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Engine Assembly (4-CYL): Removal & Installation Honda Crosstour I

Mechanical 72 illustrations ~2996 words

Engine Removal

Special Tools Required

  1. Universal Lifting Eyelet 07AAK-SNAA120
  2. Engine Hanger Adapter VSB02C000015*
  3. Engine Support Hanger, A and Reds AAR-T1256*
  4. Subframe Adapter VSB02C000016*

*: Available through the Honda Tool and Equipment Program 888-424-6857.

Note. Use fender covers to avoid damaging painted surfaces. To avoid damaging the wiring and terminals, unplug the wiring connectors carefully while holding the connector portion. Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring or hoses, or interfere with other parts.

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  1. Pry the passenger's side hood support strut clip, and release the passenger's side hood support strut from the pivot bolt (see «HOOD SUPPORT STRUT REPLACEMENT»(ref-512924-S02424225322012110400000) ).
  2. Remove the driver's side hood support strut bracket (A), then use it as shown to prop the hood in the wide-open position. NOTE: Turn the hood support strut bracket inside out. Do not attempt to close the hood with the support strut in the vertical position, as it will damage the support strut and the rod.
  3. Remove the strut brace (see «FRAME BRACE REPLACEMENT»(ref-512925-S32214065992012110400000) ).
  4. Remove the front grille cover (see «FRONT GRILLE COVER REPLACEMENT»(ref-512926-S12405382742012110400000) ).
  5. Drain the power steering fluid (see «FLUID CHECK/REPLACEMENT»(ref-512901-S07407711712012110400000) ).
  6. Relieve the fuel pressure (see «FUEL PRESSURE RELIEVING»(ref-512903-S20563776592012110400000) ).
  7. Do the battery removal procedure (see «BATTERY REMOVAL AND INSTALLATION»(ref-512910-S20680339942012110400000) ).
  8. Remove the intake air duct (see step 6 on «INTAKE MANIFOLD REMOVAL AND INSTALLATION»(ref-512902-S18459429352012110400000) ).
  9. Remove the air cleaner (see «AIR CLEANER ELEMENT INSPECTION/REPLACEMENT»(ref-512902-S06198685672012110400000) ).
  10. Remove the harness clamps (A), then remove the bolts (B) and loosen the bolts (C), then remove the battery base (D).
  11. Remove the water separator (see step 4 on «INTAKE MANIFOLD REMOVAL AND INSTALLATION»(ref-512902-S18459429352012110400000) ).
  12. Disconnect the battery cables (A) from the under-hood fuse/relay box.
  13. Disconnect the harness connector (B), and remove the harness connector from the bracket (C).
  14. Remove the PCM cover (A), then remove the three bolts (B) securing the PCM.
  15. Disconnect the PCM connectors (A) and the engine wire harness connector (B).
  16. Remove the harness clamps (C) and the bracket (D).
  17. Disconnect the EVAP canister hose (A) and the brake booster vacuum hose (B).
  18. Remove the quick-connect fitting cover (A), then disconnect the fuel feed hose (B) (see «FUEL LINE/QUICK-CONNECT FITTING REMOVAL»(ref-512903-S02781388452012110400000) ).
  19. Remove the drive belt (see «DRIVE BELT INSPECTION»(ref-512905-S20602512182012110400000) ).
  20. Disconnect the power steering pump outlet line (A) and the power steering pump inlet line (B) from the power steering pump and remove the power steering hose bracket (C), then plug the lines and the power steering pump.
  21. Remove the steering joint cover (A).
  22. Make a reference mark (B) across the steering joint (C) and the steering gearbox pinion shaft (D). Loosen the steering joint bolts (E), (F), then install the steering wheel holder tool (see «STEERING GEARBOX OVERHAUL»(ref-512901-S26962714332012110400000) ).
  23. Remove the steering joint bolt, then disconnect the steering joint from the steering gearbox pinion shaft.
  24. Wait until the engine is cool, then carefully remove the radiator cap.
  25. Remove the A/C condenser fan shroud assembly (see «CONNECTING PIPE REPLACEMENT»(ref-512899-S02601032922012110400000) ).
  26. Raise the vehicle on the lift.
  27. Remove the front wheels.
  28. Remove the engine under cover.
  29. Loosen the drain plug in the radiator, and drain the engine coolant (see «COOLANT CHECK»(ref-512899-S13443221892012110400000) ).
  30. Drain the engine oil (see «ENGINE OIL REPLACEMENT»(ref-512894-S16668778722012110400000) ).
  31. Drain the ATF (see «ATF REPLACEMENT»(ref-512900-S11111706622012110400000) ).
  32. Remove exhaust pipe A.
  33. Remove the shift cable (see step 49 on «TRANSMISSION REMOVAL»(ref-512900-S20987505282012110400000) ). Do not bend the shift cable excessively.
  34. Remove the damper fork (see step 4 on «DAMPER/SPRING REMOVAL AND INSTALLATION»(ref-512945-S07438227712012110400000) ).
  35. Separate the knuckles from the lower arms (see step 6 on «KNUCKLE BALL JOINT REPLACEMENT»(ref-512945-S05582414892012110400000) ).
  36. Remove the driveshafts (see «DRIVESHAFT INSPECTION»(ref-512898-S30943184272012110400000) ). Coat all precision-finished surfaces with new engine oil. Tie plastic bags over the driveshaft ends.
  37. Disconnect the power steering fluid hose (A). Turn the end of the hose up to prevent power steering fluid from flowing out, then plug the hose and line.
  38. Disconnect the PSP switch connector (A).
  39. Lower the vehicle on the lift.
  40. Disconnect the heater hoses (A) and the upper radiator hose (B).
  41. Disconnect the quick connector from the thermostat cover (see step 3 on «THERMOSTAT REPLACEMENT»(ref-512899-S22325265382012110400000) ).
  42. Attach the engine hanger adapter (VSB02C000015) to the threaded hole located on the rear side of the cylinder head.
  43. Install the engine support hanger (AAR-T1256) onto the vehicle as shown, and attach the hook to the slotted hole in the engine hanger adapter. Tighten the wing nut (A) by hand, and lift and support the engine/transmission. NOTE: Be careful when working around the windshield. Be careful not to damage the hood opener cable when installing the engine support hanger at the front bulkhead.
  44. Disconnect the vacuum hose (A) and remove the front engine mount stop (B), then remove the front engine mount mounting bolt (C).
  45. Remove the rear engine mount bolt (A).
  46. Raise the vehicle on the lift.
  47. Remove the lower transmission mount nuts.
  48. Disconnect the A/C compressor clutch connector (A), then remove the A/C compressor (B) without disconnecting the A/C hoses. Do not bend the A/C hoses excessively. NOTE: Hang the A/C compressor with a wire tie.
  49. Loosen the front subframe middle rubber mount bolts on both sides.
  50. Attach the subframe adapter (VSB02C000016) to the front subframe by looping the belt (A) over the front of the front subframe (B), then secure the belt with its stop (C).
  51. Raise the transmission jack and line up the slots in the subframe adapter arms with the bolt holes on the transmission jack base, then securely attach them with four bolts.
  52. Remove the front subframe mounting bolts (A), the four 12 x 1.25 mm bolts (B), (C) securing the four stiffeners (D), then lower the front subframe (E). NOTE: Check that the front subframe is free of the hoses and the electrical wiring.
  53. Lower the vehicle on the lift.
  54. Remove the ground cable (A).
  55. Remove the side engine mount bracket (B).
  56. Install the universal lifting eyelet with a 15 mm spacer (A).
  57. Attach a chain hoist (A) to the universal lifting eyelet (B) and the transmission hanger (C), then lift the engine/transmission until it is securely supported by the chain hoist, and remove the engine support hanger and the engine hanger adapter.
  58. Remove the upper transmission mount bracket mounting bolts (A). NOTE: Do not remove the TORX bolt (B) from the upper transmission mount. If the TORX bolt is removed, the upper transmission mount must be replaced as an assembly.
  59. Check that the engine/transmission is completely free of the vacuum hoses, the fuel hoses, the coolant hoses, and the electrical wiring.
  60. Slowly lower the engine/transmission about 150 mm (5.91 in). Check once again that all the hoses and the electrical wiring are disconnected and free from the engine/transmission, then lower it all the way and support it.
  61. Disconnect the chain hoist from the engine/ transmission.
  62. Raise the vehicle, and remove the engine/transmission from under the vehicle.

Engine Installation

Special Tools Required

  1. Universal Lifting Eyelet 07AAK-SNAA120
  2. Engine Hanger Adapter VSB02C000015*
  3. Engine Support Hanger, A and Reds AAR-T1256*
  4. Subframe Adapter VSB02C000016*

*: Available through the Honda Tool and Equipment Program 888-424-6857.

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  1. Install the engine mount brackets and the accessory brackets, and tighten their bolts to the specified torque.
  2. Raise the vehicle on the lift, and position the engine/ transmission under the vehicle. Lower the vehicle, and attach the universal lifting eyelet and the chain hoist (A) to the universal lifting eyelet and the transmission hanger (B), then lift the engine into position in the vehicle. NOTE: Reinstall the mounting bolts/support nuts in the sequence given in the following steps. Failure to follow this sequence may cause excessive noise and vibration, and reduce engine mount life.
  3. Attach the engine hanger adapter (VSB02C000015) to the threaded hole located on the rear side of the cylinder head.
  4. Install the engine support hanger (AAR-T1256) onto the vehicle as shown, and attach the hook to the slotted hole in the engine hanger adapter. Tighten the wing nut (A) by hand, and lift and support the engine/transmission. NOTE: Be careful when working around the windshield. Be careful not to damage the hood opener cable when installing the engine support hanger at the front bulkhead.
  5. Tighten the new upper transmission mount bracket mounting bolts (A) to the specified torque.
  6. Remove the chain hoist.
  7. Remove the universal lifting eyelet.
  8. Install the side engine mount bracket (A), and tighten the new side engine mount bracket mounting bolts (B), then tighten the side engine mount mounting bolt (C).
  9. Install the ground cable (D).
  10. Raise the vehicle on the lift.
  11. Support the front subframe (A) with the subframe adapter (VSB02C000016) and a transmission jack, raise the front subframe up to the body. NOTE: Be careful when connecting these items: Front engine mount and its bracket Lower transmission mount and front subframe Knuckle ball joints and lower arms
  12. Loosely install the new front subframe mounting bolts (four) (B), the 12 x 1.25 mm bolts (two) (C), the new 12 x 1.25 mm bolts (two) (D), and the stiffeners (four) (E).
  13. Align the front subframe with the subframe alignment pin (see «SUBFRAME REPLACEMENT»(ref-512925-S12173063442012110400000) ).
  14. Remove the transmission jack and the subframe adapter.
  15. Discard the subframe middle rubber mount bolts (A), then tighten the new bolts to the specified torque on both sides.
  16. Install the lower transmission mount nuts.
  17. Lower the vehicle on the lift.
  18. Remove the engine support hanger and the engine hanger adapter.
  19. Tighten the new front engine mount mounting bolt (A), then install the front engine mount stop (B) using new nuts (C), and connect the vacuum hose (D).
  20. Tighten the new rear engine mount mounting bolt (A).
  21. Loosen the side engine mount bracket mounting bolts, then retighten the bolts in the numbered sequence shown.
  22. Loosen the upper transmission mount bracket mounting bolts, then retighten them to the specified torque.
  23. Connect the quick connector to the thermostat cover (see step 11 on «THERMOSTAT REPLACEMENT»(ref-512899-S22325265382012110400000) ).
  24. Connect the heater hoses (A) and the upper radiator hose (B).
  25. Raise the vehicle on the lift.
  26. Connect the PSP switch connector (A).
  27. Connect the power steering fluid hose (A), then secure the hose with the clamp (B).
  28. Install the A/C compressor (A), then connect the A/C compressor clutch connector (B).
  29. Install a new set ring on the end of each driveshaft, then install the driveshafts (see «DRIVESHAFT INSTALLATION»(ref-512898-S09868592602012110400000) ). Make sure each ring "clicks" into place in the differential and the intermediate shaft.
  30. Connect the lower arms to the knuckles (see step 5 on «KNUCKLE BALL JOINT REPLACEMENT»(ref-512945-S05582414892012110400000) ).
  31. Install the damper fork (see step 4 on «DAMPER/SPRING REMOVAL AND INSTALLATION»(ref-512945-S07438227712012110400000) ).
  32. Install the shift cable (see «SHIFT CABLE REPLACEMENT»(ref-512900-S20955400822012110400000) ).
  33. Install exhaust pipe A using new gaskets (B) and new self-locking nuts (C).
  34. Install the engine under cover.
  35. Install the front wheels.
  36. Lower the vehicle on the lift.
  37. Install the A/C condenser fan shroud assembly (see «INSTALLATION»(ref-512899-S00299246402012110400000) ).
  38. Align the reference marks (A) on the steering joint and the steering gearbox pinion shaft. Connect the steering joint (B) to the steering gearbox pinion shaft (C). Loosely install the steering joint bolts.
  39. Remove the steering wheel holder tool (see step 41 on «STEERING GEARBOX INSTALLATION»(ref-512901-S07619465832012110400000) ), then tighten the steering joint bolts.
  40. Install the steering joint cover (D).
  41. Install the power steering pump outlet line (A) and the power steering pump inlet line (B) to the power steering pump and install the power steering hose bracket (C).
  42. Install the drive belt (see «DRIVE BELT INSPECTION»(ref-512905-S20602512182012110400000) ).
  43. Connect the fuel feed hose (A), then install the quick-connect fitting cover (B) (see «FUEL LINE/QUICK-CONNECT FITTING INSTALLATION»(ref-512903-S23446338642012110400000) ).
  44. Connect the EVAP canister hose (A) and the brake booster vacuum hose (B).
  45. Connect the PCM connectors (A) and the engine wire harness connector (B).
  46. Install the harness clamps (C) and the bracket (D).
  47. Install the PCM (A), then install the PCM cover (B).
  48. Connect the battery cables (A) to the under-hood fuse/ relay box.
  49. Connect the harness connector (B), and install the harness connector to the bracket (C).
  50. Install the water separator (see step 9 on «INTAKE MANIFOLD REMOVAL AND INSTALLATION»(ref-512902-S18459429352012110400000) ).
  51. Install the battery base (A), then install the harness clamps (B) and the bolts (C).
  52. Install the air cleaner (see «AIR CLEANER ELEMENT INSPECTION/REPLACEMENT»(ref-512902-S06198685672012110400000) ).
  53. Install the intake air duct (see step 7 on «INTAKE MANIFOLD REMOVAL AND INSTALLATION»(ref-512902-S18459429352012110400000) ).
  54. Install the strut brace (see «FRAME BRACE REPLACEMENT»(ref-512925-S32214065992012110400000) ).
  55. Install the front grille cover (see «FRONT GRILLE COVER REPLACEMENT»(ref-512926-S12405382742012110400000) ).
  56. Do the battery installation procedure (see «BATTERY REMOVAL AND INSTALLATION»(ref-512910-S20680339942012110400000) ).
  57. Inspect for fuel leaks. Turn the ignition switch to ON (II) (do not operate the starter) so the fuel pump runs for about 2 seconds and pressurizes the fuel line. Repeat this operation three times, then check for fuel leakage at any point in the fuel line.
  58. Refill the engine with engine oil (see «ENGINE OIL REPLACEMENT»(ref-512894-S16668778722012110400000) ).
  59. Refill the transmission with ATF (see «ATF REPLACEMENT»(ref-512900-S11111706622012110400000) ).
  60. Move the shift lever to each gear, and verify that the A/T gear position indicator follows the transmission range switch.
  61. Refill the reservoir with power steering fluid (see «FLUID CHECK/REPLACEMENT»(ref-512901-S07407711712012110400000) ).
  62. Refill the radiator with engine coolant (see step 5 on «COOLANT REPLACEMENT»(ref-512899-S11043499782012110400000) ).
  63. Do the power steering system bleeding procedure (see step 7 on «FLUID CHECK/REPLACEMENT»(ref-512901-S07407711712012110400000) ).
  64. Do the cooling system bleeding procedure (see «COOLANT CHECK»(ref-512899-S13443221892012110400000) ).
  65. Check for fluid leaks.
  66. Reinstall the driver's side hood support strut bracket (A) with the bolts to proper locations.
  67. Reattach the passenger's side hood support strut on the pivot bolt (see «HOOD SUPPORT STRUT REPLACEMENT»(ref-512924-S02424225322012110400000) ).
  68. Do the PCM reset procedure (see «HDS CLEAR COMMAND»(ref-512892-S25993029972012110400000) ).
  69. Do the CKP pattern clear/CKP pattern learn procedure (see «CKP PATTERN CLEAR/CKP PATTERN LEARN»(ref-512892-S26509502782012110400000) ).
  70. Inspect the idle speed (see «IDLE SPEED INSPECTION»(ref-512915-S34804365062012110400000) ).
  71. Inspect the ignition timing (see «IGNITION TIMING INSPECTION»(ref-512906-S20141892042012110400000) ).
  72. Check the wheel alignment (see «WHEEL ALIGNMENT»(ref-512897-S12374473402012110400000) ).

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  1. Remove the power steering fluid reservoir (A) from the bracket (B).
  2. Lift and support the engine with a jack and a wood block under the oil pan.
  3. Remove the ground cable (A), then remove the upper half of the side engine mount bracket (B).
  4. Remove the side engine mount (A).

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  1. Install the side engine mount (A) using new bolts (B).
  2. Loosely install the upper half of the side engine mount bracket (A) using new side engine mount bracket mounting bolts and the side engine mount mounting bolt.
  3. Install the ground cable (B).
  4. Remove the jack and the wood block.
  5. Tighten the mounting bolts in the numbered sequence shown.
  6. Install the power steering fluid reservoir (A) to the bracket (B).

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Scheme 602: Removal
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  1. Remove the A/C condenser fan shroud assembly, then remove the radiator fan shroud assembly (see «CONNECTING PIPE REPLACEMENT»(ref-512899-S02601032922012110400000) ).
  2. Lift and support the engine with a jack and a wood block under the engine/transmission.
  3. Disconnect the vacuum hose (A) and remove the front engine mount stop (B), then remove the front engine mount mounting bolt (C).
  4. Remove the front engine mount.

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Scheme 604: Installation
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  1. Install the front engine mount (A), using new bolts (B).
  2. Remove the jack and the wood block.
  3. Tighten the new front engine mount mounting bolt (A), then install the front engine mount stop (B) using new nuts (C), and connect the vacuum hose (D).
  4. Install the radiator fan shroud assembly, then install the A/C condenser fan shroud assembly (see «INSTALLATION»(ref-512899-S00299246402012110400000) ).

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Scheme 606: Removal
Scheme 606: Removal
  1. Remove the strut brace (see «FRAME BRACE REPLACEMENT»(ref-512925-S32214065992012110400000) ).
  2. Lift and support the engine with a jack and a wood block under the engine/transmission.
  3. Remove the rear engine mount mounting bolt (A), then remove the mount-to-subframe bolts (B).
  4. Remove the rear engine mount upper bracket (C)

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Scheme 607: Installation
Scheme 607: Installation
  1. Install the rear engine mount upper bracket (A) using new bolt and the bolts. Lift and support the engine/transmission with a jack and a wood block under the engine/transmission, then install the rear engine mount.
  2. Remove the jack and the wood block.
  3. Tighten the new rear engine mount-to-subframe bolts and the new mount mounting bolt in the numbered sequence shown.
  4. Install the strut brace (see «FRAME BRACE REPLACEMENT»(ref-512925-S32214065992012110400000) ).

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Scheme 608: Removal
Scheme 608: Removal
  1. Remove the air cleaner (see «AIR CLEANER ELEMENT INSPECTION/REPLACEMENT»(ref-512902-S06198685672012110400000) ).
  2. Lift and support the engine with a jack and a wood block under the transmission.
  3. Remove the upper transmission mount bracket mounting bolts (A). NOTE: Do not remove the TORX bolt (B) from the upper transmission mount. If the TORX bolt is removed, the upper transmission mount must be replaced as an assembly.
  4. Remove the upper transmission mount mounting bolts (C) and the ground cable (D), then remove the upper transmission mount (E).

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Scheme 609: Installation
Scheme 609: Installation
  1. Install the upper transmission mount (A), then tighten the new upper transmission mount mounting bolts (B).
  2. Loosely install the new upper transmission mount bracket mounting bolts (C).
  3. Install the ground cable (D).
  4. Remove the jack and the wood block.
  5. Tighten the upper transmission mount bracket mounting bolts.
  6. Install the air cleaner (see «AIR CLEANER ELEMENT INSPECTION/REPLACEMENT»(ref-512902-S06198685672012110400000) ).

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Scheme 610: Removal
Scheme 610: Removal
  1. Remove the engine under cover (see step 28 on ).
  2. Support the transmission with a transmission jack.
  3. Remove the lower transmission mount (A).

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Scheme 611: Installation
Scheme 611: Installation
  1. Install the lower transmission mount (A).
  2. Loosely tighten the new lower transmission mount mounting bolts (B).
  3. Remove the transmission jack.
  4. Tighten the lower transmission mount mounting bolts and the lower transmission mount mounting nuts.
  5. Install the engine under cover (see step 34 on ).

More articles — Engine Assembly (4-CYL)