Engine Block: Removal & Installation Acura TL III facelift

Oil Pan Removal

Special Tools Required

1. Front subframe adapter VSB02C000016
2. Engine support hanger, A and Reds AAR-T-12566
3. Engine hanger balance bar VSB02C000019 These special tools are available through Honda Tool and Equipment Program, 1-888-424-6857

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1. If the engine is out of the vehicle, go to step 44 .
2. Make sure you have the anti-theft codes for the audio system and the navigation system (if equipped).
3. Remove the left side engine compartment cover and the left rear engine compartment cover (see step 3 on «ENGINE REMOVAL»(ref-291534-S25836136142008072900000) ).
4. Remove the right side engine compartment cover, then remove the right rear engine compartment cover (see step 4 on «ENGINE REMOVAL»(ref-291534-S25836136142008072900000) ).
5. Remove the engine cover (see step 5 on «ENGINE REMOVAL»(ref-291534-S25836136142008072900000) ).
6. Drain the power steering system fluid, then plug the fluid reservoir and return hose (see «FLUID CHECK/REPLACEMENT»(ref-291507-S23558958212008072900000) ).
7. Disconnect the negative cable from the battery, then disconnect the positive cable.
8. Remove the battery.
9. Remove the breather pipe, then remove the intake air duct (see step 10 on «ENGINE REMOVAL»(ref-291534-S25836136142008072900000) ).
10. Remove the air cleaner assembly (see «AIR CLEANER REMOVAL/INSTALLATION»(ref-291515-S25625928812008072900000) ).
11. Remove the battery base (see step 13 on «ENGINE REMOVAL»(ref-291534-S25836136142008072900000) ).
12. Remove the under-hood fuse/ relay box (see step 15 on «ENGINE REMOVAL»(ref-291534-S25836136142008072900000) ).
13. Remove the strut brace (see step 16 on «ENGINE REMOVAL»(ref-291534-S25836136142008072900000) ).
14. Remove the power steering (P/S) pump outlet line from the P/S pump, then plug the outlet line and the P/S pump (see step 23 on «ENGINE REMOVAL»(ref-291534-S25836136142008072900000) ).
15. Remove the steering wheel (see «STEERING WHEEL REMOVAL»(ref-291507-S41261560362008072900000) ).
16. Make a reference mark across the steering joint and steering gearbox pinion shaft. Remove the steering joint bolt, and disconnect the steering joint from the steering gearbox pinion shaft (see step 28 on «ENGINE REMOVAL»(ref-291534-S25836136142008072900000) ).
17. Raise the vehicle on the lift to full height.
18. Remove the front wheels.
19. Remove the engine under cover (see step 32 on «ENGINE REMOVAL»(ref-291534-S25836136142008072900000) ).
20. Remove the splash shield (see step 33 on «ENGINE REMOVAL»(ref-291534-S25836136142008072900000) ).
21. Drain the engine oil (see «ENGINE OIL REPLACEMENT»(ref-291505-S37399934022008072900000) ).
22. Disconnect the stabilizer links (see «STABILIZER LINK REMOVAL/INSTALLATION»(ref-291535-S07980061372008072900000) ).
23. Remove the damper fork (see step 5 on «DAMPER/SPRING REMOVAL AND INSTALLATION»(ref-291535-S10797837902008072900000) ).
24. Separate the tie-rod end ball joints from the knuckles (see step 11 on «KNUCKLE/HUB/WHEEL BEARING REPLACEMENT»(ref-291535-S01218744072008072900000) ).
25. Separate the knuckles from the lower arms (see step 5 on «LOWER ARM REMOVAL/INSTALLATION»(ref-291535-S38064929132008072900000) ).
26. Remove the exhaust pipe A (see step 42 on «ENGINE REMOVAL»(ref-291534-S25836136142008072900000) ).
27. Remove the P/S hose, then plug the line and the hose (see step 43 on «ENGINE REMOVAL»(ref-291534-S25836136142008072900000) ).
28. Disconnect the power steering pressure switch connector (see step 44 on «ENGINE REMOVAL»(ref-291534-S25836136142008072900000) ).
29. M/T model: Remove the transmission lower front mount and transmission lower rear mount (see step 45 on «ENGINE REMOVAL»(ref-291534-S25836136142008072900000) ).
30. A/T model: Remove the transmission lower mount (see step 46 on «ENGINE REMOVAL»(ref-291534-S25836136142008072900000) ).
31. Lower the vehicle.
32. A/T model: Remove the shift cable bracket from the front subframe (see step 55 on «ENGINE REMOVAL»(ref-291534-S25836136142008072900000) ).
33. Install the engine support hanger and engine hanger balance bar (see step 56 on «ENGINE REMOVAL»(ref-291534-S25836136142008072900000) ).
34. Remove the front engine mount stop, then remove the front engine mount bolt and vacuum hose (see step 57 on «ENGINE REMOVAL»(ref-291534-S25836136142008072900000) ).
35. M/T model: Remove the rear engine damper (see step 58 on «ENGINE REMOVAL»(ref-291534-S25836136142008072900000) ).
36. Remove the rear engine mount stop, then remove the rear engine mount bolt (see step 59 on «ENGINE REMOVAL»(ref-291534-S25836136142008072900000) ).
37. Remove the vacuum hose (see step 60 on «ENGINE REMOVAL»(ref-291534-S25836136142008072900000) ).
38. M/T model: Remove the shift cable bracket (see step 61 on «ENGINE REMOVAL»(ref-291534-S25836136142008072900000) ).
39. Raise the vehicle on the lift to full height.
40. Make the appropriate reference lines at both ends of the subframe that line up with the edge of the stiffeners (see step 63 on «ENGINE REMOVAL»(ref-291534-S25836136142008072900000) ).
41. Attach the front subframe adapter to the subframe (see step 64 on «ENGINE REMOVAL»(ref-291534-S25836136142008072900000) ).
42. Remove the subframe middle mount (see step 66 on «ENGINE REMOVAL»(ref-291534-S25836136142008072900000) ).
43. Remove the mounting bolts securing the subframe stiffeners and front subframe (see step 67 on «ENGINE REMOVAL»(ref-291534-S25836136142008072900000) ).
44. Remove the rear warm up three way catalytic converter (rear WU-TWC) bracket.
45. Remove the torque converter cover (A/T) or clutch cover (M/T) (A) and the four bolts (B) securing the transmission.
46. Remove the bolts securing the oil pan.
47. Using a flat-tip screwdriver, separate the oil pan from the block in the places shown.
48. Remove the oil pan.

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1. Remove the engine/ transmission (see «ENGINE REMOVAL»(ref-291534-S25836136142008072900000) ).
2. Remove the transmission: Manual transmission (see «TRANSMISSION REMOVAL»(ref-291511-S29615184822008072900000) ) Automatic transmission (see «TRANSMISSION REMOVAL»(ref-291503-S09879575052008072900000) )
3. M/T model: Remove the flywheel (see «CLUTCH DISC AND PRESSURE PLATE INSTALLATION»(ref-291527-S33408434802008072900000) ).
4. A/T model: Remove the drive plate (see «DRIVE PLATE REMOVAL AND INSTALLATION»(ref-291503-S42665118292008072900000) ).
5. Remove the cylinder heads (see «CYLINDER HEAD REMOVAL»(ref-291519-S10770469302008072900000) ).
6. Remove the crankshaft position (CKP) sensor (see «CKP SENSOR REPLACEMENT»(ref-291526-S33736210532008072900000) ).
7. Remove the timing belt drive pulley from the crankshaft.
8. Remove the oil pan (see «OIL PAN REMOVAL»(ref-291539-S38366192002008072900000) ).
9. Remove the engine block end cover.
10. Remove the rocker arm oil control solenoid/ oil filter assembly.
11. Remove the oil screen (A), baffle plate (B), and oil pump (C).
12. If you can feel a ridge of metal or hard carbon around the top of any cylinder, remove it with a ridge reamer (A). Follow the reamer manufacturer's instructions. If the ridge is not removed, it may damage the piston as it's pushed out.
13. Remove the connecting rod caps after setting the crank pin at bottom dead center (BDC) for each cylinder. Remove the piston/ connecting rod assembly by pushing on the connecting rod. Take care not to damage the crank pin or cylinder with the connecting rod. CORRECT INCORRECT
14. Remove the bearing from the cap. Keep all caps/ bearings in order.
15. Remove the upper bearing halves from the connecting rods, and set them aside with their respective caps.
16. After removing a piston/ connecting rod assembly, reinstall the cap on the rod.
17. To avoid confusion during reassembly, mark each piston/ connecting rod assembly with its cylinder number.
18. Loosen the bearing cap bolts and bearing cap side bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened.
19. Remove the bearing cap bolts (A) and bearing cap side bolts (B), then remove the bearing caps (C).
20. Lift the crankshaft (A) out of the engine block, being careful not to damage the journals.
21. Reinstall the main caps and bearings on the engine block in the proper order.

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1. Remove the crankshaft from the engine block (see «CRANKSHAFT AND PISTON REMOVAL»(ref-291539-S22503994952008072900000) ).
2. Clean the crankshaft oil passages with pipe cleaners or a suitable brush.
3. Check the keyway and threads.
4. Measure out-of-round at the middle of each rod and main journal in two place. The difference between measurements on each journal must not be more than the service limit. Journal Out-of-Round Standard (New): 0.005 mm (0.0002 in.) max. Service Limit: 0.010 mm (0.0004 in.)
5. Measure taper at the edges of each rod and main journal. The difference between measurements on each journal must not be more than the service limit. Journal Taper Standard (New): 0.005 mm (0.0002 in.) max. Service Limit: 0.010 mm (0.0004 in.) Straightness
6. Place the engine block on a flat surface, crankshaft side up.
7. Clean and install the bearings on the No. 1 and No. 4 journal of the engine block.
8. Lower the crankshaft into the engine block.
9. Measure the runout on all of the main journals. Rotate the crankshaft two complete revolutions. The difference between measurements on each journal must not be more than the service limit. Crankshaft Total Runout Standard (New): 0.025 mm (0.0010 in.) max. Service Limit: 0.030 mm (0.0012 in.)

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1. Remove the pistons from the engine block (see «CRANKSHAFT AND PISTON REMOVAL»(ref-291539-S22503994952008072900000) ).
2. Check the pistons for distortion or cracks.
3. Measure each piston diameter at a point 16.0 mm (0.63 in.) from the bottom of the skirt. Piston Diameter Standard (New): 88.975-88.985 mm (3.5029-3.5033 in.) Service Limit: 88.965 mm (3.5026 in.) Oversize Piston Diameter 0.25: 89.225-89.235 mm (3.5128-3.5132 in.)
4. Measure wear and taper in direction X and Y at three levels in each cylinder as shown. If measurements in any cylinder are beyond the oversize bore service limit, replace the engine block. If the engine block has to be rebored, refer to step 7 after reboring. Cylinder Bore Size Standard (New): 89.000-89.015 mm (3.5039-3.5045 in.) Service Limit: 89.065 mm (3.5065 in.) Oversize 0.25: 89.250-89.265 mm (3.5138-3.5144 in.) Reboring Limit: 0.25 mm (0.01 in.) Bore Taper Limit: (Difference between first and third measurement) 0.05 mm (0.002 in.)
5. Hone any scored or scratched cylinder bores (see «CYLINDER BORE HONING»(ref-291539-S09635736562008072900000) ).
6. Check the top of the engine block for warpage. Measure along the edges and across the center as shown. Engine Block Warpage Standard (New): 0.07 mm (0.003 in.) max. Service Limit: 0.10 mm (0.004 in.)
7. Calculate the difference between cylinder bore diameter and piston diameter. If the clearance is near or exceeds the service limit, inspect the piston and cylinder bore for excessive wear. Piston-to-Block Clearance Standard (New): 0.015-0.040 mm (0.0006-0.0016 in.) Service Limit: 0.08 mm (0.003 in.)

Scheme 312

1. Measure the cylinder bores (see step 4 on «BLOCK AND PISTON INSPECTION»(ref-291539-S15585536962008072900000) ). If the engine block is to be reused, hone the cylinders and remeasure the bores. Only scored or scratched cylinder bores must be honed.
2. Hone the cylinder bores with honing oil and a fine (400 grit) stone in a 60 degree crosshatch pattern. NOTE: Use only a rigid hone with 400 grit or finer stone, such as Sunnen, Ammco, or equivalent. Do not use stones that are worn or broken.
3. When honing is complete, thoroughly clean the engine block of all metal particles. Wash the cylinder bores with hot soapy water, then dry and oil them immediately to prevent rusting. Never use solvent, it will only redistribute the grit on the cylinder walls.
4. If scoring or scratches are still present in the cylinder bores after honing to the service limit, rebore the engine block. Some light vertical scoring and scratching is acceptable if it is not deep enough to catch your fingernail and does not run the full length of the bore.

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1. Remove the pistons from the engine block (see «CRANKSHAFT AND PISTON REMOVAL»(ref-291539-S22503994952008072900000) ).
2. Apply new engine oil to the piston pin snap rings (A) and turn them in the ring grooves until the end gaps are lined up with the cutouts in the piston pin bores (B). NOTE: Take care not to damage the ring grooves.
3. Remove the snap rings (A) from both sides of each piston. Start at the cutout in the piston pin bore. Remove the snap rings carefully so they do not go flying or get lost. Wear eye protection.
4. Separately heat each piston and connecting rod assembly to about 158°F (70°C), then remove the piston pin.

Crankshaft and Piston Installation

Special Tools Required

1. Driver 07749-0010000
2. Driver attachment, 106 mm 070AD-RCAA200

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1. Check the connecting rod bearing clearance with plastigage (see «CONNECTING ROD BEARING REPLACEMENT»(ref-291539-S11441078402008072900000) ).
2. Check the main bearing clearance with plastigage (see «CRANKSHAFT MAIN BEARING REPLACEMENT»(ref-291539-S17716557072008072900000) ).
3. Install the bearing halves in the engine block and connecting rods.
4. Apply new engine oil to the main bearings and rod bearings.
5. Lower the crankshaft (A) into the engine block.
6. Apply new engine oil to the side with the thrust washer groove. Install the thrust washers (A) in the No. 3 journal.
7. Install the bearings (A) and bearing caps (B) with the arrow (C) facing the timing belt end of the engine.
8. Apply new engine oil to the bolt threads and flanges, then loosely install the bearing cap bolts (D) and bearing cap side bolts (E).
9. Set the crankshaft to bottom dead center (BDC) for the cylinder you are installing the piston in.
10. Apply new engine oil to the piston, inside of the ring compressor, and the cylinder bore.
11. Attach the ring compressor to the piston/ connecting rod assembly, and check that the bearing is securely in place.
12. Position the piston/ connecting rod assembly with the arrow (A) facing the timing belt side of the engine.
13. Position the piston/ connecting rod assembly in the cylinder, and tap it in using the wooden handle of a hammer (A). Maintain downward force on the ring compressor (B) to prevent the rings from expanding before entering the cylinder bore.
14. Stop after the ring compressor pops free, and check the connecting rod-to-crank journal alignment before pushing the piston into place.
15. Measure the diameter of each connecting rod bolt at point A and point B.
16. Calculate the difference in diameter between point A and point B. Point A-Point B = Difference in Diameter Difference in Diameter Specification: 0-0.1 mm (0-0.004 in.)
17. If the difference in diameter is out of tolerance, replace the connecting rod bolt.
18. Line up the mark (A) on the connecting rod and cap, then install the cap.
19. Apply new engine oil to the bolt threads and flanges. Torque the bolts (B) to 20 N.m (2.0 kgf.m, 15 lbf.ft).
20. Mark the connecting rod (A) and bolt head (B) as shown.
21. Tighten the bolt until the mark on the bolt head lines up with the mark on the connecting rod (turn the bolt 90°). NOTE: Remove the connecting rod bolt if you tightened it beyond the specified angle, and go back to step 15 of the procedure. Do not loosen it back to the specified angle.
22. Tighten the bearing cap bolts, and then the bearing cap side bolts to the specified torque in the sequence shown. Repeat the torque sequence again to make sure the bolts are properly torqued.
23. Remove any old liquid gasket from the engine block end cover mating surfaces, bolts, and bolt holes.
24. Clean and dry the engine block end cover mating surfaces.
25. The seal mating surface on the engine block end cover should be dry. Apply a light coat of multipurpose grease to the crankshaft and to the lip of the seal.
26. Drive the new crankshaft oil seal until the special tool bottoms on the engine block end cover.
27. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009, evenly to the engine block mating surface of the engine block end cover. Install the component within 5 minutes of applying the liquid gasket. NOTE: If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes. If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply the new liquid gasket.
28. Install the dowel pins (A), new O-ring (B), and the engine block end cover (C) on the engine block.
29. Clean the excess grease off the crankshaft, and check the seal for distortion.
30. Install a new crankshaft oil seal in the oil pump (see step 2 on «INSTALLATION»(ref-291505-S24847736642008072900000) ).
31. Remove all of the old liquid gasket from the oil pump mating surfaces, bolts, and bolt holes.
32. Clean and dry the oil pump mating surfaces.
33. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009, evenly to the engine block mating surface of the oil pump. Install the component within 5 minutes of applying the liquid gasket. NOTE: If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes. If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply the new liquid gasket.
34. Grease the lip of the crankshaft oil seal, and apply new engine oil to the new O-ring (A).
35. Install the dowel pins (B), then align the inner rotor with the crankshaft and install the oil pump (C).
36. Clean the excess grease off the crankshaft, and check the seal for distortion.
37. Install the baffle plate (D), then install the oil screen (E) with a new O-ring (F).
38. Install the rocker arm oil control solenoid/ oil filter assembly (A), with a new rocker arm oil control solenoid filter (B).
39. Install the oil pan (see «OIL PAN INSTALLATION»(ref-291539-S08127018622008072900000) ).
40. Install the crankshaft position (CKP) sensor (see «CKP SENSOR REPLACEMENT»(ref-291526-S33736210532008072900000) ).
41. Install the cylinder heads (see «CYLINDER HEAD INSTALLATION»(ref-291519-S30975361402008072900000) ).
42. M/T model: Install the flywheel (see «CLUTCH DISC AND PRESSURE PLATE INSTALLATION»(ref-291527-S33408434802008072900000) ).
43. A/T model: Install the drive plate (see «DRIVE PLATE REMOVAL AND INSTALLATION»(ref-291503-S42665118292008072900000) ).
44. Install the transmission: Manual transmission (see «TRANSMISSION INSTALLATION»(ref-291511-S24989440272008072900000) ) Automatic transmission (see «TRANSMISSION INSTALLATION»(ref-291503-S11599712372008072900000) )
45. Install the engine/ transmission (see «ENGINE INSTALLATION»(ref-291534-S27292188742008072900000) ). NOTE: After you replace any crankshaft or connecting rod bearings, run the engine at idle until it reaches normal operating temperature, then continue to run it for about 15 minutes.

Oil Pan Installation

Special Tools Required

1. Front subframe adapter VSB02C000016
2. Engine support hanger, A and Reds AAR-T-12566
3. Engine hanger balance bar VSB02C000019 These special tools are available through Acura Tool and Equipment Program, 1-888-424-6857

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1. Remove all of the old liquid gasket from the oil pan mating surfaces, bolts, and bolt holes.
2. Clean and dry the oil pan mating surfaces.
3. Apply liquid gasket, P/N 08717-0004, 08718-0001, 08718-0003, or 08718-0009, evenly to the oil pan mating surface of the engine block. Install the component within 5 minutes of applying the liquid gasket. NOTE: If you apply liquid gasket P/N 08718-0012, the component must be installed within 4 minutes. If too much time has passed after applying the liquid gasket, remove the old liquid gasket and residue, then reapply the new liquid gasket.
4. Install the oil pan on the engine block.
5. Tighten the bolts in three steps. In the final step, tighten all bolts, in sequence, to 12 N.m (1.2 kgf.m, 8.8 lbf.ft). NOTE: Wait at least 30 minutes before filling the engine with oil. Do not run the engine for at least 3 hours after installing the oil pan.
6. Tighten the four bolts (A) securing the transmission, then install the torque converter cover (A/T) or clutch cover (M/T) (B).
7. Install the rear warm up three way catalytic converter (rear WU-TWC) bracket.
8. If the engine is still in the vehicle, do the following steps.
9. Using the subframe adapter and a jack, loosely install the new front subframe bolts and the stiffeners (see step 9 on «ENGINE INSTALLATION»(ref-291534-S27292188742008072900000) ).
10. Loosely install the subframe middle mount (see step 10 on «ENGINE INSTALLATION»(ref-291534-S27292188742008072900000) ).
11. Remove the jack and front subframe adapter.
12. Align the reference marks with the edge of both rear stiffeners, and tighten the rear subframe mounting bolts, then the front bolts, and finally the stiffener bolts to the specified torque (see step 12 on «ENGINE INSTALLATION»(ref-291534-S27292188742008072900000) ).
13. Tighten the bolts securing the subframe middle mounts (see step 10 on «ENGINE INSTALLATION»(ref-291534-S27292188742008072900000) ).
14. M/T model: Tighten the nuts securing the transmission lower front mount and transmission lower rear mount (see step 14 on «ENGINE INSTALLATION»(ref-291534-S27292188742008072900000) ).
15. A/T model: Tighten the bolts securing the transmission lower mount (see step 15 on «ENGINE INSTALLATION»(ref-291534-S27292188742008072900000) ).
16. Lower the vehicle.
17. M/T model: Install the shift cable bracket (see step 17 on «ENGINE INSTALLATION»(ref-291534-S27292188742008072900000) ).
18. Install the vacuum hose (see step 18 on «ENGINE INSTALLATION»(ref-291534-S27292188742008072900000) ).
19. Tighten the rear engine mount bolt, then install the rear engine mount stop (see step 19 on «ENGINE INSTALLATION»(ref-291534-S27292188742008072900000) ).
20. M/T model: Install the rear engine damper (see step 20 on «ENGINE INSTALLATION»(ref-291534-S27292188742008072900000) ).
21. Tighten the front engine mount bolt, then install the front engine mount stop and vacuum hose (see step 21 on «ENGINE INSTALLATION»(ref-291534-S27292188742008072900000) ).
22. Remove the engine support hanger and engine hanger balance bar.
23. A/T model: Install the shift cable bracket to the front subframe (see step 29 on «ENGINE INSTALLATION»(ref-291534-S27292188742008072900000) ).
24. Raise the vehicle on the lift to full height.
25. Connect the power steering pressure switch connector (see step 35 on «ENGINE INSTALLATION»(ref-291534-S27292188742008072900000) ).
26. Install the power steering (P/S) hose (see step 36 on «ENGINE INSTALLATION»(ref-291534-S27292188742008072900000) ).
27. Install exhaust pipe A using new gaskets and new self locking nuts (see step 37 on «ENGINE INSTALLATION»(ref-291534-S27292188742008072900000) ).
28. Connect the suspension lower arm ball joints (see step 5 on «LOWER ARM REMOVAL/INSTALLATION»(ref-291535-S38064929132008072900000) ).
29. Connect the tie-rod end ball joints (see step 11 on «KNUCKLE/HUB REPLACEMENT»(ref-291535-S00920984002008072900000) ).
30. Install the damper fork (see step 2 on «INSTALLATION»(ref-291535-S17575507652008072900000) ).
31. Connect the stabilizer links (see «STABILIZER LINK REMOVAL/INSTALLATION»(ref-291535-S07980061372008072900000) ).
32. Install the splash shield (see step 43 on «ENGINE INSTALLATION»(ref-291534-S27292188742008072900000) ).
33. Install the engine under cover (see step 44 on «ENGINE INSTALLATION»(ref-291534-S27292188742008072900000) ).
34. Install the front wheels.
35. Lower the vehicle.
36. Align the reference mark on the steering joint and steering gearbox pinion shaft. Connect the steering joint to the steering gearbox pinion shaft. Tighten the steering joint bolt (see step 47 on «ENGINE INSTALLATION»(ref-291534-S27292188742008072900000) ).
37. Install the steering wheel (see «STEERING WHEEL INSTALLATION»(ref-291507-S19146754002008072900000) ).
38. Install the P/S pump outlet hose with a new O-ring (see step 50 on «ENGINE INSTALLATION»(ref-291534-S27292188742008072900000) ).
39. Install the strut brace (see step 59 on «ENGINE INSTALLATION»(ref-291534-S27292188742008072900000) ).
40. Install the under-hood fuse/ relay box (see step 60 on «ENGINE INSTALLATION»(ref-291534-S27292188742008072900000) ).
41. Install the battery base (see step 62 on «ENGINE INSTALLATION»(ref-291534-S27292188742008072900000) ).
42. Install the air cleaner assembly (see «AIR CLEANER REMOVAL/INSTALLATION»(ref-291515-S25625928812008072900000) ).
43. Install the intake air duct, then install the breather pipe (see step 64 on «ENGINE INSTALLATION»(ref-291534-S27292188742008072900000) ).
44. Install the battery. Clean the battery posts and cable terminals, then assemble them and apply grease to prevent corrosion.
45. Install the engine cover (see step 65 on «ENGINE INSTALLATION»(ref-291534-S27292188742008072900000) ).
46. Refill the engine with engine oil (see «ENGINE OIL REPLACEMENT»(ref-291505-S37399934022008072900000) ).
47. Refill the power steering reservoir with the power steering fluid (see «FLUID CHECK/REPLACEMENT»(ref-291507-S23558958212008072900000) ).
48. Bleed air from the P/S system, if necessary, add more fluid (see «FLUID CHECK/REPLACEMENT»(ref-291507-S23558958212008072900000) ).
49. Check the wheel alignment (see «WHEEL ALIGNMENT»(ref-291508-S39115575212008072900000) ).
50. Install the right rear engine compartment cover, then install the right side engine compartment cover (see step 81 on «ENGINE INSTALLATION»(ref-291534-S27292188742008072900000) ).
51. Install the left rear engine compartment cover and the left side engine compartment cover (see step 82 on «ENGINE INSTALLATION»(ref-291534-S27292188742008072900000) ).
52. Enter the anti-theft codes for the audio system and the navigation system (if equipped).
53. Set the clock (on vehicles without navigation).

Pulley End Crankshaft Oil Seal Installation - In Car

Special Tools Required

Oil seal driver, 64 mm 070AD-RCAA100

Scheme 335

1. Remove the crankshaft position (CKP) sensor, the timing belt, and the timing belt drive pulley (see «TIMING BELT DRIVE PULLEY REPLACEMENT»(ref-291519-S08161338882008072900000) ).
2. Remove the crankshaft pulley end crankshaft oil seal.
3. Clean and dry the crankshaft oil seal housing.
4. Apply a light coat of multipurpose grease to the crankshaft and to the lip of the seal.
5. Using the oil seal driver, drive in the crankshaft oil seal until the oil seal driver bottoms against the oil pump. When the seal is in place, clean any excess grease off the crankshaft, and check that the oil seal lip is not distorted.
6. Install the timing belt drive pulley, CKP sensor, and timing belt (see «TIMING BELT DRIVE PULLEY REPLACEMENT»(ref-291519-S08161338882008072900000) ).

Transmission End Crankshaft Oil Seal Installation - In Car

Special Tools Required

1. Driver 07749-0010000
2. Driver attachment, 106 mm 070AD-RCAA200

Scheme 336

1. M/T model: Remove the transmission (see «TRANSMISSION REMOVAL»(ref-291511-S29615184822008072900000) ), the clutch disc and pressure plate (see «PRESSURE PLATE AND CLUTCH DISC REMOVAL»(ref-291527-S23171669682008072900000) ), and the flywheel (see «CLUTCH DISC AND PRESSURE PLATE INSTALLATION»(ref-291527-S33408434802008072900000) ).
2. A/T model: Remove the transmission (see «TRANSMISSION REMOVAL»(ref-291503-S09879575052008072900000) ) and the drive plate (see «DRIVE PLATE REMOVAL AND INSTALLATION»(ref-291503-S42665118292008072900000) ).
3. Remove the transmission end crankshaft oil seal.
4. Clean and dry the crankshaft oil seal housing.
5. Apply a light coat of multipurpose grease to the crankshaft and to the lip of the seal.
6. Using the driver and driver attachment, drive in the crankshaft oil seal until the driver attachment bottoms against the engine block end cover. Align the hole in the driver attachment with the pin on the crankshaft.
7. Clean any excess grease off the crankshaft, and check that the oil seal lip is not distorted.
8. M/T model: Install the flywheel (see «CLUTCH DISC AND PRESSURE PLATE INSTALLATION»(ref-291527-S33408434802008072900000) ), the clutch disc and pressure plate (see «CLUTCH DISC AND PRESSURE PLATE INSTALLATION»(ref-291527-S33408434802008072900000) ), and the transmission (see «TRANSMISSION INSTALLATION»(ref-291511-S24989440272008072900000) ).
9. A/T model: Install the drive plate (see «DRIVE PLATE REMOVAL AND INSTALLATION»(ref-291503-S42665118292008072900000) ), and the transmission (see «TRANSMISSION INSTALLATION»(ref-291503-S11599712372008072900000) ).

Drain Bolt Installation

Note. When installing the drain bolts, always use new washers.

Scheme 337