ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:

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

PROCEDURE


  1. INSTALL ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. B007ZXZN01

      Install the engine mounting insulator LH with the 5 bolts.

      Torque:
      71 N*m  { 724 kgf*cm, 52 ft.*lbf }

      Note

      Temporarily tighten the bolt (A), and then fully tighten the 2 bolts in the order of (B) and (A).

  2. INSTALL ENGINE MOUNTING SPACER

    Tech Tips

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


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

      Torque:
      71 N*m  { 724 kgf*cm, 52 ft.*lbf }
  3. 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. Temporarily install the engine mounting insulator sub-assembly RH with the 2 bolts and nut.

    2. B007YAVN01

      Install the engine mounting insulator sub-assembly RH with the bolt (A) and nut.

      Torque:
      71 N*m  { 724 kgf*cm, 52 ft.*lbf }
    3. B007YCEC01
      *a Torque Wrench Fulcrum Length

      Using SST, install the engine mounting insulator sub-assembly RH with the bolt (B).

      SST
      09961-01270
      Torque:
      Specified tightening torque
      71 N*m  { 724 kgf*cm, 52 ft.*lbf }

      Tech Tips


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

      • When using SST (fulcrum length of 200 mm (7.87 in.)) + torque wrench (fulcrum length of 255 mm (10.04 in.)):

        40 N*m (408 kgf*cm, 30 ft.*lbf)]

    4. Connect the brake actuator with bracket with the bolt.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }
    5. Connect the cooler compressor bracket with the bolt.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
    6. Connect the earth wire with the bolt.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }
  4. INSTALL REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. Install the rear engine mounting insulator with the 4 nuts.

      Torque:
      71 N*m  { 724 kgf*cm, 52 ft.*lbf }
    2. Install the 2 hole plugs to the front frame assembly.

  5. INSTALL FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. Install the front engine mounting insulator with the 3 nuts.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }
    2. Install the hole plug to the front frame assembly.

  6. INSTALL ENGINE HANGERS

    Click here

  7. REMOVE ENGINE FROM ENGINE STAND


    1. Remove the engine assembly from the engine stand.

  8. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  9. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY

    for 2WD: Click here

    for AWD: Click here

  10. INSTALL FRONT FRAME ASSEMBLY


    1. Temporarily install the front engine mounting insulator with front frame assembly to the front engine mounting bracket with the bolt.

    2. B00800LC01
      *a Protrusion
      *b Rib

      Install the rear engine mounting insulator assembly to the rear engine mounting bracket with the bolt.

      Torque:
      71 N*m  { 724 kgf*cm, 52 ft.*lbf }

      Note

      If tightening the bolt before installation of the front frame assembly, ensure that the edge of the protrusion of the bracket is within the width of the rib.

    3. Fully tighten the bolt of the front engine mounting insulator.

      Torque:
      87 N*m  { 887 kgf*cm, 64 ft.*lbf }
    4. Connect the vacuum hose to the vacuum switching valve assembly.

  11. INSTALL TRANSFER STIFFENER PLATE RH (for AWD)

    Click here

  12. INSTALL STEERING LINK ASSEMBLY

    Click here

  13. INSTALL FRONT STABILIZER BAR

    Click here

  14. INSTALL FRONT NO. 1 STABILIZER BRACKET LH

    Click here

  15. INSTALL FRONT NO. 1 STABILIZER BRACKET RH

    Tech Tips

    Perform the same procedure as for the LH side.

  16. CONNECT WIRE HARNESS

    for 2WD: Click here

    for AWD: Click here

  17. INSTALL NO. 2 INTERCOOLER COOLING WATER PIPE


    1. Install the No. 2 intercooler cooling water pipe to the engine assembly with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    2. Connect the No. 6 intercooler cooling water hose to the No. 2 water by-pass pipe and slide the clip to secure it.

  18. INSTALL NO. 3 INTERCOOLER COOLING WATER PIPE


    1. Install the No. 3 intercooler cooling water pipe to the engine assembly with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    2. Connect the No. 2 intercooler cooling water hose to the No. 1 turbo water pipe sub-assembly and slide the clip to secure it.

    3. Connect the No. 5 intercooler cooling water hose to the No. 2 water by-pass pipe and slide the clip to secure it.

  19. REMOVE ENGINE HANGER

    Click here

  20. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    Tech Tips

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

    Click here


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

      Note


      • 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 engine assembly from unexpectedly moving, securely support the engine assembly until it is secured to an engine stand.

    2. Operate the engine lifter to 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 wirings and hoses.

      • While lowering the engine assembly with transaxle from the vehicle, do not allow it to contact the vehicle.

    3. B007ZWEC02
      B007WXX Bolt
      B00803L Nut

      Install the frame side rail plate sub-assembly RH and front suspension member bracket sub-assembly RH with the 6 bolts and 2 nuts.

      Torque:
      Bolt (A)
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }
      Bolt (B) and Nut
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }
    4. Install the frame side rail plate sub-assembly LH and front suspension member bracket sub-assembly LH with the 6 bolts and 2 nuts.

      Torque:
      Bolt (A)
      85 N*m  { 867 kgf*cm, 63 ft.*lbf }
      Bolt (B) and Nut
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }
    5. B007WMHC01
      *a Nut (A)
      *b Nut (B)
      *c Bolt

      Type A:


      1. Install the engine mounting insulator sub-assembly RH from the engine mounting bracket RH with the 2 bolts and 2 nuts.

        Torque:
        Bolt and Nut (A)
        71 N*m  { 724 kgf*cm, 52 ft.*lbf }
        Nut (B)
        40 N*m  { 408 kgf*cm, 30 ft.*lbf }
    6. B007XG4C01
      *a Nut (A)
      *b Nut (B)
      *c Bolt

      Type B:


      1. Install the engine mounting insulator sub-assembly RH to the engine mounting bracket RH with the bolt and 3 nuts.

        Torque:
        Bolt and Nut (A)
        71 N*m  { 724 kgf*cm, 52 ft.*lbf }
        Nut (B)
        40 N*m  { 408 kgf*cm, 30 ft.*lbf }
    7. Connect the engine mounting insulator LH to the engine mounting bracket LH with the bolt and nut.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }
  21. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

    for 2WD: Click here

    for AWD: Click here

  22. INSTALL FLYWHEEL HOUSING UNDER COVER


    1. Install the flywheel housing under cover to the engine assembly.

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

    Click here

  24. INSTALL FRONT DRIVE SHAFT ASSEMBLY

    Click here

  25. CONNECT STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  26. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  27. INSTALL CENTER EXHAUST PIPE ASSEMBLY (TWC: Rear Catalyst)

    Click here

  28. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY


    1. Connect the transmission control cable assembly to the control shift lever with the nut.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
    2. Connect the transmission control cable assembly to the No. 1 transmission control cable bracket with a new clip.

  29. INSTALL TRANSMISSION OIL THERMOSTAT

    for 2WD: Click here

    for AWD: Click here

  30. CONNECT TRANSMISSION OIL COOLER


    1. B007YYPN01

      Temporarily install the transmission oil cooler to the front engine mounting bracket with the bolt (A).

    2. Install the bolt (B).

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
    3. Install the bolt (C).

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
    4. Tighten the bolt (A).

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }
    5. Engage the clamp and connect the No. 1 breather plug (ATM) to the breather plug hose clamp.

  31. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY


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

  32. CONNECT NO. 1 FUEL HOSE


    1. Connect the No. 1 fuel hose to the 2 fuel pipes.

    2. Install the No. 2 fuel pipe clamp to the fuel tube connector.

  33. CONNECT UNION TO CHECK VALVE HOSE (for LHD)


    1. Connect the union to check valve hose to the vacuum switching valve hose assembly and slide the clip to secure it.

  34. CONNECT UNION TO CONNECTOR TUBE HOSE (for RHD)


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

  35. INSTALL STARTER ASSEMBLY

    Click here

  36. CONNECT ENGINE WIRE


    1. Connect the No. 2 earth wire to the compressor assembly with pulley with the bolt.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }
    2. Connect the earth wire with the bolt.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    3. Connect the battery state sensor assembly connector.

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

    5. Connect the 3 connectors to the No. 1 engine room relay block and No. 1 junction block assembly.

    6. Install the nut.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }
    7. Connect the engine wire, engage the 2 engine wire clamps and install the nut.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }
    8. Install the engine room relay block assembly.

  37. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

    Click here

  38. CONNECT SUCTION HOSE SUB-ASSEMBLY

    Click here

  39. CONNECT HEATER HOSE


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

    2. Connect the inlet heater hose to the cylinder head sub-assembly and slide the clip to secure it.

  40. 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.

  41. CONNECT NO. 2 RADIATOR HOSE


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

  42. INSTALL NO. 3 INTERCOOLER COOLING WATER HOSE


    1. Connect the No. 3 intercooler cooling water hose to the No. 3 intercooler cooling water pipe and slide the clip to secure it.

  43. INSTALL NO. 1 AIR TUBE


    1. B007ZNIC01
      *1 No. 2 Fuel Vapor Feed Hose
      *2 Fuel Tube Sub-assembly
      *3 No. 2 Fuel Tube Sub-assembly
      *4 No. 3 Ventilation Hose
      *5 Vacuum Switching Valve Hose Assembly
      *6 No. 1 Air Tube

      Connect the No. 1 air tube to the intercooler assembly and tighten the clamp to secure it.

      Torque:
      6.3 N*m  { 64 kgf*cm, 56 in.*lbf }
    2. Install the 2 bolts (B).

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    3. Connect the vacuum switching valve hose assembly to the No. 1 air tube with the bolt (A).

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }
    4. Connect the No. 3 ventilation hose to the No. 1 air tube and slide the clip to secure it.

    5. Engage the 2 clamps to connect the fuel tube sub-assembly and No. 2 fuel tube sub-assembly to the No. 1 air tube.

    6. Engage the 2 clamps to connect the No. 2 fuel vapor feed hose to the No. 1 air tube.

  44. INSTALL INTAKE AIR RESONATOR

    Click here

  45. INSTALL OUTLET COMPRESSOR ELBOW

    Click here

  46. INSTALL NO. 5 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  47. INSTALL NO. 2 AIR CLEANER HOSE

    Click here

  48. INSTALL INTAKE AIR CONNECTOR

    Click here

  49. INSTALL INTERCOOLER RESERVE TANK ASSEMBLY


    1. Connect the No. 1 intercooler cooling water hose to the intercooler reserve tank assembly and slide the clip to secure it.

    2. Connect the No. 4 intercooler cooling water hose to the intercooler reserve tank assembly and slide the clip to secure it.

    3. Connect the No. 1 turbo water hose to the intercooler reserve tank assembly and slide the clip to secure it.

    4. Install the intercooler reserve tank assembly with the 2 bolts.

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

    Click here

  51. INSTALL AIR CLEANER BRACKET

    Click here

  52. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  53. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Click here

  54. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

    Click here

  55. 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 }
  56. INSTALL BATTERY BRACKET REINFORCEMENT


    1. Install the battery bracket reinforcement with the 2 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
  57. INSTALL BATTERY CARRIER SUB-ASSEMBLY


    1. w/ NO. 3 Battery Clamp:


      1. Install the battery carrier sub-assembly with the 4 bolts.

        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      2. Install the NO. 3 battery clamp with the 2 bolts.

        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      3. Engage the 3 clamps and connect the wire harness to battery carrier sub-assembly.

    2. w/o NO. 3 Battery Clamp:


      1. Install the battery carrier sub-assembly with the 6 bolts.

        Torque:
        20 N*m  { 204 kgf*cm, 15 ft.*lbf }
      2. Engage the 3 clamps and connect the wire harness to battery carrier sub-assembly.

  58. INSTALL BATTERY

    Click here

  59. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  60. INSTALL FRONT WHEELS

    Click here

  61. ADD ENGINE OIL

    Click here

  62. ADD TRANSFER OIL (for AWD)

    Click here

  63. ADD ENGINE COOLANT

    Click here

  64. ADD COOLANT (for Intercooler)

    Click here

  65. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    for HFC-134a (R134a): Click here

    for HFO-1234yf (R1234yf): Click here

  66. ADD AUTOMATIC TRANSAXLE FLUID

    for 2WD: Click here

    for AWD: Click here

  67. INSPECT FOR FUEL LEAK

    Click here

  68. INSPECT FOR ENGINE OIL LEAK

    Click here

  69. INSPECT FOR COOLANT LEAK (for Intercooler)

    Click here

  70. INSPECT FOR COOLANT LEAK

    Click here

  71. INSPECT AUTOMATIC TRANSAXLE FLUID LEAK

  72. WARM UP ENGINE

    for HFC-134a (R134a): Click here

    for HFO-1234yf (R1234yf): Click here

  73. CHECK ENGINE OIL LEVEL

    Click here

  74. INSPECT ENGINE COOLANT LEVEL

    Click here

  75. INSPECT FOR EXHAUST GAS LEAK

    Click here

  76. INSPECT FOR REFRIGERANT LEAK

    for HFC-134a (R134a): Click here

    for HFO-1234yf (R1234yf): Click here

  77. INSPECT IGNITION TIMING

    Click here

  78. INSPECT ENGINE IDLE SPEED

    Click here

  79. INSPECT CO/HC

    Click here

  80. INSPECT TEST MODE (SPEED SENSOR CHECK)

    Click here

  81. INSPECT SHIFT LEVER POSITION

    Click here

  82. ADJUST SHIFT LEVER POSITION

    Click here

  83. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  84. INSTALL FRONT FLOOR COVER LH

    Click here

  85. INSTALL NO. 2 ENGINE UNDER COVER


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

  86. INSTALL FRONT FENDER APRON SEAL LH


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

  87. INSTALL FRONT FENDER APRON SEAL RH


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

  88. INSTALL FRONT LOWER BUMPER ABSORBER


    1. Engage the 2 claws.

    2. Install the front lower bumper absorber with the 4 screws and 2 clips.

  89. INSTALL NO. 1 ENGINE UNDER COVER


    1. Install the No. 1 engine under cover with the 3 bolts, 2 screws and clip.

  90. INSTALL NO. 3 ENGINE UNDER COVER


    1. Install the No. 3 engine under cover with the 5 bolts, 2 screws and 2 clips.

  91. INSTALL FRONT WHEEL OPENING EXTENSION PAD LH


    1. Install the front wheel opening extension pad LH with the 2 screws.

  92. INSTALL FRONT WHEEL OPENING EXTENSION PAD RH


    1. Install the front wheel opening extension pad RH with the 2 screws.

  93. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. Engage the 3 clips to install the No. 1 engine cover sub-assembly.

  94. INSTALL COOL AIR INTAKE DUCT SEAL

    Click here