly with transaxle to the vehicle.

      Note


      • 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.

      • 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.

    4. A002A0OC05
      B003ZIE Bolt
      B003Z8F Nut

      Install the frame side rail plate RH and frame side rail plate LH with the 6 bolts and 2 nuts.

      Torque:
      Bolt (A)
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }
      Bolt (B) and Nut (A)
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

    5. Install the front suspension member rear brace RH and front suspension member rear brace LH with the 6 bolts and 2 nuts.

      Torque:
      Bolt (C)
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }
      Bolt (D) and Nut (B)
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

      Tech Tips

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

      Click here

  16. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

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  17. INSTALL FLYWHEEL HOUSING UNDER COVER


    1. Install the flywheel housing under cover.

  18. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY

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  19. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH (for LH Side)

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  20. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

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  21. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

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  22. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY

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  23. CONNECT TIE ROD ASSEMBLY LH

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  24. CONNECT TIE ROD ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  25. INSTALL FRONT SPEED SENSOR

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  26. INSTALL FRONT STABILIZER LINK ASSEMBLY

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  27. INSTALL FRONT AXLE SHAFT NUT

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  28. INSTALL FRONT EXHAUST PIPE ASSEMBLY

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  29. CONNECT FUEL TUBE SUB-ASSEMBLY

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  30. CONNECT SUCTION HOSE SUB-ASSEMBLY

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  31. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

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  32. CONNECT UNION TO VACUUM TUBE HOSE


    1. Connect the 2 union to vacuum tube hoses to the No. 1 vacuum hose assembly and slide the 2 clips to secure them.

  33. INSTALL ENGINE MOVING CONTROL ROD

    Tech Tips

    Perform this procedure only when replacement of the engine moving control rod is necessary.


    1. Temporarily install the engine moving control rod to the engine moving control rod bracket with the bolt.

  34. INSTALL ENGINE MOVING CONTROL ROD BRACKET


    1. When replacing the engine moving control rod sub-assembly or No. 3 engine mounting stay RH.


      1. A0029CGN01

        Install the engine moving control rod bracket with engine moving control rod sub-assembly with the 4 bolts.

        Torque:
        38 N*m  { 387 kgf*cm, 28 ft.*lbf }

        Note

        Temporarily tighten bolt (A) and bolt (B), and then fully tighten the 4 bolts in the order of bolt (C), bolt (D), bolt (A) and bolt (B).

      2. Tighten the bolt (E).

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

    2. When not replacing the engine moving control rod sub-assembly or No. 3 engine mounting stay RH.


      1. A002BO1N01

        Install the engine moving control rod bracket with engine moving control rod sub-assembly with the 4 bolts.

        Torque:
        38 N*m  { 387 kgf*cm, 28 ft.*lbf }

        Note

        Temporarily tighten bolt (A) and bolt (B), and then fully tighten the 4 bolts in the order of bolt (C), bolt (D), bolt (A) and bolt (B).

  35. INSTALL NO. 2 ENGINE MOUNTING STAY RH


    1. Install the No. 2 engine mounting stay RH with the 2 bolts.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  36. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY


    1. A0027H5

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

    2. A002B6Y

      Install the transmission control cable assembly to the control shaft lever with the nut.

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

  37. INSTALL NO. 1 AIR CLEANER BRACKET


    1. Install the No. 1 air cleaner bracket to the battery carrier with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    2. Connect the 2 wire clamps.

  38. CONNECT ENGINE WIRE


    1. A002AK8

      Engage the 2 wire harness clamps.

    2. Push down the lock lever to connect the ECM connector.

      Note


      • When connecting the ECM connector, make sure that dirt, water or other foreign matter do not contact the connecting part of the ECM connector.

      • Be sure to securely connect the ECM connectors.

    3. Connect the engine wire to the engine room relay block assembly.

    4. Connect the 4 connectors and install the engine wire to the engine room relay block assembly with the nut.

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

    5. Connect the 3 wire clamps.

    6. Install the earth wire with the bolt.

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

    7. Install the No. 1 relay block cover to the engine room relay block assembly.

  39. INSTALL STARTER ASSEMBLY

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  40. CONNECT OUTLET NO. 1 OIL COOLER HOSE


    1. Connect the outlet No. 1 oil cooler hose and slide the clip to secure it.

  41. CONNECT INLET NO. 1 OIL COOLER HOSE


    1. Connect the inlet No. 1 oil cooler hose and slide the clip to secure it.

  42. CONNECT OUTLET HEATER WATER HOSE


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

    2. Engage the 2 claws to connect the inlet heater water hose and outlet heater water hose A.

  43. CONNECT INLET HEATER WATER HOSE


    1. Connect the inlet heater water hose to the cylinder head sub-assembly and slide the clip to secure it.

  44. CONNECT NO. 2 RADIATOR HOSE


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

  45. 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 the air fuel ratio sensor wire to the No. 1 radiator hose with the hose clamp.

  46. INSTALL BATTERY


    1. Install the battery and battery tray.

    2. Install the battery clamp with the bolt and nut.

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

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

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

  47. INSTALL RESERVOIR BRACKET

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  48. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY

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  49. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. A002BVJC01
      *a Hole
      *b Projection

      Insert the projection of the air cleaner case sub-assembly into the hole of the No. 1 air cleaner bracket as shown in the illustration.

    2. Install the 2 bolts.

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

  50. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


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

      Note

      Install the air cleaner filter element sub-assembly with the printed side facing the vehicle front.

  51. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

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  52. INSTALL INLET AIR CLEANER ASSEMBLY


    1. Install the inlet air cleaner assembly with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  53. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


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

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

      Note

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

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  54. ADD ENGINE OIL

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  55. ADD ENGINE COOLANT

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  56. ADD AUTOMATIC TRANSAXLE FLUID

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  57. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

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  58. WARM UP ENGINE

  59. INSPECT FOR FUEL LEAK

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  60. INSPECT FOR OIL LEAK

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  61. INSPECT FOR COOLANT LEAK

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  62. INSPECT FOR EXHAUST GAS LEAK

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  63. INSPECT FOR REFRIGERANT LEAK

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  64. INSPECT IGNITION TIMING

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  65. INSPECT ENGINE IDLE SPEED

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  66. INSPECT CO/HC

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  67. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. Engage the 3 pins to install the No. 1 engine cover sub-assembly.

  68. INSTALL COOL AIR INTAKE DUCT SEAL

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  69. INSTALL RADIATOR SIDE SEAL RH

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  70. INSTALL RADIATOR SIDE DEFLECTOR SEAL LH

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  71. INSPECT AND ADJUST SHIFT LEVER POSITION

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  72. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY

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  73. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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  74. INSTALL FRONT FENDER APRON SEAL LH


    1. Install the front fender apron seal LH with the 2 bolts and clip.

  75. INSTALL FRONT FENDER APRON SEAL RH


    1. Install the front fender apron seal RH with the 2 bolts and clip.

  76. INSTALL FRONT FENDER LINER LH


    1. Install the front fender liner LH with the 3 screws and 3 clips.

  77. INSTALL FRONT FENDER LINER RH


    1. Install the front fender liner RH with the 2 screws and 3 clips.

  78. INSTALL FLOOR UNDER COVER LH

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  79. INSTALL NO. 2 ENGINE UNDER COVER


    1. Install the No. 2 engine under cover with the 2 bolts, 2 screws and clip.

  80. INSTALL NO. 1 ENGINE UNDER COVER


    1. Install the No. 1 engine under cover with the 6 bolts, 8 screws and 3 clips.

  81. INSTALL FRONT WHEEL

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

  82. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

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  83. INSPECT SPEED SENSOR SIGNAL

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