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, No. 2 camshaft, camshaft timing gear assembly, camshaft timing exhaust gear assembly, piston sub-assembly or piston ring.


PROCEDURE


  1. INSTALL DRIVE SHAFT BEARING BRACKET


    1. Install the drive shaft bearing bracket to the cylinder block and stiffening crankcase assembly with the 3 bolts.

      Torque:
      63.7 N*m  { 650 kgf*cm, 47 ft.*lbf }

  2. INSTALL ENGINE MOUNTING INSULATOR LH

    Tech Tips

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


    1. B008ILKC04
      *1 Bracket

      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 }

    3. Install the bracket with the bolt.

      Torque:
      7.7 N*m  { 79 kgf*cm, 68 in.*lbf }

  3. INSTALL ENGINE MOUNTING SPACER

    Tech Tips

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


    1. B008HVRN02

      Temporarily install the engine mounting spacer with the 2 bolts.

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

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

  4. 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. B008J2ZC03
      *1 Radiator Reservoir Bracket

      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 }

  5. INSTALL REAR ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. B008I63N02

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

    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 }

  6. INSTALL ENGINE HANGER

    Click here

  7. 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.

  8. FIX ENGINE ASSEMBLY

    Click here

  9. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  10. INSTALL TRANSFER ASSEMBLY (for AWD)

    Click here

  11. INSTALL REAR ENGINE MOUNTING BRACKET

    Click here

  12. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY


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

      Note

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

    2. Install the automatic transaxle assembly.


  13. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

    Tech Tips

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


    1. B008HLR

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

    2. B008IGGC02
      *a Rib
      *b Protrusion

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

      Tech Tips

      Make sure the protrusion of the rear engine mounting bracket is aligned with the rib of the rear engine mounting insulator.

    3. Set the engine assembly with transaxle on an engine lifter.

      Note


      • Using height adjustment attachments and plate lift attachments, place the engine assembly with transaxle horizontally.

      • 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 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 transaxle.

    4. Remove the 3 bolts, No. 1 engine hanger and No. 2 engine hanger.

    5. 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.

    6. Temporarily install the front suspension crossmember with the 2 bolts.

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

    8. 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.

    9. B008IC7C02
      *a Nut A
      *b Nut B
      *c Bolt

      Install the engine mounting insulator sub-assembly RH with the 2 bolts 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 }
    10. B008JKJ

      Tighten the 2 bolts of the front suspension crossmember sub-assembly.

      Torque:
      137 N*m  { 1397 kgf*cm, 101 ft.*lbf }
    11. B008JLMC02
      *a Bolt A
      *b Bolt B

      Tighten the 6 bolts of the front suspension member brace RH and front suspension member brace LH.

      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 }
    12. B008H8RC02
      *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 through bolt of the rear engine mounting insulator.

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

      Tech Tips


      • Make sure that the side of the protrusion of the rear engine mounting bracket is aligned with the side of the rib of the rear engine mounting insulator.

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

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

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

      Note

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

  14. 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 }

  15. 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 }

  16. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT

    Click here

  17. INSTALL FLYWHEEL HOUSING UNDER COVER

    Click here

  18. INSTALL FRONT NO. 2 EXHAUST PIPE SUB-ASSEMBLY

    Click here

  19. INSTALL FRONT EXHAUST PIPE SUB-ASSEMBLY

    Click here

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

    Click here

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

    Click here

  22. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

    Click here

  23. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH

    Click here

  24. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

    Click here

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

    Click here

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

    Tech Tips

    Use the same procedure described for the LH side.

  27. CONNECT TIE ROD END SUB-ASSEMBLY LH

    Click here

  28. CONNECT TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  29. CONNECT FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  30. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Use the same procedure described for the LH side.

  31. CONNECT FRONT SPEED SENSOR LH

    Click here

  32. CONNECT FRONT SPEED SENSOR RH

    Tech Tips

    Use the same procedure described for the LH side.

  33. INSTALL FRONT AXLE SHAFT NUT LH

    Click here

  34. INSTALL FRONT AXLE SHAFT NUT RH

    Tech Tips

    Use the same procedure described for the LH side.

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

    Click here

  36. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  37. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

  38. 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 control cable bracket with a new clip.

  39. INSTALL STARTER ASSEMBLY


  40. INSTALL TRANSMISSION OIL COOLER

    Click here

  41. CONNECT UNION TO CONNECTOR TUBE HOSE


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

  42. CONNECT FUEL TUBE SUB-ASSEMBLY


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

    2. Install the fuel pipe clamp to the fuel tube sub-assembly and No. 2 fuel tube sub-assembly.

  43. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY


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

  44. CONNECT WIRE HARNESS


    1. B008GJIC01
      *1 Engine Room Main Wire
      *2 Battery Current Sensor Connector
      *3 Ground Wire

      Connect the ground wire to the body with the bolt.

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

    2. Connect the battery current sensor connector to the battery current sensor.

    3. Connect the engine room main wire to the positive (+) battery terminal with the nut.

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

    4. Connect the terminal to the No. 1 relay block side cover.

    5. B008JNH

      Connect the 3 connectors, attach the 2 claws and connect the engine wire to the No. 1 relay block.

    6. Install the nut.

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

    7. Attach the 2 wire harness clamps and connect the engine wire with the bolt.

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

  45. CONNECT SUCTION HOSE SUB-ASSEMBLY

    Click here

  46. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

    Click here

  47. CONNECT NO. 1 TRANSMISSION OIL COOLER HOSE ASSEMBLY (w/ Air Cooled Transmission Oil Cooler)


    1. Connect the No. 1 transmission oil cooler hose assembly to the transmission oil cooler and automatic transaxle assembly and secure the hose with the 2 hose clips.

  48. INSTALL HEATER HOSE


    1. Install the heater hose to the engine.


      1. Connect the No. 5 water by-pass hose to the transmission oil cooler and slide the hose clip to secure the hose.

      2. Connect the No. 6 water by-pass hose to the transmission oil cooler and slide the hose clip to secure the hose.

      3. Connect the inlet water hose sub-assembly to the No. 2 water by-pass pipe and slide the hose clamp to secure the hose.

      4. Connect the outlet water hose to the No. 1 water by-pass pipe and slide the hose clamp to secure the hose.

      5. Connect the outlet water hose sub-assembly to the heater core and slide the hose clamp to secure the hose.

      6. Connect the inlet water hose sub-assembly to the heater core and slide the hose clamp to secure the hose.

  49. CONNECT NO. 1 RADIATOR HOSE


    1. Connect the No. 1 radiator hose to the cylinder head and slide the hose clip to secure the hose.

  50. CONNECT NO. 2 RADIATOR HOSE


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

  51. INSTALL NO. 3 INTERCOOLER COOLING WATER PIPE


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

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

    2. Connect the No. 4 sub-radiator hose to the No. 3 intercooler cooling water pipe and slide the hose clip to secure the hose.

    3. Connect the No. 2 turbo water hose to the No. 1 turbo water pipe sub-assembly and slide the hose clip to secure the hose.

    4. Connect the No. 5 sub-radiator hose to the No. 2 water by-pass pipe and slide the hose clip to secure the hose.

    5. Connect the ground wire to the No. 3 intercooler cooling water pipe with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    6. Install the clamp to the radiator reservoir bracket.

  52. INSTALL NO. 2 INTERCOOLER COOLING WATER PIPE


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

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    2. Connect the No. 1 sub-radiator hose to the No. 2 intercooler cooling water pipe and slide the hose clip to secure the hose.

    3. Connect the No. 1 turbo water hose to the No. 2 intercooler cooling water pipe and slide the hose clip to secure the hose.

    4. Connect the No. 6 radiator hose sub-assembly to the No. 2 water by-pass pipe and slide the hose clip to secure the hose.

  53. INSTALL NO. 1 AIR TUBE

    Click here

  54. INSTALL INTAKE AIR RESONATOR

    Click here

  55. INSTALL COMPRESSOR OUTLET ELBOW

    Click here

  56. INSTALL NO. 5 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  57. INSTALL NO. 2 AIR CLEANER HOSE

    Click here

  58. INSTALL INTAKE AIR CONNECTOR

    Click here

  59. INSTALL DIFFERENTIAL PRESSURE SENSOR (w/ GPF)

    Click here

  60. CONNECT RADIATOR RESERVOIR ASSEMBLY


    1. Connect the radiator reservoir assembly to the radiator reservoir bracket and body with the 2 bolts.

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

  61. INSTALL ECM

    Click here

  62. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

    Click here

  63. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Click here

  64. INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

    Click here

  65. INSTALL BATTERY BRACKET REINFORCEMENT

    Click here

  66. INSTALL BATTERY CARRIER ASSEMBLY

    Click here

  67. INSTALL BATTERY TRAY

  68. INSTALL BATTERY

  69. INSTALL BATTERY INSULATOR

  70. INSTALL BATTERY CLAMP SUB-ASSEMBLY

    Click here

  71. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

    Click here

  72. ADD ENGINE OIL

    Click here

  73. ADD TRANSFER OIL (for AWD)

    Click here

  74. ADD AUTOMATIC TRANSAXLE FLUID


  75. ADD COOLANT (for Intercooler)

    Click here

  76. ADD ENGINE COOLANT

    Click here

  77. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT


  78. INSPECT FOR FUEL LEAK

    Click here

  79. INSPECT FOR OIL LEAK

    Click here

  80. INSPECT FOR COOLANT LEAK (for Intercooler)

    Click here

  81. INSPECT FOR COOLANT LEAK

    Click here

  82. INSPECT AUTOMATIC TRANSAXLE FLUID LEAK

  83. WARM UP ENGINE

    Click here

  84. INSPECT ENGINE OIL LEVEL

    Click here

  85. INSPECT ENGINE COOLANT LEVEL

    Click here

  86. INSPECT AUTOMATIC TRANSAXLE FLUID LEVEL

    Click here

  87. INSPECT FOR EXHAUST GAS LEAK

    Click here

  88. INSPECT FOR REFRIGERANT LEAK


  89. INSPECT IGNITION TIMING

    Click here

  90. INSPECT ENGINE IDLE SPEED

    Click here

  91. INSPECT CO/HC

    Click here

  92. INSPECT TEST MODE (SPEED SENSOR CHECK)

    Click here

  93. ADJUST SHIFT LEVER POSITION

    Click here

  94. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  95. STABILIZE SUSPENSION

    Click here

  96. ADJUST FRONT WHEEL ALIGNMENT

    Click here

  97. INSTALL FRONT FLOOR COVER CENTER LH

    Click here

  98. INSTALL REAR ENGINE UNDER COVER LH


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

  99. INSTALL REAR ENGINE UNDER COVER RH


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

  100. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY


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

  101. INSTALL RADIATOR SUPPORT OPENING COVER

    Click here

  102. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY


    1. Align the 3 grommets of the No. 1 engine cover sub-assembly with the 3 pins, and install the No. 1 engine cover sub-assembly by pressing it.