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


      • Pay attention to the angle of the sling device as the engine assembly or No. 1 engine hanger and No. 2 engine hanger may be damaged or deformed if the angle is incorrect.

      • 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 (for 2WD)

    Click here

  5. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for AWD)

    Click here

  6. INSTALL TRANSFER STIFFENER PLATE RH (for AWD)

    Click here

  7. INSTALL RADIATOR PIPE CLAMP (for 2WD)

    Click here

  8. INSTALL RADIATOR PIPE CLAMP (for AWD)

    Click here

  9. INSTALL ENGINE WIRE


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

  10. INSTALL MANIFOLD STAY

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  11. TEMPORARILY INSTALL FRONT ENGINE MOUNTING INSULATOR ASSEMBLY

    Tech Tips

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


    1. Temporarily install the front engine mounting insulator assembly with the 3 nuts.

  12. 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.

  13. 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.

  14. TEMPORARILY INSTALL REAR ENGINE MOUNTING INSULATOR ASSEMBLY

    Tech Tips

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


    1. Temporarily install the rear engine mounting insulator with the 2 nuts.

  15. INSTALL FRONT FRAME ASSEMBLY


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

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

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

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

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

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

    4. Install the rear engine mounting insulator assembly with the 2 bolts.

      Torque:
      75 N*m  { 765 kgf*cm, 55 ft.*lbf }

    5. Connect the 2 wire clamps.

    6. Fully tighten the 11 temporarily installed nuts of the engine mounting insulators.

      Tech Tips

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

      B003ZETC01
      *1 Front Engine Mounting Insulator Assembly *2 Engine Mounting Insulator RH
      *3 Engine Mounting Insulator LH *4 Rear Engine Mounting Insulator
      Torque:
      Nut (A)
      58 N*m  { 591 kgf*cm, 43 ft.*lbf }
      Torque:
      Nut (B)
      99 N*m  { 1010 kgf*cm, 73 ft.*lbf }

    7. Install the 7 hole plugs to the front frame assembly.

      Tech Tips

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

  16. INSTALL STEERING LINK ASSEMBLY (for AWD)

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  17. INSTALL FRONT STABILIZER BAR (for AWD)

    Click here

  18. INSTALL FRONT NO. 1 STABILIZER BRACKET LH (for AWD)

    Click here

  19. INSTALL FRONT NO. 1 STABILIZER BRACKET RH (for AWD)

    Tech Tips

    Perform the same procedure as for the LH side.

  20. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY

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  21. INSTALL V-RIBBED BELT

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  22. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


    1. Set the engine assembly with transaxle on the 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.

      • 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.

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

    2. Remove the engine hangers.

      Click here

    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. B003Z3TC03
      B003ZIE Bolt
      B003Z8F Nut

      Install the frame side plate RH and frame side 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

  23. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT (for 2WD)

    Click here

  24. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT (for AWD)

    Click here

  25. INSTALL FLYWHEEL HOUSING UNDER COVER


    1. Install the flywheel housing under cover with the 2 bolts.

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

  26. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Upper Side)


    1. Install the No. 1 exhaust pipe support bracket with the 2 bolts.

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

  27. CONNECT SUCTION HOSE SUB-ASSEMBLY

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  28. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

    Click here

  29. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY (for 2WD)

    Click here

  30. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY (for AWD)

    Click here

  31. INSTALL FRONT DRIVE SHAFT ASSEMBLY

    Click here

  32. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  33. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET (for Lower Side)

    Click here

  34. INSTALL FRONT NO. 3 EXHAUST PIPE SUB-ASSEMBLY

    Click here

  35. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD)

    Click here

  36. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. Install a new clip to the No. 1 transmission control cable bracket.

    2. B00405GC02
      *a Claw (A)
      *b Claw (B)
      *c Transmission Control Cable Assembly

      Install the transmission control cable assembly to the No. 1 transmission control cable bracket.

      Note


      • Make sure that the claws (A) on the clip are securely fit into the No. 1 transmission control cable bracket holes.

      • Make sure that the transmission control cable assembly is securely installed inside of the claws (B) of the clip.

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

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

      Note

      Before connecting the transmission control cable assembly, check that the park/neutral position switch assembly and the shift lever are in neutral.

  37. CONNECT ENGINE WIRE


    1. Engage the 2 wire harness clamps.

    2. A002AK8

      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 2 earth wires with the 2 bolts.

      Torque:
      8.4 N*m  { 86 kgf*cm, 6 ft.*lbf }

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

  38. INSTALL STARTER ASSEMBLY

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  39. CONNECT NO. 1 INLET OIL COOLER HOSE


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

  40. CONNECT NO. 1 OUTLET OIL COOLER HOSE


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

  41. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. Push the fuel tube connector onto the fuel main tube until the fuel tube connector makes a "click" sound.

      Note


      • Check that there is no damage or foreign matter on the fuel tube connector.

      • After connecting, check that the fuel tube connector and the fuel main tube are securely connected by pulling on them.

    2. Install the No. 1 fuel pipe clamp.

  42. CONNECT OUTLET HEATER WATER HOSE


    1. Connect the outlet heater water hose to the water outlet and slide the clip to secure it.

  43. CONNECT INLET HEATER WATER HOSE


    1. Connect the inlet heater water hose to the water inlet 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 radiator pipe clamp.

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

  46. CONNECT UNION TO CHECK VALVE HOSE


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

  47. CONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. Connect the No. 1 fuel vapor feed hose to the No. 1 vacuum switching valve and slide the clip to secure it.

  48. INSTALL ENGINE MOVING CONTROL ROD

    Tech Tips

    Perform this procedure only when replacement of the engine moving control rod or No. 3 engine mounting stay RH is necessary.


    1. B003Z59C01
      *1 Engine Moving Control Rod
      *2 No. 3 Engine Mounting Stay RH
      *3 Engine Moving Control Rod Bracket

      Temporarily install the No. 3 engine mounting stay RH and engine moving control rod to the engine moving control rod bracket with the 2 bolts.

    2. Tighten the bolt (A).

      Torque:
      78 N*m  { 795 kgf*cm, 58 ft.*lbf }

  49. INSTALL ENGINE MOVING CONTROL ROD BRACKET


    1. B003Z4FN01

      When replacing the engine moving control rod or No. 3 engine mounting stay RH.


      1. Install the engine moving control rod bracket with engine moving control rod with the 4 bolts.

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

        Note

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

      2. Tighten the bolt (E).

        Torque:
        52 N*m  { 530 kgf*cm, 38 ft.*lbf }
    2. B003Z75N01

      When not replacing the engine moving control rod or No. 3 engine mounting stay RH.


      1. Install the engine moving control rod bracket with engine moving control rod with the 4 bolts.

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

        Note

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

  50. INSTALL NO. 2 ENGINE MOUNTING STAY RH


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

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

    2. Tighten the 2 nuts.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

  51. INSTALL RESERVOIR BRACKET (for LHD)

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  52. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY (for LHD)

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  53. INSTALL RESERVOIR BRACKET (for RHD)

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  54. INSTALL BRAKE MASTER CYLINDER RESERVOIR ASSEMBLY (for RHD)

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  55. INSTALL BATTERY


    1. Install the battery and battery tray.

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

      Torque:
      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 }

  56. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


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

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

  57. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY


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

  58. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

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  59. 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 }

    2. Connect the 2 vacuum hose clamps to the inlet air cleaner assembly.

  60. INSPECT VACUUM HOSES


    1. Visually check the vacuum hoses.

      A002A0X

  61. 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.

      Click here

  62. INSTALL FRONT WHEELS

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

  63. ADD ENGINE OIL

    Click here

  64. ADD ENGINE COOLANT

    Click here

  65. ADD AUTOMATIC TRANSAXLE FLUID (for 2WD)

    Click here

  66. ADD AUTOMATIC TRANSAXLE FLUID (for AWD)

    Click here

  67. ADD TRANSFER OIL (for AWD)

    Click here

  68. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

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  69. WARM UP ENGINE

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  70. INSPECT FOR REFRIGERANT LEAK

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  71. INSPECT ENGINE OIL LEVEL

    Click here

  72. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR TANK

    Click here

  73. INSPECT FOR FUEL LEAK

    Click here

  74. INSPECT FOR COOLANT LEAK

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  75. INSPECT FOR OIL LEAK

  76. INSPECT FOR EXHAUST GAS LEAK

  77. INSPECT IGNITION TIMING

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  78. INSPECT ENGINE IDLE SPEED

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  79. INSPECT CO/HC

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  80. CHECK FOR SPEED SENSOR SIGNAL

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  81. INSPECT SHIFT LEVER POSITION (for 2WD)

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  82. INSPECT SHIFT LEVER POSITION (for AWD)

    Click here

  83. ADJUST SHIFT LEVER POSITION (for 2WD)

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  84. ADJUST SHIFT LEVER POSITION (for AWD)

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  85. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

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  86. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. Engage the 3 retainers to install the V-bank cover sub-assembly.

  87. INSTALL COOL AIR INTAKE DUCT SEAL

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  88. INSTALL RADIATOR SIDE SEAL RH

    Click here

  89. INSTALL RADIATOR SIDE DEFLECTOR SEAL LH

    Click here

  90. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for LHD)

    Click here

  91. INSTALL OUTER COWL TOP PANEL SUB-ASSEMBLY (for RHD)

    Click here

  92. INSTALL WINDSHIELD WIPER MOTOR AND LINK ASSEMBLY

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  93. INSTALL FRONT FENDER APRON SEAL LH


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

  94. INSTALL FRONT FENDER APRON SEAL RH


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

  95. INSTALL FRONT FENDER LINER LH


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

  96. INSTALL FRONT FENDER LINER RH


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

  97. INSTALL FRONT FLOOR COVER LH

    Click here

  98. INSTALL NO. 2 ENGINE UNDER COVER


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

  99. INSTALL NO. 1 ENGINE UNDER COVER


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