ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:

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

Tech Tips

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

Click here

PROCEDURE


  1. INSTALL ENGINE HANGER

    Click here

  2. REMOVE ENGINE FROM ENGINE STAND


    1. Remove the engine assembly from the engine stand.

  3. INSTALL COMPRESSOR WITH PULLEY ASSEMBLY

    Click here

  4. INSTALL GENERATOR ASSEMBLY

    Click here

  5. INSTALL FAN AND GENERATOR V BELT

    Click here

  6. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  7. INSTALL ENGINE ASSEMBLY

    Click here

  8. INSTALL NO. 5 WATER BY-PASS HOSE


    1. Install the No. 5 water by-pass hose to the No. 3 water by-pass pipe and oil cooler and slide the 2 clips to secure it.

    2. Engage the 2 clamps.

  9. INSTALL NO. 3 WATER BY-PASS HOSE


    1. Install the No. 3 water by-pass hose to the cylinder head sub-assembly and oil cooler and slide the 2 clips to secure it.

    2. Engage the clamp.

  10. INSTALL ENGINE WIRE


    1. Connect all the connectors and clamps, and install the engine wire to the engine assembly with transaxle.

  11. INSTALL FLYWHEEL HOUSING SIDE COVER


    1. Install the flywheel housing side cover to the cylinder block sub-assembly.

  12. INSTALL STARTER ASSEMBLY

    Click here

  13. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    Tech Tips

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


    1. A005PMNC01
      *a Temporarily Tighten

      Temporarily install the engine mounting insulator sub-assembly RH to the vehicle.

    2. Install the 2 bolts and nut in the order shown in the illustration.

      Torque:
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }

    3. Connect the air conditioner tube and accessory assembly to the engine mounting insulator sub-assembly RH with the bolt and nut.

      Torque:
      Bolt
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
      Nut
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

    4. Install the No. 2 earth wire to the engine mounting insulator sub-assembly RH and vehicle with the 2 bolts.

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

  14. INSTALL ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. A005OBFC01
      *a Temporarily Tighten

      Temporarily install the engine mounting insulator LH to the vehicle.

    2. Install the 4 bolts and nut in the order shown in the illustration.

      Torque:
      42 N*m  { 428 kgf*cm, 31 ft.*lbf }

  15. REMOVE ENGINE HANGER

    Click here

  16. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the wire harness clamp bracket with the bolt.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

    2. Connect the air fuel ratio sensor connector.

    3. Engage the 5 clamps.

  17. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


    1. Using height adjustment attachments and plate lift attachments to keep the engine assembly with transaxle and front suspension crossmember sub-assembly level, set an engine lifter underneath the engine assembly with transaxle and front suspension crossmember sub-assembly.

      Note


      • Using height adjustment attachments and plate lift attachments, keep the engine assembly with transaxle horizontal.

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

    2. Operate the engine lifter and install the engine assembly with transaxle to the vehicle.

      CAUTION:

      Do not raise the engine assembly with transaxle more than necessary. If the engine is raised excessively, the vehicle may also be lifted up.

      Note


      • 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.

    3. Connect the front suspension crossmember sub-assembly to the vehicle with the 6 bolts.

      Torque:
      141 N*m  { 1438 kgf*cm, 104 ft.*lbf }

    4. Install the engine mounting insulator LH to the engine mounting bracket LH with the bolt and nut.

      Torque:
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }

      Note

      While holding the nut in place, tighten the bolt.

    5. Install the engine mounting insulator sub-assembly RH to the engine mounting bracket RH with the 2 bolts and nut.

      Torque:
      Bolt
      72 N*m  { 734 kgf*cm, 53 ft.*lbf }
      Nut
      41 N*m  { 418 kgf*cm, 30 ft.*lbf }

  18. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

    Click here

  19. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  20. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

    Click here

  21. INSTALL FLYWHEEL HOUSING UNDER COVER

    Click here

  22. INSTALL DRIVE SHAFT ASSEMBLY

    Click here

  23. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Front and Rear Catalyst)

    Click here

  24. INSTALL FRONT FLOOR CENTER BRACE

    Click here

  25. CONNECT NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  26. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  27. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  28. CONNECT SUCTION HOSE SUB-ASSEMBLY

    Click here

  29. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

    Click here

  30. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. Connect the fuel tube connector 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 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. Engage the claw and install the No. 1 fuel pipe clamp.

  31. CONNECT INLET HEATER WATER HOSE


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

  32. CONNECT OUTLET HEATER WATER HOSE


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

    2. Engage the clamp.

  33. CONNECT UNION TO CONNECTOR TUBE HOSE


    1. Connect the union to connector tube hose to the vacuum pump assembly and slide the clip to secure it.

  34. CONNECT FUEL VAPOR FEED HOSE


    1. Connect the fuel vapor feed hose to the purge valve (purge VSV) and slide the clip to secure it.

  35. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY

    Click here

  36. CONNECT NO. 2 RADIATOR HOSE


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

  37. 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.

  38. INSTALL BATTERY CLAMP SUB-ASSEMBLY


    1. Install the air battery clamp sub-assembly to the vehicle with the 3 bolts.

      Torque:
      15.4 N*m  { 157 kgf*cm, 11 ft.*lbf }

    2. Engage the clamp to connect the engine wire to the battery clamp sub-assembly.

  39. CONNECT WIRE HARNESS


    1. Connect the engine wire to the transaxle assembly with the bolt.

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

    2. Connect the engine wire to the positive (+) battery terminal with the 3 nuts.

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

    3. Connect the engine wire to the battery clamp sub-assembly with the bolt and nut.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }
    4. A005Q9MC01
      *A for Type A
      *B for Type B

      Connect the engine wire to the vehicle with the 2 bolts.

      Torque:
      for Type A
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }
      for Type B
      10.5 N*m  { 107 kgf*cm, 8 ft.*lbf }

  40. INSTALL ECM

    Click here

  41. INSTALL BATTERY

    Click here

  42. ADD ENGINE OIL

    Click here

  43. ADD ENGINE COOLANT

    Click here

  44. ADD CONTINUOUSLY VARIABLE TRANSAXLE FLUID

    Click here

  45. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click here

  46. WARM UP ENGINE

    Click here

  47. INSPECT SHIFT LEVER POSITION

    Click here

  48. ADJUST SHIFT LEVER POSITION

    Click here

  49. INSPECT FOR ENGINE OIL LEAK

    Click here

  50. INSPECT FOR COOLANT LEAK

    Click here

  51. INSPECT FOR CONTINUOUSLY VARIABLE TRANSAXLE FLUID LEAK

  52. INSPECT FOR REFRIGERANT LEAK

    Click here

  53. INSPECT FOR FUEL LEAK

    Click here

  54. INSPECT FOR EXHAUST GAS LEAK

    Click here

  55. CHECK ENGINE OIL LEVEL

    Click here

  56. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR TANK

    Click here

  57. INSTALL REAR ENGINE UNDER COVER LH


    1. Install the rear engine under cover LH to the vehicle with the 6 clips.

  58. INSTALL REAR ENGINE UNDER COVER RH


    1. Install the rear engine under cover RH to the vehicle with the 6 clips.

  59. INSTALL NO. 1 ENGINE UNDER COVER


    1. A005OKWC01
      *1 Bolt

      Install the No. 1 engine under cover to the vehicle with the 4 bolts, 4 screws and 4 clips.

      Torque:
      Bolt
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  60. INSTALL FRONT WHEELS

    Click here

  61. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  62. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  63. PERFORM INITIALIZATION

    Click here

  64. INSPECT IGNITION TIMING

    Click here

  65. INSPECT ENGINE IDLE SPEED

    Click here

  66. INSPECT CO/HC

    Click here

  67. INSTALL NO. 2 CYLINDER HEAD COVER

    Click here

  68. CHECK SPEED SENSOR SIGNAL

    Click here