ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:

As the engine assembly with transaxle is extremely heavy, the engine lifter may suddenly drop if the instructions listed in the repair manual are not followed. Therefore, always follow the instructions listed in the repair manual when performing this procedure.

Tech Tips

Perform "Inspection After Repairs" after replacing the engine assembly, cylinder head sub-assembly, camshaft housing sub-assembly, camshaft timing gear assembly, camshaft timing exhaust gear assembly, piston sub-assembly or piston ring.

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PROCEDURE


  1. INSTALL ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. B008HJNN01

      Temporarily install the engine mounting insulator LH with the 4 bolts.

    2. Tighten the 4 bolts in the sequence shown in the illustration.

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

  2. 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. B008IBJN01

      Temporarily install the engine mounting insulator sub-assembly RH with the 3 bolts.

    2. Tighten the 3 bolts in the sequence shown in the illustration.

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

    3. Install the radiator reservoir bracket with the bolt.

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

  3. INSTALL REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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


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

      B008H61C02
      *A for 2WD *B for AWD

    2. Tighten the 2 bolts and 2 nuts in the sequence shown in the illustration.

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

  4. INSTALL ENGINE HANGER

    Click here

  5. REMOVE ENGINE FROM ENGINE STAND

    Note


    • Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.

    • With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.


    1. Attach a sling device and hang the engine with a chain block.

    2. Lift the engine and remove it from the engine stand.

  6. FIX ENGINE ASSEMBLY

    Click here

  7. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine.

  8. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  9. INSTALL CONTINUOUSLY VARIABLE TRANSAXLE ASSEMBLY


    1. Set the height adjustment attachments and plate lift attachments, and then set the engine lifter to the continuously variable transaxle assembly.

      Note

      Using rope, attachments or equivalent tools, firmly secure the continuously variable transaxle assembly to the engine lifter.

    2. Install the continuously variable transaxle assembly.


  10. INSTALL STARTER ASSEMBLY

    Click here

  11. INSTALL FLYWHEEL HOUSING SIDE COVER

    Click here

  12. INSTALL TRANSMISSION OIL COOLER BRACKET

    Click here

  13. INSTALL OIL COOLER

    Click here

  14. CONNECT NO. 2 TRANSMISSION OIL COOLER HOSE

    Click here

  15. CONNECT NO. 1 TRANSMISSION OIL COOLER HOSE

    Click here

  16. CONNECT NO. 4 WATER BY-PASS HOSE

    Click here

  17. 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 the hose.

    2. Attach the 2 clamps.

  18. INSTALL TRANSFER ASSEMBLY (for AWD)

    Click here

  19. INSTALL NO. 1 STEERING COLUMN HOLE COVER SUB-ASSEMBLY

    Click here

  20. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE


    1. Temporarily install the front engine mounting insulator with the through bolt and nut.

    2. B008HFZC01
      *a Alignment Mark
      *b Protrusion

      Temporarily install the front suspension crossmember with the through bolt and nut.

      Tech Tips

      When installing the front suspension crossmember, align the protrusion of the engine mounting bracket with the alignment mark of the rear engine mounting insulator.

    3. Place the engine on an engine lifter.

      Tech Tips

      Place the engine on wooden blocks or equivalent so that the engine is level.

    4. Operate the engine lifter and install the engine to the vehicle.

      CAUTION:

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

      Note


      • Make sure that the engine is clear of all wiring and hoses.

      • While raising the engine into the vehicle, do not allow it to contact the vehicle.

    5. Temporarily install the front suspension crossmember sub-assembly with 2 bolts.

    6. Temporarily install the front suspension member rear brace RH and LH with the 6 bolts.

    7. Install the engine mounting insulator LH with the through bolt and nut.

      Torque:
      56 N*m  { 571 kgf*cm, 41 ft.*lbf }

      Note

      While holding the through bolt in place, tighten the nut.

    8. B008JBUN01

      Install the engine mounting insulator sub-assembly RH with the bolt and 2 nuts.

      Torque:
      for bolt and nut A
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }
      for nut B
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

    9. Tighten the 2 front suspension crossmember bolts.

      Torque:
      137 N*m  { 1397 kgf*cm, 101 ft.*lbf }
    10. B008JLMC01
      *a Bolt A
      *b Bolt B

      Tighten the 6 front suspension member rear brace bolts.

      Torque:
      for bolt A
      137 N*m  { 1397 kgf*cm, 101 ft.*lbf }
      for bolt B
      93 N*m  { 948 kgf*cm, 69 ft.*lbf }

    11. Remove the 2 bolts and No. 1 and No. 2 engine hangers.

    12. B008H8RC01
      *a Bolt A
      *b Bolt B

      Install the front crossmember sub-assembly with the 6 bolts.

      Torque:
      for bolt A
      99 N*m  { 1010 kgf*cm, 73 ft.*lbf }
      for bolt B
      95 N*m  { 969 kgf*cm, 70 ft.*lbf }

    13. Tighten the rear engine mounting insulator bolt and the nut.

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

      Note

      While holding the nut in place, tighten the through bolt.

      Tech Tips

      Check that the protrusion of the engine mounting bracket is aligned with the alignment mark of the rear engine mounting insulator.

    14. Tighten the front engine mounting insulator through bolt and nut.

      Torque:
      145 N*m  { 1479 kgf*cm, 107 ft.*lbf }

      Note

      While holding the nut in place, tighten the through bolt.

  21. INSTALL AIR FUEL RATIO SENSOR BRACKET


    1. Install the air fuel ratio sensor bracket with the bolt.

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

    2. Attach the clamp to connect the fuel tube to the air fuel ratio sensor bracket.

    3. Connect the air fuel ratio sensor connector.

  22. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH


    1. Install the front suspension member reinforcement LH with the 4 bolts.

      Torque:
      99 N*m  { 1010 kgf*cm, 73 ft.*lbf }

  23. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH


    1. Install the front suspension member reinforcement RH with the 4 bolts.

      Torque:
      99 N*m  { 1010 kgf*cm, 73 ft.*lbf }

  24. INSTALL FRONT LOWER ENGINE MOUNTING BRACKET REINFORCEMENT (for 2WD)


    1. Install the front lower engine mounting bracket reinforcement with the 2 bolts.

      Torque:
      99 N*m  { 1010 kgf*cm, 73 ft.*lbf }

  25. INSTALL FLYWHEEL HOUSING UNDER COVER


    1. Install the flywheel housing under cover.

  26. INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT

    Click here

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

    Click here

  28. TIGHTEN PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for AWD)

    Click here

  29. CONNECT HEATED OXYGEN SENSOR


    1. for AWD:

      Click here

  30. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  31. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH

    Click here

  32. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

  33. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

    Click here

  34. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY LH

    Click here

  35. CONNECT FRONT LOWER NO. 1 SUSPENSION ARM SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  36. CONNECT TIE ROD END SUB-ASSEMBLY LH

    Click here

  37. CONNECT TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  38. CONNECT FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  39. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  40. CONNECT FRONT SPEED SENSOR LH

    Click here

  41. CONNECT FRONT SPEED SENSOR RH

    Tech Tips

    Use the same procedure described for the LH side.

  42. INSTALL FRONT AXLE SHAFT NUT LH

    Click here

  43. INSTALL FRONT AXLE SHAFT NUT RH

    Tech Tips

    Use the same procedure described for the LH side.

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

    Click here

  45. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  46. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  47. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. Connect the transmission control cable assembly to the rear engine mounting insulator with the bolt.

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

    2. Connect the transmission control cable assembly to the continuously variable transaxle assembly with the nut.

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

    3. Connect the transmission control cable assembly to the transmission control cable bracket with a new clip.

    4. Connect the transmission control cable assembly to the control shaft lever with the nut.

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

  48. CONNECT WIRE HARNESS AND HOSE


    1. Connect the fuel vapor feed hose to the purge VSV, and slide the clamp to secure the hose.

    2. Connect the heater water outlet hose and heater water outlet hose to the heater core and slide the 2 clamps to secure the hoses.

    3. Attach the wire harness clamp to connect the bond cable to the engine mounting insulator sub-assembly RH

    4. Connect the bond cable to the cylinder head cover assembly.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

    5. Connect the connector tube hose to the air tube and slide the hose clamp to secure the hose.

    6. B008HQ3C01
      *1 Engine Wire
      *2 Engine Room Main Wire

      Connect the engine wire and engine room main wire to battery positive (+) terminal with the nut as shown in the illustration.

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

    7. Connect the engine wire to the body with the bolt.

      Torque:
      11.4 N*m  { 116 kgf*cm, 8 ft.*lbf }

    8. Slide the engine wire and attach the 2 claws to connect the engine wire to the No. 1 engine room relay block and junction block assembly.

    9. Connect the 3 No. 1 engine room relay block and junction block assembly connectors and install the nut.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    10. Install the bolt and attach the 2 wire harness clamps.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

  49. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. Connect the fuel tube sub-assembly to the fuel pipe, and then install the No. 1 fuel pipe clamp.

      Click here

  50. CONNECT NO. 1 RADIATOR HOSE


    1. Connect the No. 1 radiator hose to the cylinder head sub-assembly, and slide the hose clamp to secure the hose.

  51. INSTALL ECM

    Click here

  52. INSTALL BATTERY BRACKET REINFORCEMENT

    Click here

  53. INSTALL BATTERY CARRIER ASSEMBLY

    Click here

  54. CONNECT RADIATOR HOSE SUB-ASSEMBLY

    Click here

  55. INSTALL BATTERY TRAY

  56. INSTALL BATTERY

  57. INSTALL BATTERY CLAMP SUB-ASSEMBLY

    Click here

  58. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  59. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Click here

  60. INSTALL AIR CLEANER CAP AND HOSE

    Click here

  61. CONNECT COMPRESSOR ASSEMBLY WITH PULLEY


    1. Using an E8 "TORX" socket wrench, connect the compressor assembly with pulley with the 2 stud bolts.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    2. B008JD1N01

      Install the 2 bolts and 2 nuts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Tech Tips

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

    3. Connect the compressor assembly with pulley connector and attach the wire harness clamp.

  62. CONNECT NO. 2 RADIATOR HOSE


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

  63. INSTALL GENERATOR ASSEMBLY

    Click here

  64. INSTALL V-RIBBED BELT

    Click here

  65. INSTALL RADIATOR RESERVOIR ASSEMBLY


    1. Install the radiator reservoir assembly with the 2 bolts.

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

    2. Connect the water by-pass hose and No. 2 water by-pass hose to the radiator reservoir assembly, and slide the 2 hose clamps to secure the hoses.

  66. CONNECT CABLE TO POSITIVE BATTERY TERMINAL

  67. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  68. ADD TRANSFER OIL (for AWD)

    Click here

  69. ADD ENGINE OIL

    Click here

  70. ADD ENGINE COOLANT

    Click here

  71. ADD CONTINUOUSLY VARIABLE TRANSAXLE FLUID


  72. INSPECT SHIFT LEVER POSITION

    Click here

  73. INSPECT FOR FUEL LEAK

    Click here

  74. INSPECT FOR COOLANT LEAK

    Click here

  75. INSPECT FOR OIL LEAK

    Click here

  76. INSPECT FOR EXHAUST GAS LEAK

    Click here

  77. INSPECT IGNITION TIMING

    Click here

  78. INSPECT ENGINE IDLE SPEED

    Click here

  79. INSPECT CO/HC

    Click here

  80. ADJUST FRONT WHEEL ALIGNMENT

    Click here

  81. INSTALL FRONT CENTER FLOOR COVER LH

    Click here

  82. INSTALL REAR ENGINE UNDER COVER RH


    1. Install the rear engine under cover RH with the 3 clips.

  83. INSTALL REAR ENGINE UNDER COVER LH


    1. Install the rear engine under cover LH with the 2 clips.

  84. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY


    1. Install the No. 1 engine under cover assembly with the 2 screws, 4 bolts and 8 clips.

  85. INSTALL NO. 2 CYLINDER HEAD COVER

    Click here

  86. RESET MEMORY