ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

*1	thermostat (thermostat housing assembly)	*2	oil cooler hose sub-assembly
*3	oil cooler assembly (for air cooled type)	-	-

Note:

When the oil cooler assembly (for air cooled type) has been removed/installed or the oil cooler hose sub-assembly has been disconnected/reconnected, check the engine oil level after warming up the engine oil to between 100°C and 120°C to open the thermostat between the engine and oil cooler assembly (for air cooled type).

1. Powertrain > Engine > Data List

   Tester Display
   Engine Oil Temperature

2. 
   
   1. 
      
3. 
   
   10. 
       

CAUTION / NOTICE / HINT

PROCEDURE

1. Click here

   INSTALL NO. 1 ENGINE HANGER

   Click here

2. Click here

   REMOVE ENGINE FROM ENGINE STAND

   
   

   1. Remove the engine assembly from the engine stand.

3. Click here

   INSTALL FRONT ENGINE MOUNTING INSULATOR

   Tip:

   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.

      70 N*m

      714 kgf*cm

      52 ft.*lbf

   2. Install the 2 engine mounting spacers.

4. Click here

   INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

   
   

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

      35 N*m

      357 kgf*cm

      26 ft.*lbf

5. Click here

   INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

   Click here

6. Click here

   INSTALL NO. 1 ENGINE MOUNTING BRACKET

   
   

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

      13 N*m

      133 kgf*cm

      10 ft.*lbf

7. Click here

   INSTALL REAR ENGINE MOUNTING HEAT INSULATOR

   
   

   1. Install the rear engine mounting heat insulator to the rear engine mounting insulator with the 4 bolts.

      13 N*m

      133 kgf*cm

      10 ft.*lbf

8. Click here

   INSTALL REAR ENGINE MOUNTING INSULATOR

   Tip:

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

   
   

   1. Install the rear engine mounting insulator to the automatic transmission assembly with the 4 bolts.

      40 N*m

      408 kgf*cm

      30 ft.*lbf

      Tip:

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

9. Click here

   INSTALL REAR ENGINE MOUNTING MEMBER

   Tip:

   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.

      13 N*m

      133 kgf*cm

      10 ft.*lbf

10. Click here

    INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

    Click here

11. Click here

    INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

    Click here

12. Click here

    INSTALL STARTER ASSEMBLY

    Click here

13. Click here

    INSTALL GENERATOR ASSEMBLY

    Click here

14. Click here

    INSTALL COMPRESSOR ASSEMBLY WITH PULLEY

    
    
    1. 

       Install the compressor assembly with pulley with the 2 bolts and 2 nuts.

       24.5 N*m

       250 kgf*cm

       18 ft.*lbf

       Tip:

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

15. Click here

    INSTALL OIL COOLER TUBE

    
    

    1. Install the oil cooler tube with the 3 bolts.

       13.5 N*m

       138 kgf*cm

       10 ft.*lbf

    2. Engage the clamp to the oil cooler tube.

16. Click here

    CONNECT WIRE HARNESS

    Click here

17. Click here

    INSTALL V-RIBBED BELT

    Click here

18. Click here

    INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

19. Click here

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

    Click here

20. Click here

    INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

21. Click here

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

    Click here

22. Click here

    INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

23. Click here

    INSTALL ENGINE MOUNTING DAMPER

    
    

    1. Install the 2 engine mounting dampers with the 2 bolts.

       10 N*m

       102 kgf*cm

       7 ft.*lbf

24. Click here

    INSTALL ENGINE UNDER COVER SUB-ASSEMBLY RH

    
    

    1. Engage the 2 clamps to install the engine under cover sub-assembly RH to the front suspension crossmember sub-assembly.

25. Click here

    INSTALL ENGINE UNDER COVER SUB-ASSEMBLY LH

    
    

    1. Engage the 2 clamps to install the engine under cover sub-assembly LH to the front suspension crossmember sub-assembly.

26. Click here

    INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

27. Click here

    INSTALL ENGINE OIL LEVEL DIPSTICK

    Click here

28. Click here

    INSTALL ENGINE ASSEMBLY WITH TRANSMISSION

    
    

    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 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 2 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 the steering sliding yoke sub-assembly.

    4. 

       *a

       Nut

       Install the strut bar bracket reinforcement LH, strut bar bracket reinforcement RH and front suspension crossmember sub-assembly with the 8 bolts and 2 nuts.

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

       Bolt (C)
       49 N*m	500 kgf*cm	36 ft.*lbf

    6. 

       Install the rear engine mounting member to the vehicle body with the 4 bolts.

       34.7 N*m

       354 kgf*cm

       26 ft.*lbf

    7. 

       Install the 2 No. 2 frame crossmember assemblies with the 6 bolts.

       20 N*m

       204 kgf*cm

       15 ft.*lbf

    8. 

       Install the 2 oil cooler brackets with the 8 nuts and 2 bolts.

       8.0 N*m

       82 kgf*cm

       71 in.*lbf

29. Click here

    CONNECT WIRE HARNESS (for LHD)

    
    

    1. Engage the 2 wire harness clamps to the power steering link assembly.

    2. Connect the 3 power steering link assembly connectors.

       Tip:

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

30. Click here

    CONNECT WIRE HARNESS (for RHD)

    
    

    1. Engage the 2 wire harness clamps to the power steering link assembly.

    2. Connect the 3 power steering link assembly connectors.

       Tip:

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

31. Click here

    CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY

    Click here

32. Click here

    INSTALL TIE ROD ASSEMBLY LH

    Click here

33. Click here

    INSTALL TIE ROD ASSEMBLY RH

    Tip:

    Perform the same procedure as for the LH side.

34. Click here

    INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY

    Click here

35. Click here

    INSTALL FRONT LOWER BALL JOINT ASSEMBLY LH

    Click here

36. Click here

    INSTALL FRONT LOWER BALL JOINT ASSEMBLY RH

    Tip:

    Perform the same procedure as for the LH side.

37. Click here

    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.

       108 N*m

       1101 kgf*cm

       80 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.

38. Click here

    CONNECT FRONT SHOCK ABSORBER ASSEMBLY RH

    Tip:

    Perform the same procedure as for the LH side.

39. Click here

    INSTALL FRONT SKID CONTROL SENSOR WIRE

    Click here

40. Click here

    INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

41. Click here

    INSTALL NO. 1 ENGINE ROOM RELAY BLOCK AND NO. 1 JUNCTION BLOCK ASSEMBLY

    for LHD:Click here

    for RHD:Click here

42. Click here

    INSTALL BATTERY TRAY

    for LHD:Click here

    for RHD:Click here

43. Click here

    INSTALL POWER STEERING ECU ASSEMBLY

    
    

    • for LHD

      Click here

    
    

    • for RHD

      Click here

44. Click here

    CONNECT WIRE HARNESS (for LHD)

    
    

    1. Connect the ground cable to the generator assembly with the bolt.

       21 N*m

       214 kgf*cm

       15 ft.*lbf

    2. Engage the clamp.

    3. Engine room LH side:

       
       

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

          Click here

       2. Connect the engine wire clamp.

    4. Engine room RH side:

       
       

       1. Install the No. 3 engine wire to the vehicle body with the bolt.

          8.5 N*m

          87 kgf*cm

          75 in.*lbf

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

       3. Engage the No. 4 engine wire clamp.

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

          10.5 N*m

          107 kgf*cm

          8 ft.*lbf

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

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

          7.6 N*m

          77 kgf*cm

          67 in.*lbf

       7. Engage the No. 2 engine wire clamp.

       8. Engage the 4 clamps to install the No. 1 center cowl top ventilator louver to the cowl top ventilator louver sub-assembly.

45. Click here

    CONNECT WIRE HARNESS (for RHD)

    
    

    1. Connect the ground cable to the generator assembly with the bolt.

       21 N*m

       214 kgf*cm

       15 ft.*lbf

    2. Engage the clamp.

    3. Engine room LH side:

       
       

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

          Click here

       2. Engage the engine wire clamp.

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

       4. Engage the No. 4 engine wire clamp.

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

          10.5 N*m

          107 kgf*cm

          8 ft.*lbf

       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.

          7.6 N*m

          77 kgf*cm

          67 in.*lbf

       8. Engage the No. 2 engine wire clamp.

       9. Engage the 4 clamps to install the No. 1 center cowl top ventilator louver to the cowl top ventilator louver sub-assembly.

    4. Engine room RH side:

       
       

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

          8.5 N*m

          87 kgf*cm

          75 in.*lbf

46. Click here

    INSTALL ENGINE ROOM ECU COVER

    Click here

47. Click here

    CONNECT SUCTION HOSE

    Click here

48. Click here

    CONNECT NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

49. Click here

    CONNECT FUEL TUBE SUB-ASSEMBLY

    
    

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

       CAUTION:

       Align the fuel tube connector with the fuel pipe, then push the fuel tube connector in until the retainer makes a "click" sound. If it is difficult to push the fuel tube connector in, apply a small amount of clean engine oil to the tip of the fuel pipe. After connecting, pull the fuel pipe and fuel tube connector to make sure that they are securely connected.

    2. Install the fuel pipe clamp.

50. Click here

    CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY

    
    

    1. Connect the No. 2 fuel tube sub-assembly to the fuel pipe.

       CAUTION:

       Align the fuel tube connector with the fuel pipe, then push the fuel tube connector in until the retainer makes a "click" sound. If it is difficult to push the fuel tube connector in, apply a small amount of clean engine oil to the tip of the fuel pipe. After connecting, pull the fuel pipe and fuel tube connector to make sure that they are securely connected.

    2. Install the fuel pipe clamp.

51. Click here

    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.

52. Click here

    CONNECT UNION TO CHECK VALVE HOSE (for LHD)

    
    

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

    2. Engage the union to check valve hose to the clamp.

53. Click here

    CONNECT UNION TO CHECK VALVE HOSE (for RHD)

    
    

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

    2. Engage the union to check valve hose to the clamp.

54. Click here

    CONNECT HEATER WATER OUTLET HOSE

    
    

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

    2. Install the water hose set.

55. Click here

    CONNECT HEATER WATER INLET HOSE

    
    

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

    2. Install the water hose set.

56. Click here

    INSTALL FRONT SUSPENSION UPPER TO COWL BRACE RH

    
    

    1. Install the front suspension upper to cowl brace RH with the bolt and 3 nuts.

       19 N*m

       194 kgf*cm

       14 ft.*lbf

57. Click here

    INSTALL FRONT SUSPENSION UPPER TO COWL BRACE LH

    
    

    1. Install the front suspension upper to cowl brace LH with the bolt and 3 nuts.

       19 N*m

       194 kgf*cm

       14 ft.*lbf

58. Click here

    INSTALL OIL COOLER HOSE SUB-ASSEMBLY

    
    

    1. Apply a small amount of engine oil to 2 new O-rings and install them to the oil cooler hose sub-assembly.

       Note:

       Do not damage the O-rings.

    2. Connect the oil cooler hose sub-assembly with the 2 bolts.

       10 N*m

       102 kgf*cm

       7 ft.*lbf

59. Click here

    CONNECT NO. 2 OIL COOLER OUTLET HOSE

    
    

    1. Connect the No. 2 oil cooler outlet hose to the oil cooler assembly and slide the clip to secure it.

60. Click here

    CONNECT NO. 2 OIL COOLER INLET HOSE

    
    

    1. Connect the No. 2 oil cooler inlet hose to the oil cooler assembly and slide the clip to secure it.

61. Click here

    CONNECT NO. 2 RADIATOR HOSE

    
    

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

62. Click here

    CONNECT NO. 1 RADIATOR HOSE

    
    

    1. Connect the No. 1 radiator hose to the front water by-pass joint and slide the clip to secure it.

63. Click here

    INSTALL RADIATOR RESERVE TANK ASSEMBLY

    Click here

64. Click here

    INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Tip:

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

    
    

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

       5.0 N*m

       51 kgf*cm

       44 in.*lbf

    2. Connect the vacuum switching valve connector and engage the clamp.

    3. Connect the vacuum hose assembly and engage the 2 clamps.

65. Click here

    INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    
    

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

66. Click here

    INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

    Click here

67. Click here

    INSTALL INLET NO. 1 AIR CLEANER

    Click here

68. Click here

    INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY

    Click here

69. Click here

    INSTALL NO. 2 ENGINE UNDER COVER

    
    

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

70. Click here

    INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR

    
    

    1. Install the front lower suspension member protector with the 4 bolts.

       5.5 N*m

       56 kgf*cm

       49 in.*lbf

71. Click here

    INSTALL FRONT SUSPENSION MEMBER BRACE SUB-ASSEMBLY

    
    

    1. Install the front suspension member brace sub-assembly with the 6 bolts and 4 nuts.

       Bolt
       52 N*m	530 kgf*cm	38 ft.*lbf
       Nut
       19 N*m	194 kgf*cm	14 ft.*lbf

72. Click here

    INSTALL FRONT FENDER LINER LH

    
    

    1. Install the front fender liner LH with the 2 screws.

73. Click here

    INSTALL FRONT FENDER LINER RH

    
    

    1. Install the front fender liner RH with the 2 screws.

74. Click here

    INSTALL REAR ENGINE UNDER COVER LH

    
    

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

75. Click here

    INSTALL REAR ENGINE UNDER COVER RH

    Tip:

    Perform the same procedure as for the LH side.

76. Click here

    CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    
    

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

       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

77. Click here

    ADD ENGINE OIL

    Click here

78. Click here

    ADD ENGINE COOLANT

    Click here

79. Click here

    ADD AUTOMATIC TRANSMISSION FLUID

    Click here

80. Click here

    INSPECT FOR REFRIGERANT

    
    

    • for HFC-134a (R134a)

      Click here

    
    

    • for HFO-1234yf (R1234yf)

      Click here

81. Click here

    INSPECT SHIFT LEVER POSITION

    Click here

82. Click here

    ADJUST SHIFT LEVER POSITION

    Click here

83. Click here

    INSPECT FOR COOLANT LEAK

    Click here

84. Click here

    INSPECT FOR ENGINE OIL LEAK

    Click here

85. Click here

    INSPECT FOR FUEL LEAK

    Click here

86. Click here

    INSPECT FOR EXHAUST GAS LEAK

    Click here

87. Click here

    INSPECT FOR REFRIGERANT LEAK

    
    

    • for HFC-134a (R134a)

      Click here

    
    

    • for HFO-1234yf (R1234yf)

      Click here

88. Click here

    INSTALL FRONT WHEELS

    Click here

89. Click here

    ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

90. Click here

    INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

91. Click here

    PERFORM INITIALIZATION

    Click here

92. Click here

    INSPECT IGNITION TIMING

    Click here

93. Click here

    INSPECT ENGINE IDLE SPEED

    Click here

94. Click here

    INSPECT CO/HC

    Click here

95. Click here

    INSPECT ENGINE COOLANT LEVEL IN RESERVOIR

    Click here

96. Click here

    CHECK ENGINE OIL LEVEL

    Click here

97. Click here

    INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

    
    

    1. Install the No. 1 engine under cover assembly with the 13 screws and 3 clips.

98. Click here

    INSTALL COOL AIR INTAKE DUCT SEAL

    Click here

99. Click here

    INSTALL V-BANK COVER SUB-ASSEMBLY

    
    
    1. 

       *a	Tip (Sphere)

       Attach the 4 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 (sphere).