ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

CAUTION:


  • B000UK0C22
    *a Heavy object exceeding the capacity of the engine lifter

    Because the weight of the engine with transmission assembly is extremely heavy, make sure to follow the work procedures described in the repair manual.

  • If work is not performed according to the procedures described in the repair manual, there is a danger that the engine lifter could drop and components could fall down.

Tech Tips

Perform "Inspection After Repairs" after replacing the engine assembly, cylinder head sub-assembly, camshaft timing control motor with EDU assembly, camshaft (for intake or exhaust camshaft), camshaft timing intake gear assembly, camshaft timing exhaust gear assembly, piston sub-assembly or piston ring.


PROCEDURE


  1. INSTALL NO. 1 ENGINE HANGER

    Click here

  2. REMOVE ENGINE FROM ENGINE STAND


    1. Remove the engine assembly from the engine stand.

  3. INSTALL FRONT ENGINE MOUNTING INSULATOR

    Tech Tips

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


    1. Install the 2 front engine mounting insulators to the front suspension crossmember sub-assembly with the 2 nuts.

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }
  4. INSTALL FRONT FRAME CROSSMEMBER SUB-ASSEMBLY


    1. Install the front suspension crossmember sub-assembly to the engine assembly with the 2 nuts.

      Torque:
      57 N*m  { 581 kgf*cm, 42 ft.*lbf }
  5. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  6. INSPECT DRIVE PLATE AND RING GEAR SUB-ASSEMBLY

    Click here

  7. INSTALL REAR ENGINE MOUNTING INSULATOR

    Click here

  8. INSTALL REAR ENGINE MOUNTING MEMBER

    Tech Tips

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


    1. B000X5K

      Install the engine rear mounting member to the rear engine mounting insulator with the 3 nuts.

      Torque:
      34 N*m  { 347 kgf*cm, 25 ft.*lbf }
  9. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

    Click here

  10. INSTALL DRIVE PLATE AND TORQUE CONVERTER ASSEMBLY SETTING BOLT

    Click here

  11. INSTALL STARTER ASSEMBLY

    Click here

  12. INSTALL GENERATOR ASSEMBLY

    Click here

  13. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY

    Click here

  14. INSTALL OIL COOLER TUBE

    Click here

  15. CONNECT WIRE HARNESS

    Click here

  16. INSTALL FAN AND GENERATOR V BELT

    Click here

  17. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  18. INSTALL EXHAUST MANIFOLD TO HEAD GASKET LH

    Click here

  19. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

    Click here

  20. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  21. INSTALL EXHAUST MANIFOLD TO HEAD GASKET

    Click here

  22. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

    Click here

  23. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  24. INSTALL ENGINE MOUNTING DAMPER


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

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
  25. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  26. INSTALL ENGINE WITH TRANSMISSION ASSEMBLY

    Tech Tips

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



    1. B000YDJC01
      B000WCN Place Wooden Block or Plate Attachments

      Set the engine on an engine lifter.

      Note


      • Place wooden blocks or plate lift attachments so that the engine is level.

      • 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.

      • Never install attachments to the oil pan of the engine assembly or transmission as doing so may deform the oil pan.

    2. Operate the engine lifter and install the engine and transmission assembly to the vehicle.

      Note

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

    3. B000WKDC01
      B000XM7 Bolt
      B000TT4 Nut

      Install the engine and transmission assembly to the vehicle with the 2 bolts and 2 nuts.

      Torque:
      170 N*m  { 1734 kgf*cm, 125 ft.*lbf }
    4. B000WN7

      Install the rear engine mounting member with the 6 bolts.

      Torque:
      34.7 N*m  { 354 kgf*cm, 26 ft.*lbf }
    5. Remove the 4 bolts and 2 engine hangers.

  27. CONNECT NO. 2 GROUND WIRE


    1. B000VDV

      Connect the No. 2 ground wire with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
  28. CONNECT NO. 2 PARKING LOCK RELEASE CABLE ASSEMBLY


    1. B000Z9MC01
      *1 Parking Lock Release Lever Assembly Cable End
      *2 No. 2 Parking Lock Release Cable Assembly Cable End

      Connect the parking lock release lever assembly cable end to the No. 2 parking lock release cable assembly cable end.

    2. B000W8VC02
      *1 Cover
      B000TT4 Arrow
      B000WYJ Connect

      Attach the 2 claws and connect the cover to the No. 2 parking lock release cable assembly as shown in the illustration.

  29. INSTALL REAR LOWER ARM MOUNTING REINFORCEMENT SUB-ASSEMBLY LH

    Click here

  30. INSTALL REAR LOWER ARM MOUNTING REINFORCEMENT SUB-ASSEMBLY RH

    Tech Tips

    Install the RH side following the same procedure as for the LH side.

  31. INSTALL ENGINE SIDE COVER LH

    Click here

  32. INSTALL ENGINE SIDE COVER RH

    Tech Tips

    Install the RH side following the same procedure as for the LH side.

  33. TEMPORARILY TIGHTEN STEERING KNUCKLE LH


    1. B000V0S

      Install the steering knuckle LH with the 2 bolts and 2 nuts.

  34. TEMPORARILY TIGHTEN STEERING KNUCKLE RH

    Tech Tips

    Install the RH side following the same procedure as for the LH side.

  35. CONNECT FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  36. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tech Tips

    Install the RH side following the same procedure as for the LH side.

  37. CONNECT TIE ROD ASSEMBLY LH

    Click here

  38. CONNECT TIE ROD ASSEMBLY RH

    Tech Tips

    Install the RH side following the same procedure as for the LH side.

  39. INSTALL FRONT DISC BRAKE DUST COVER LH

    Click here

  40. INSTALL FRONT DISC BRAKE DUST COVER RH

    Tech Tips

    Install the RH side following the same procedure as for the LH side.

  41. INSTALL FRONT DISC LH

    Click here

  42. INSTALL FRONT DISC RH

    Tech Tips

    Install the RH side following the same procedure as for the LH side.

  43. CONNECT DISC BRAKE CYLINDER ASSEMBLY LH

    Click here

  44. CONNECT DISC BRAKE CYLINDER ASSEMBLY RH

    Tech Tips

    Install the RH side following the same procedure as for the LH side.

  45. CONNECT FRONT HEIGHT CONTROL SENSOR SUB-ASSEMBLY LH

    Click here

  46. CONNECT FRONT HEIGHT CONTROL SENSOR SUB-ASSEMBLY RH

    Tech Tips

    Install the RH side following the same procedure as for the LH side.

  47. CONNECT FRONT SKID CONTROL SENSOR WIRE LH

    Click here

  48. CONNECT FRONT SKID CONTROL SENSOR WIRE RH

    Tech Tips

    Install the RH side following the same procedure as for the LH side.

  49. CONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY

    Click here

  50. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  51. INSTALL NO. 2 FUEL TANK PROTECTOR

    Click here

  52. INSTALL FRONT NO. 1 FLOOR HEAT INSULATOR

    Click here

  53. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY

    Click here

  54. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  55. INSTALL FRONT CENTER FLOOR BRACE SUB-ASSEMBLY

    Click here

  56. INSTALL HEATED OXYGEN SENSOR (for Bank 2)

    Click here

  57. INSTALL HEATED OXYGEN SENSOR (for Bank 1)

    Click here

  58. CONNECT HEATED OXYGEN SENSOR CONNECTOR

    Click here

  59. INSTALL FRONT SEAT ASSEMBLY

    Click here

  60. INSTALL FRONT FLOOR COVER LH

    Click here

  61. INSTALL FRONT FLOOR COVER RH

    Click here

  62. INSTALL FRONT FENDER SEAL LH

    Click here

  63. INSTALL FRONT FENDER SEAL RH

    Click here

  64. INSTALL REAR FLOOR SIDE MEMBER COVER LH

    Click here

  65. INSTALL REAR FLOOR SIDE MEMBER COVER RH

    Click here

  66. INSTALL REAR FRAME RAIL SUB-ASSEMBLY LH


    1. B000UP9C02
      *a Bolt A
      *b Bolt B

      Install the rear frame rail sub-assembly LH with the 3 bolts and 2 nuts.

      Torque:
      Bolt A
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
      Bolt B
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }
  67. INSTALL REAR FRAME RAIL SUB-ASSEMBLY RH


    1. B000VJ6C02
      *a Bolt A
      *b Bolt B

      Install the rear frame rail sub-assembly RH with the 3 bolts and 2 nuts.

      Torque:
      Bolt A
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
      Bolt B
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }
  68. INSTALL RADIATOR SUPPORT OPENING COVER

    Click here

  69. INSTALL RADIATOR SUPPORT EXTENSION LH

    Click here

  70. INSTALL RADIATOR SUPPORT EXTENSION RH

    Click here

  71. INSTALL NO. 2 FRONT BUMPER REINFORCEMENT SUB-ASSEMBLY


    1. Install the No. 2 front bumper reinforcement sub-assembly with the 6 nuts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
  72. INSTALL FRONT BUMPER COVER

    Click here

  73. CONNECT NO. 3 ENGINE WIRE


    1. Connect the No. 3 engine wire from the generator assembly with the bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    2. Attach the 2 clamps.

  74. CONNECT NO. 3 ENGINE ROOM WIRE (for LHD)


    1. B000WIHC01
      *a LH Side

      Connect the No. 3 engine room wire with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. B000WA5C01
      *a RH Side

      Attach the 3 clamps and connect the No. 3 engine room wire.

    3. Connect the 2 connectors.

  75. CONNECT NO. 3 ENGINE ROOM WIRE (for RHD)


    1. B000UOD

      Connect the No. 3 engine room wire with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    2. Attach the claw and connect the No. 10 connector holder.

    3. Connect the 2 connectors.

  76. CONNECT ENGINE WIRE (for LHD)


    1. B000UL4C01
      B000WYJ Connect in this Direction

      Attach the 2 claws and connect the connector holder to the No. 1 engine room relay block.

    2. Attach the claw and disconnect the junction connector.

    3. Connect the 2 connectors.

    4. Attach the 2 claws and connect the No. 1 semiconductor power integration ECU to the No. 1 engine room relay block.

    5. Attach the clamp.

    6. Connect the ECM connector.

      Click here

    7. Attach the 2 claws and connect the engine wire to the No. 1 engine room relay block.

    8. Install the nut.

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

  77. CONNECT ENGINE WIRE (for RHD)


    1. B000X1JC01
      B000WYJ Connect in this Direction

      Attach the 2 claws and connect the connector holder to the No. 1 engine room relay block.

    2. Attach the claw and disconnect the junction connector.

    3. Connect the 2 connectors.

    4. Attach the 2 claws and connect the No. 1 semiconductor power integration ECU to the No. 1 engine room relay block.

    5. Attach the clamp.

    6. Connect the ECM connector.

      Click here

    7. Attach the 2 claws and connect the engine wire to the No. 1 engine room relay block.

    8. Install the nut.

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

  78. CONNECT NO. 2 ENGINE WIRE (for LHD)


    1. Attach the 2 claws and connect the No. 2 engine wire to the No. 1 engine room relay block.

    2. Tighten the nut.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    3. Attach the 2 clamps.

    4. Install the upper relay block cover to the No. 1 engine room relay block.

  79. CONNECT NO. 2 ENGINE WIRE (for RHD)


    1. Attach the 2 claws and connect the No. 2 engine wire to the No. 1 engine room relay block.

    2. Tighten the nut.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    3. Attach the 2 clamps.

    4. Install the upper relay block cover to the No. 1 engine room relay block.

  80. CONNECT SUCTION HOSE SUB-ASSEMBLY A

    Click here

  81. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

    Click here

  82. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. Connect the fuel tube sub-assembly.

      Click here

    2. Install the fuel pipe clamp to the fuel tube sub-assembly.

  83. CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY


    1. Connect the No. 2 fuel tube sub-assembly.

      Click here

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

  84. CONNECT NO. 1 FUEL VAPOR FEED HOSE


    1. Connect the No. 1 fuel vapor feed hose to the purge VSV and slide the clip to secure it.

  85. CONNECT HEATER WATER OUTLET HOSE


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

  86. CONNECT HEATER WATER INLET HOSE


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

  87. CONNECT RADIATOR HOSE SUB-ASSEMBLY

    Click here

  88. INSTALL NO. 1 OIL COOLER OUTLET HOSE

    Click here

  89. INSTALL NO. 1 OIL COOLER INLET HOSE

    Click here

  90. CONNECT NO. 3 RADIATOR HOSE

    Click here

  91. INSTALL WATER BY-PASS HOSE

    Click here

  92. INSTALL NO. 4 TRANSMISSION OIL COOLER HOSE

    Click here

  93. CONNECT NO. 1 RADIATOR HOSE

    Click here

  94. INSTALL RESERVE TANK OUTLET HOSE

    Click here

  95. INSTALL RADIATOR RESERVE TANK ASSEMBLY

    Click here

  96. INSTALL NO. 2 INTAKE AIR CONNECTOR PIPE

    Click here

  97. INSTALL INTAKE AIR SOUND CREATOR

    Click here

  98. INSTALL INTAKE AIR CONNECTOR PIPE

    Click here

  99. INSTALL AIR CLEANER HOSE ASSEMBLY


    1. Connect the air cleaner hose assembly to the throttle body with motor assembly.

    2. Tighten the 2 hose clamps.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
  100. CONNECT NO. 3 PCV HOSE

    Click here

  101. CONNECT NO. 2 PCV HOSE

    Click here

  102. INSTALL AIR CLEANER WITH ELEMENT ASSEMBLY RH


    1. Connect the air cleaner with element assembly RH.

    2. Insert the 3 air cleaner with element assembly RH pins into the air cleaner support bracket and radiator upper support.

    3. Tighten the hose clamp.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    4. Connect the 2 vacuum hose sub-assemblies.

    5. Attach the 2 clamps and connect the wire harness clamp to the air cleaner with element assembly RH.

    6. Connect the vacuum switching valve assembly connector.

    7. Connect the mass air flow meter sub-assembly connector.

  103. INSTALL AIR CLEANER WITH ELEMENT ASSEMBLY LH


    1. Connect the air cleaner with element assembly LH.

    2. Insert the 3 air cleaner with element assembly LH pins into the air cleaner support bracket and radiator upper support.

    3. Tighten the hose clamp.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    4. Connect the vacuum hose sub-assembly.

    5. Attach the clamp and connect the wire harness clamp to the air cleaner with element assembly LH.

    6. Connect the mass air flow meter sub-assembly connector.

  104. INSTALL FENDER APRON BRACE SUB-ASSEMBLY LH (for LHD)


    1. Install the fender apron brace sub-assembly LH with the 2 bolts.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }
  105. INSTALL FENDER APRON BRACE SUB-ASSEMBLY LH (for RHD)


    1. Install the fender apron brace sub-assembly LH with the 2 bolts.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }
    2. Attach the 2 claws and install the center cowl top ventilator louver.

  106. INSTALL FENDER APRON BRACE SUB-ASSEMBLY RH (for LHD)


    1. Install the fender apron brace sub-assembly RH with the 2 bolts.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }
    2. Attach the 2 claws and install the center cowl top ventilator louver.

  107. INSTALL FENDER APRON BRACE SUB-ASSEMBLY RH (for RHD)


    1. Install the fender apron brace sub-assembly RH with the 2 bolts.

      Torque:
      49 N*m  { 500 kgf*cm, 36 ft.*lbf }
  108. INSTALL RADIATOR SUPPORT TO CROSSMEMBER BRACE SUB-ASSEMBLY LH

    Click here

  109. INSTALL RADIATOR SUPPORT TO CROSSMEMBER BRACE SUB-ASSEMBLY RH

    Click here

  110. 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

  111. PERFORM INITIALIZATION

    Click here

  112. PARKING LOCK FORCED RELEASE

    Click here

  113. CHECK SHIFT LEVER OPERATION

    Click here

  114. ADD ENGINE OIL

    Click here

  115. ADD ENGINE COOLANT

    Click here

  116. ADD AUTOMATIC TRANSMISSION FLUID

    Click here

  117. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT


  118. WARM UP ENGINE


  119. INSPECT FOR COOLANT LEAK

    Click here

  120. INSPECT FOR ENGINE OIL LEAK

    Click here

  121. INSPECT FOR FUEL LEAK

    Click here

  122. INSPECT FOR EXHAUST GAS LEAK

    Click here

  123. INSPECT FOR REFRIGERANT LEAK


  124. INSTALL FRONT WHEELS

    Click here

  125. STABILIZE SUSPENSION

    Click here

  126. FULLY TIGHTEN LOWER NO. 2 SUSPENSION ARM ASSEMBLY LH

    Click here

  127. FULLY TIGHTEN LOWER NO. 2 SUSPENSION ARM ASSEMBLY RH

    Tech Tips

    Install the RH side following the same procedure as for the LH side.

  128. FULLY TIGHTEN FRONT LOWER SUSPENSION ARM ASSEMBLY LH

    Click here

  129. FULLY TIGHTEN FRONT LOWER SUSPENSION ARM ASSEMBLY RH

    Tech Tips

    Install the RH side following the same procedure as for the LH side.

  130. ALIGN FRONT WHEELS FACING STRAIGHT AHEAD

  131. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

    Click here

  132. VARIABLE GEAR RATIO STEERING SYSTEM CALIBRATION

    Click here

  133. INSPECT THROTTLE WITH MOTOR BODY ASSEMBLY

    Click here

  134. INSPECT IGNITION TIMING

    Click here

  135. INSPECT ENGINE IDLE SPEED

    Click here

  136. INSPECT CO/HC

    Click here

  137. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR

    Click here

  138. CHECK ENGINE OIL LEVEL

    Click here

  139. INSTALL STRUT BAR BRACKET SUPPORT SUB-ASSEMBLY


    1. Install the strut bar bracket support sub-assembly with 4 new bolts.

      Torque:
      7.9 N*m  { 81 kgf*cm, 70 in.*lbf }
  140. INSTALL NO. 2 ENGINE UNDER COVER ASSEMBLY


    1. Install the No. 2 engine under cover assembly with 10 new bolts and clip.

      Torque:
      7.9 N*m  { 81 kgf*cm, 70 in.*lbf }
  141. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY


    1. Install the No. 1 engine under cover assembly with the 15 screws and 3 clips.

  142. INSTALL LOWER RADIATOR AIR DEFLECTOR

    Click here

  143. INSTALL RADIATOR SUPPORT TO FRAME SEAL RH

    Click here

  144. INSTALL RADIATOR SUPPORT TO FRAME SEAL LH

    Click here

  145. INSTALL V-BANK COVER SUB-ASSEMBLY


    1. B000XADC01
      *a Tip (Sphere)

      Attach the 4 clips in the order shown in the illustration to install the V-bank cover sub-assembly.

      Note


      • Securely attach the clips.

      • If the clips are forcibly attached or struck with an object, they may be damaged.

      • Do not apply any oil to the tips (sphere).