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.

Note:

for Manual Transaxle:

When the transaxle is removed, be sure to use a new clutch release with bearing cylinder and new installation bolts. Removal of the transaxle allows the compressed clutch release with bearing cylinder to return to its original position, and dust could damage the seal of the clutch release with bearing cylinder, possibly causing clutch fluid leaks.

Tip:

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 ENGINE MOUNTING INSULATOR LH

    Tip:

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

    1. Install the wire harness clamp bracket with the bolt.

      7.7 N*m

      79 kgf*cm

      68 in.*lbf

    2. A297339N01

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

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

      95 N*m

      969 kgf*cm

      70 ft.*lbf

  2. INSTALL ENGINE MOUNTING SPACER

    Tip:

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

    1. A297331N01

      Temporarily install the engine mounting spacer with the 2 bolts.

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

      95 N*m

      969 kgf*cm

      70 ft.*lbf

  3. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

    Tip:

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

    1. Install the radiator reservoir bracket with the bolt.

      5.0 N*m

      51 kgf*cm

      44 in.*lbf

    2. A297340N01

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

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

      95 N*m

      969 kgf*cm

      70 ft.*lbf

  4. INSTALL REAR ENGINE MOUNTING INSULATOR

    Tip:

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

    1. A297341N01

      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.

      95 N*m

      969 kgf*cm

      70 ft.*lbf

  5. INSTALL FRONT ENGINE MOUNTING INSULATOR

    Tip:

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

    1. Install the front engine mounting insulator with the 2 bolts.

      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 ENGINE WIRE

    1. Install the engine wire to the engine.

  10. INSTALL CLUTCH RELEASE WITH BEARING CYLINDER ASSEMBLY (for Manual Transaxle)

    Click here

  11. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transaxle)

    Click here

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

    Click here

  13. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)

    Click here

  14. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)

    Click here

  15. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transaxle)

    Click here

  16. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle)

  17. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)

  18. INSTALL TRANSFER ASSEMBLY (for 4WD/AWD)

    Click here

  19. INSTALL STARTER ASSEMBLY

    Click here

  20. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE

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

    2. A302705C01

      *1

      Alignment Mark

      *2

      Protrusion

      Temporarily install the front suspension crossmember with the through bolt.

      Tip:

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

    3. Place the engine on an engine lifter.

      Tip:

      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. A296309

      Temporarily install the front suspension crossmember with the 2 bolts.

    6. A296308

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

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

      56 N*m

      571 kgf*cm

      41 ft.*lbf

      Note:

      While holding the bolt in place, tighten the nut.

    8. A297332C01
      V100135

      Bolt
      V100136

      Nut

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

      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. A296309

      Tighten the 2 front suspension member bolts.

      137 N*m

      1397 kgf*cm

      101 ft.*lbf

    10. A297333C01
      V100135

      Bolt A
      V100136

      Bolt B

      Tighten the 6 member rear brace bolts.

      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. A297334C01
      V100135

      Bolt A
      V100136

      Bolt B

      Install the front crossmember with the 6 bolts.

      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.

      95 N*m

      969 kgf*cm

      70 ft.*lbf

      Tip:

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

    14. A297351

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

      145 N*m

      1479 kgf*cm

      107 ft.*lbf

      Note:

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

  21. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH

    1. A296303

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

      99 N*m

      1010 kgf*cm

      73 ft.*lbf

  22. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH

    1. A296302

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

      99 N*m

      1010 kgf*cm

      73 ft.*lbf

  23. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY (for 4WD/AWD)

    Click here

  24. INSTALL DRIVE PLATE AND TORQUE CONVERTER SETTING BOLT (for Automatic Transaxle)

  25. INSTALL FLYWHEEL HOUSING UNDER COVER

    1. Install the flywheel housing under cover.

  26. INSTALL FRONT EXHAUST PIPE SUB-ASSEMBLY

    Click here

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

    Click here

  28. CONNECT CLUTCH HOSE (for Manual Transaxle)

    1. A296890

      Temporarily install the clutch line.

    2. Install the clutch hose with a new clip.

    3. Using a union nut wrench, tighten the 2 clutch lines to the accumulator to flexible hose tube.

      15 N*m

      153 kgf*cm

      11 ft.*lbf

      Note:

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench.

      Click hereClick here

  29. INSTALL DRIVE SHAFT BEARING BRACKET

    1. Install the bracket with the 3 bolts.

      63.7 N*m

      650 kgf*cm

      47 ft.*lbf

  30. INSTALL FRONT DRIVE SHAFT HOLE SNAP RING LH

  31. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

  32. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

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

    Click here

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

    Tip:

    Use the same procedure described for the LH side.

  35. CONNECT TIE ROD END SUB-ASSEMBLY LH

    Click here

  36. CONNECT TIE ROD END SUB-ASSEMBLY RH

    Tip:

    Use the same procedure described for the LH side.

  37. CONNECT FRONT STABILIZER LINK ASSEMBLY LH

    Click here

  38. CONNECT FRONT STABILIZER LINK ASSEMBLY RH

    Tip:

    Use the same procedure described for the LH side.

  39. CONNECT FRONT SPEED SENSOR LH

    Click hereClick here

  40. CONNECT FRONT SPEED SENSOR RH

    Tip:

    Use the same procedure described for the LH side.

  41. INSTALL FRONT AXLE SHAFT NUT LH

    Click hereClick here

  42. INSTALL FRONT AXLE SHAFT NUT RH

    Tip:

    Use the same procedure described for the LH side.

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

    Click here

  44. CONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY

    Click here

  45. INSTALL COLUMN HOLE COVER SILENCER SHEET

    Click here

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

    1. Connect the 2 transmission control cables with 2 new clips.

    2. Install the 2 new clips.

  47. CONNECT TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)

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

    2. Connect the transmission control cable to the control shaft lever with the nut.

      12 N*m

      122 kgf*cm

      9 ft.*lbf

  48. CONNECT WIRE HARNESS AND HOSE

    1. for Automatic Transaxle:

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

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

    2. for Manual Transaxle:

      1. Attach the heater hose to the clamp.

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

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

    3. Connect the vacuum hose to the No. 1 hose to hose tube, and slide the clip to secure it.

    4. Connect the wire harness with the bolt.

      11.4 N*m

      116 kgf*cm

      8 ft.*lbf

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

    6. Connect the wire harness to the engine room No. 1 relay block with the nut.

      12.8 N*m

      131 kgf*cm

      9 ft.*lbf

    7. Connect the wire harness with the bolt.

      8.4 N*m

      86 kgf*cm

      74 in.*lbf

    8. Connect the 2 clamps and wire harness.

    9. Connect the clamp.

    10. Connect the starter wire with the nut.

      9.8 N*m

      100 kgf*cm

      87 in.*lbf

    11. Install the terminal cap.

  49. CONNECT FUEL TUBE SUB-ASSEMBLY

    1. Connect the fuel tube connector.

      Click here

    2. Install the No. 1 fuel pipe clamp.

  50. INSTALL TRANSMISSION OIL COOLER (for Automatic Transaxle)

  51. CONNECT SUCTION HOSE SUB-ASSEMBLY

    Click here

  52. CONNECT DISCHARGE HOSE SUB-ASSEMBLY

    Click here

  53. CONNECT RADIATOR HOSE SUB-ASSEMBLY

    Click hereClick here

  54. INSTALL RADIATOR HOSE HOSE CLAMP

    Click hereClick here

  55. CONNECT NO. 2 RADIATOR HOSE

    Click hereClick here

  56. INSTALL GENERATOR ASSEMBLY

    Click here

  57. INSTALL FAN AND GENERATOR V BELT

    Click here

  58. CONNECT RADIATOR RESERVOIR ASSEMBLY

    Click here

  59. INSTALL ECM

    Click here

  60. INSTALL BATTERY BRACKET REINFORCEMENT

    Click here

  61. INSTALL FRONT BATTERY BRACKET

    Click here

  62. INSTALL BATTERY TRAY

    Click here

  63. INSTALL BATTERY

    Click here

  64. INSTALL BATTERY INSULATOR

    Click here

  65. INSTALL BATTERY CLAMP SUB-ASSEMBLY

    Click here

  66. INSTALL AIR CLEANER CASE

    Click here

  67. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  68. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note:

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

    Click hereClick here

  69. CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

    Click hereClick here

  70. ADD MANUAL TRANSAXLE OIL (for Manual Transaxle)

  71. INSPECT MANUAL TRANSAXLE OIL (for Manual Transaxle)

  72. ADD AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle)

  73. ADD TRANSFER OIL (for 4WD/AWD)

    Click here

  74. ADD ENGINE COOLANT

    Click here

  75. ADD ENGINE OIL

    Click here

  76. INSPECT FOR FUEL LEAK

    Click here

  77. INSPECT FOR COOLANT LEAK

    Click here

  78. INSPECT FOR OIL LEAK

    Click here

  79. INSPECT FOR EXHAUST GAS LEAK

    Click here

  80. INSPECT FOR REFRIGERANT LEAK

    Click hereClick here

  81. INSPECT IGNITION TIMING

    Click here

  82. INSPECT ENGINE IDLE SPEED

    Click here

  83. INSPECT CO/HC

    Click here

  84. ADJUST FRONT WHEEL ALIGNMENT

    Click here

  85. INSTALL NO. 2 ENGINE UNDER COVER (w/ Cover)

    1. Install the No. 2 engine under cover with the clip and bolt.

      5.5 N*m

      56 kgf*cm

      49 in.*lbf

  86. INSTALL FRONT FLOOR COVER (w/ Cover)

    Click here

  87. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

    Click here

  88. INSTALL REAR ENGINE UNDER COVER RH

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

  89. INSTALL REAR ENGINE UNDER COVER LH

    1. for Half Cover Type:

      Install the rear engine under cover LH with the 3 clips.

    2. for Full Cover Type:

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

  90. INSTALL NO. 1 ENGINE UNDER COVER

    1. for Half Cover Type:

      Install the No. 1 engine under cover with the 6 screws and 5 clips.

    2. for Full Cover Type:

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