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 HANGERS

    Click here

  2. REMOVE ENGINE ASSEMBLY FROM ENGINE STAND


    1. Remove the engine assembly from the engine stand.

  3. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY (w/o Air Conditioning System)


    1. Using an E8 "TORX" socket wrench, install the 2 stud bolts.

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

    2. Install the No. 1 idler pulley sub-assembly.

    3. Install the bolt and 2 nuts.

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

  4. INSTALL NO. 1 IDLER PULLEY (w/o Air Conditioning System)

    Tech Tips

    Perform this procedure only when replacement of the No. 1 idler pulley is necessary.


    1. Install the No. 1 idler pulley and 2 idler pulley cover plate to the idler pulley bracket with the bolt.

      Torque:
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

  5. INSTALL COMPRESSOR WITH PULLEY ASSEMBLY (w/ Air Conditioning System)

    Click here

  6. INSTALL GENERATOR ASSEMBLY


  7. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. Install the V-ribbed belt tensioner assembly to the timing chain cover assembly with the 2 bolts.

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

  8. INSTALL FAN AND GENERATOR V BELT

    Click here

  9. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for CVT)

    Click here

  10. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)

    Click here

  11. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)


  12. INSTALL ENGINE ASSEMBLY (for CVT)


  13. INSTALL ENGINE ASSEMBLY (for Manual Transaxle)


  14. INSTALL ENGINE WIRE


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

  15. INSTALL FLYWHEEL HOUSING SIDE COVER


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

  16. INSTALL STARTER ASSEMBLY


    • for Denso Made with Stop and Start System:

      Click here

    • for Denso Made without Stop and Start System:

      Click here

    • for Valeo Made Cold Area Specification Vehicles:

      Click here

    • for Valeo Made except Cold Area Specification Vehicles:

      Click here

  17. INSTALL WATER HOSE (for CVT)


    1. Install the water hose to the engine assembly with transaxle and slide the 5 clips to secure it.

    2. Engage the 3 clamps to the engine assembly with transaxle.

  18. INSTALL WATER HOSE (for Manual Transaxle)


    1. Install the water hose to the engine assembly with transaxle and slide the 3 clips to secure it.

    2. Engage the 3 clamps to the engine assembly with transaxle.

  19. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH (w/ Air Conditioning System)

    Tech Tips

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


    1. B008LG1C01
      *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. for DENSO Made:


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

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

    4. for VALEO Made:


      1. Connect the air conditioner tube and accessory 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 }

    5. 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 }

  20. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH (w/o Air Conditioning System)

    Tech Tips

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


    1. B008LEHC01
      *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. 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 }

  21. INSTALL ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. B008LICC02
      *A for CVT
      *B for Manual Transaxle
      *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 }

  22. REMOVE ENGINE HANGERS

    Click here

  23. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the wire harness clamp bracket to the cylinder head sub-assembly with the bolt.

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

    2. Install the engine wire to the wire harness clamp bracket with the nut.

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

    3. Engage the 3 clamps.

  24. 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 }

  25. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY LH

    Click here

  26. INSTALL REAR SIDE RAIL REINFORCEMENT SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure as for the LH side.

  27. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT (for CVT)


  28. INSTALL FLYWHEEL HOUSING UNDER COVER (for CVT)


  29. CONNECT NO. 1 CLUTCH HOSE (for Manual Transaxle)


    1. Connect the No. 1 clutch hose to the clutch flexible hose bracket with a new clip.

    2. B008KOOC01
      *a 10 mm Union Nut Wrench
      *b Torque Wrench Fulcrum Length

      Using a 10 mm union nut wrench, connect the bleeder clutch release tube to the No. 1 clutch hose.

      Torque:
      Specified tightening torque
      15.2 N*m  { 155 kgf*cm, 11 ft.*lbf }

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click here

      • When using a 10 mm union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 13.4 N*m (137 kgf*cm, 10 ft.*lbf)

  30. INSTALL FRONT DRIVE SHAFT ASSEMBLY


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

    Click here

  32. INSTALL FRONT EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst) (for 2WD)

    Click here

  33. INSTALL FRONT EXHAUST PIPE ASSEMBLY (for AWD)

    Click here

  34. INSTALL NO. 2 CENTER EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst) (for AWD)

    Click here

  35. INSTALL FRONT FLOOR CENTER BRACE (for 2WD)

    Click here

  36. INSTALL FRONT FLOOR CENTER BRACE (for AWD)

    Click here

  37. INSTALL FRONT FLOOR COVER LH (w/ Cover)

    Click here

  38. INSTALL FRONT FLOOR COVER RH (w/ Cover)

    Tech Tips

    Use the same procedure as for the LH side.

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

    Click here

  40. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  41. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  42. CONNECT SUCTION HOSE SUB-ASSEMBLY (w/ Air Conditioning System)

    Click here

  43. CONNECT DISCHARGE HOSE SUB-ASSEMBLY (w/ Air Conditioning System)

    Click here

  44. CONNECT FUEL TUBE SUB-ASSEMBLY

    Click here

  45. CONNECT INLET HEATER WATER HOSE

    Click here

  46. CONNECT OUTLET HEATER WATER HOSE

    Click here

  47. CONNECT FUEL VAPOR FEED HOSE


    1. Connect the fuel vapor feed hose to the fuel vapor feed pipe and slide the clip to secure it.

  48. CONNECT UNION TO CONNECTOR TUBE HOSE

    Click here

  49. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for CVT)


  50. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)


  51. CONNECT NO. 4 INTERCOOLER COOLING WATER HOSE

    Click here

  52. CONNECT NO. 1 INTERCOOLER COOLING WATER HOSE

    Click here

  53. CONNECT NO. 2 RADIATOR HOSE


    1. Connect the No. 2 radiator hose to the water inlet with thermostat sub-assembly and slide the clip to secure it.

  54. CONNECT NO. 1 RADIATOR HOSE


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

  55. INSTALL BATTERY CLAMP SUB-ASSEMBLY


    1. Install the 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.

  56. 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. B008LK0C01
      *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 }

  57. INSTALL ECM

    Click here

  58. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


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

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

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

  59. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE


    1. Connect the air cleaner cap with air cleaner hose and tighten the hose clamp.

      Torque:
      2.0 N*m  { 20 kgf*cm, 18 in.*lbf }

    2. Engage the 2 guides to install the air cleaner cap sub-assembly to the air cleaner case sub-assembly.

    3. Engage the 2 air cleaner cap sub-assembly clamps to install the air cleaner cap sub-assembly.

    4. Engage the clamp to the air cleaner cap sub-assembly.

    5. Connect the mass air flow meter connector.

  60. INSTALL NO. 1 AIR CLEANER INLET

    Click here

  61. INSTALL RADIATOR COVER

    Click here

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

    Click here

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

    Click here

  64. INSTALL COWL BODY MOUNTING REINFORCEMENT RH

    Click here

  65. INSTALL COWL BODY MOUNTING REINFORCEMENT LH

    Click here

  66. INSTALL WATER GUARD PLATE LH

    Click here

  67. INSTALL NO. 1 HEATER AIR DUCT SPLASH SHIELD SEAL

    Click here

  68. INSTALL WINDSHIELD WIPER MOTOR AND LINK

    Click here

  69. INSTALL BATTERY

    Click here

  70. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Click here

    Note

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

    Click here

  71. BLEED CLUTCH LINE (for Manual Transaxle)


  72. ADD ENGINE OIL

    Click here

  73. ADD ENGINE COOLANT

    Click here

  74. ADD COOLANT (for Intercooler)

    Click here

  75. ADD MANUAL TRANSAXLE OIL (for Manual Transaxle)


  76. ADD CONTINUOUSLY VARIABLE TRANSAXLE FLUID (for CVT)


  77. ADD TRANSFER OIL (for AWD)

    Click here

  78. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT (w/ Air Conditioning System)


  79. WARM UP ENGINE (w/ Air Conditioning System)


    1. Keep the A/C switch on for at least 2 minutes to warm up the compressor.

      Note

      To prevent damage to the compressor, be sure to warm up the compressor when turning the air conditioning on after removing and installing any air conditioning system lines (including the compressor).

  80. INSPECT TRANSAXLE OIL (for Manual Transaxle)


  81. ADJUST SHIFT LEVER POSITION (for Manual Transaxle)


  82. INSPECT SHIFT LEVER POSITION (for CVT)


  83. ADJUST SHIFT LEVER POSITION (for CVT)


  84. INSPECT FOR ENGINE OIL LEAK

    Click here

  85. INSPECT FOR COOLANT LEAK

    Click here

  86. INSPECT FOR COOLANT LEAK (for Intercooler)

    Click here

  87. INSPECT FOR CONTINUOUSLY VARIABLE TRANSAXLE FLUID LEAK (for CVT)

  88. INSPECT MANUAL TRANSAXLE OIL LEAK (for Manual Transaxle)

  89. INSPECT FOR REFRIGERANT LEAK (w/ Air Conditioning System)


  90. INSPECT FOR FUEL LEAK

    Click here

  91. INSPECT FOR EXHAUST GAS LEAK

    Click here

  92. CHECK ENGINE OIL LEVEL

    Click here

  93. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR

    Click here

  94. INSTALL REAR ENGINE UNDER COVER LH


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

  95. INSTALL REAR ENGINE UNDER COVER RH


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

  96. INSTALL NO. 1 ENGINE UNDER COVER


    1. B008KJIC01
      *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 }

  97. INSTALL FRONT WHEELS

    Click here

  98. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  99. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  100. PERFORM INITIALIZATION

    Click here

  101. INSPECT IGNITION TIMING

    Click here

  102. INSPECT ENGINE IDLE SPEED

    Click here

  103. INSPECT CO/HC

    Click here

  104. CHECK SPEED SENSOR SIGNAL

    Click here