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Home >> Honda >> 2012 >> CR-Z Base, Standard Trans >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Assembly >> Engine Installation

Engine Installation

Special Tools Required 

NOTE: IMA components are located in this area. The IMA is a high-voltage system. You must be familiar with the IMA system before working on or around it. Make sure you have read the IMA service precaution before doing repairs or service (see SERVICE PRECAUTIONS ).
  1. Raise the vehicle on the lift, and position the engine/IMA motor/transmission under the vehicle.

    Be sure that they are properly aligned. Carefully lower the vehicle until the engine/IMA motor/transmission are properly positioned in the engine compartment. Make sure the vehicle is not resting on any part of the engine/IMA motor/transmission. Support the engine/IMA motor/transmission with a chain hoist (A) and carefully raise the engine/IMA motor/transmission into place.

    NOTE:
    • Attach the first universal lifting eyelet (B) to the cam chain case (see step  59 ).
    • Reinstall the mounting bolts and 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.
    • Wrap the VSA modulator-control unit with the clean shop towel.
      Fig 1: Attaching First Universal Lifting Eyelet To Cam Chain Case
      G06949278Courtesy of AMERICAN HONDA MOTOR CO., INC.
  2. Install the side engine mount/bracket assembly (A), then tighten the new side engine mount/bracket assembly mounting bolts (B).
    NOTE: Refer to the installation of the side engine mount bracket if you take the side engine mount and the side engine mount bracket apart (see SIDE ENGINE MOUNT REPLACEMENT  ).
    Fig 2: Locating Side Engine Mount/Bracket Assembly And Side Engine Mount/Bracket Assembly Mounting Bolts With Torque Specifications
    G06949279Courtesy of AMERICAN HONDA MOTOR CO., INC.
  3. Loosely install the new side engine mount/bracket assembly mounting nuts (C).
  4. Install the ground cable (D).
  5. Install the transmission mount bracket (A), and loosely install the new transmission mount bracket mounting bolts (B) and nuts (C).
    Fig 3: Locating Transmission Mount Bracket, Transmission Mount Bracket Mounting Bolts And Nuts (M/T Model) With Torque Specifications
    G06949280Courtesy of AMERICAN HONDA MOTOR CO., INC.
    Fig 4: Locating Transmission Mount Bracket, Transmission Mount Bracket Mounting Bolts And Nuts (CVT Model) With Torque Specifications
    G06949281Courtesy of AMERICAN HONDA MOTOR CO., INC.
  6. Install the harness holder (D) and the ground cable (E).
  7. Attach the second universal lifting eyelet (A) to the cylinder head with a spacer (B) and an 8 x 1, 25 mm bolt (C).
    NOTE: Select a spacer that is long enough that the universal lifting eyelet does not interfere with the fuel feed tube (D).
    Fig 5: Locating Second Universal Lifting Eyelet, Spacer And 8 x 1, 25 mm Bolt
    G06949282Courtesy of AMERICAN HONDA MOTOR CO., INC.
  8. Install the engine hanger adapter (V5B02C000026) to the engine support hanger (AAR-T1256), then install the engine support hanger onto the vehicle, and attach the hook (A) to the second universal lifting eyelet (B), Tighten the wing nut (C) by hand, and lift and support the engine/IMA motor/transmission.
    NOTE: Be careful when working around the windshield.
    Fig 6: Attaching Hook To Second Universal Lifting Eyelet
    G06949283Courtesy of AMERICAN HONDA MOTOR CO., INC.
  9. Remove the chain hoist from the engine/IMA motor/transmission, then remove the first universal lifting eyelet from the cam chain case.
  10. Raise the vehicle on the lift.
  11. Support the front subframe with a transmission jack.
  12. Install the front subframe, then loosely install the new front subframe mounting bolts.
    NOTE:
    • Be sure that the pinion shaft grommet is in place securely. Make sure the pinion shaft grommet is not turned up. Incorrect installation can cause leakage of water or mud, and noise.
    • Take care not to damage the lower arm ball joint boot with the edge of the knuckle, etc.
      Fig 7: Supporting Front Subframe With Transmission Jack
      G06949284Courtesy of AMERICAN HONDA MOTOR CO., INC.
  13. Align the front subframe (see SUBFRAME REPLACEMENT ), then torque the subframe mounting bolts to specification.
  14. Remove the transmission jack from under the subframe.
  15. Support the transmission with a transmission jack and wood block under the transmission.
  16. Install the torque rod (A). Install the bolt with the tab (B) on the bolt head aligned with the guide (C) on the front subframe, then loosely install the new torque rod mounting bolt and nut (D).
    NOTE: Be sure to install the torque rod with the "UP" mark facing up.
    Fig 8: Locating Torque Rod, Tab On Bolt Head And Guide On Front Subframe (M/T Model)
    G06949285Courtesy of AMERICAN HONDA MOTOR CO., INC.
    Fig 9: Locating Torque Rod, Tab On Bolt Head And Guide On Front Subframe (CVT Model)
    G06949286Courtesy of AMERICAN HONDA MOTOR CO., INC.
  17. Remove the transmission jack and wood block from under the transmission.
  18. Lower the vehicle on the lift.
  19. Remove the engine support hanger and the second universal lifting eyelet.
  20. Tighten the side engine mount/bracket assembly mounting nuts.
    Fig 10: Side Engine Mount/Bracket Assembly Mounting Nuts Tightening Torque With Torque Specifications
    G06949287Courtesy of AMERICAN HONDA MOTOR CO., INC.
  21. Tighten the transmission mount mounting bolts and nuts in the numbered sequence shown.
    Fig 11: Transmission Mount Mounting Bolts And Nuts Tightening Sequence (M/T Model) With Torque Specifications
    G06949288Courtesy of AMERICAN HONDA MOTOR CO., INC.
    Fig 12: Transmission Mount Mounting Bolts And Nuts Tightening Sequence (CVT Model) With Torque Specifications
    G06949289Courtesy of AMERICAN HONDA MOTOR CO., INC.
  22. Raise the vehicle on the lift.
  23. Tighten the torque rod mounting bolt and nut in the numbered sequence shown.
    Fig 13: Rod Mounting Bolt And Nut Tightening Sequence (M/T Model) With Torque Specifications
    G06949290Courtesy of AMERICAN HONDA MOTOR CO., INC.
    Fig 14: Rod Mounting Bolt And Nut Tightening Sequence (CVT Model) With Torque Specifications
    G06949291Courtesy of AMERICAN HONDA MOTOR CO., INC.
  24. Install the A/C compressor.
    Fig 15: Identifying A/C Compressor Bolts Tightening Torques
    G06949292Courtesy of AMERICAN HONDA MOTOR CO., INC.
  25. Install the driveshafts (see DRIVESHAFT INSTALLATION ).
  26. Wipe off any grease contamination from the tapered section and threads of the ball joint. Connect the lower arm to the knuckle. Install a new castle nut, and tighten it to the specified torque on both sides (see STEP 18
  27. Install the lock pin on both side (see STEP 19
  28. Wipe off any grease contamination from the tapered section and threads of the tie-rod end ball joint. Connect the tie-rod end to the knuckles. Install the nut, and tighten it to the specified torque on both sides (see STEP 20
  29. Install a new cotter pin, and bend it as shown on both sides (see STEP 21
  30. Install the stabilizer links to the stabilizer (see STABILIZER LINK REMOVAL/INSTALLATION ).
  31. Install the under-floor TWC (A) and the harness clamp (B).
    NOTE: Use new gaskets (C) and new self-locking nuts (D).
    Fig 16: Locating Under-Floor TWC, Harness Clamp, Gaskets And Self-Locking Nuts With Torque Specifications
    G06949293Courtesy of AMERICAN HONDA MOTOR CO., INC.
  32. Install the splash shield (see SPLASH SHIELD REPLACEMENT ).
  33. Install the front wheels.
  34. Lower the vehicle on the lift.
  35. Install the heater hoses (A).
    Fig 17: Locating Heater Hoses
    G06949294Courtesy of AMERICAN HONDA MOTOR CO., INC.
  36. Connect the IMA motor power cable connector (A) and the harness clamp (B).
    NOTE: Make sure you have read the IMA system service precautions (see SERVICE PRECAUTIONS ).
    Fig 18: Locating IMA Motor Power Cable Connector And Harness Clamp
    G06949295Courtesy of AMERICAN HONDA MOTOR CO., INC.
  37. Connect the EPS connectors (A).
    Fig 19: Locating EPS Connectors
    G06949296Courtesy of AMERICAN HONDA MOTOR CO., INC.
  38. Install the radiator (see RADIATOR REPLACEMENT ).
  39. Install the drive belt (see DRIVE BELT REPLACEMENT ).
  40. M/T model: Connect the reverse lockout solenoid 2P connector (see step 38 on TRANSMISSION INSTALLATION ).
  41. M/T model: Install the shift cables (see step 39 on TRANSMISSION INSTALLATION ).
    NOTE: Make sure not to get any silicone grease on the terminal part of the connectors and switches, especially if you have silicone grease on your hands or gloves.
  42. M/T model: Install the slave cylinder. Be careful not to bend the clutch line (see step 40 on TRANSMISSION INSTALLATION ).
  43. M/T model: Install the cable guard bracket and the clutch line bracket (see step 41 on TRANSMISSION INSTALLATION ).
  44. CVT model: Secure the shift cable holder on the transmission with the bolts (see step 36 on TRANSMISSION INSTALLATION ).
  45. CVT model: Install the clamp bracket (see step 37 on TRANSMISSION INSTALLATION ).
  46. CVT model: Attach the shift cable end to the selector control lever, then insert the control pin (see step 38 on TRANSMISSION INSTALLATION ).
  47. CVT model: Insert the lock pin into the control pin (see step 39 on TRANSMISSION INSTALLATION ).
  48. Connect the steering joint onto the steering gearbox pinion shaft, then install the steering joint cover (see STEERING GEARBOX REMOVAL AND INSTALLATION ), then remove the steering wheel holder tool.
  49. Connect the secondary HO2S connector (A), then install the secondary HO2S harness to the clamps (B).
    Fig 20: Locating Secondary HO2S Connector And Secondary HO2S Harness Clamps
    G06949297Courtesy of AMERICAN HONDA MOTOR CO., INC.
  50. Connect the fuel feed hose (A) (see FUEL LINE/QUICK-CONNECT FITTING INSTALLATION ), then install the quick-connect fitting cover (B) and the fuel feed hose clamp bracket (C).
    Fig 21: Locating Fuel Feed Hose, Quick-Connect Fitting Cover And Fuel Feed Hose Clamp Bracket With Torque Specifications
    G06949298Courtesy of AMERICAN HONDA MOTOR CO., INC.
  51. Install the EVAP canister hose (A) and the brake booster vacuum hose (B).
    Fig 22: Locating EVAP Canister Hose And Brake Booster Vacuum Hose
    G06949299Courtesy of AMERICAN HONDA MOTOR CO., INC.
  52. Connect the engine compartment wire harness connectors (A), then install the harness clamp (B).
    Fig 23: Locating Engine Compartment Wire Harness Connectors And Harness Clamp
    G06949300Courtesy of AMERICAN HONDA MOTOR CO., INC.
  53. Install the harness holder (C).
  54. Install the ECM/PCM with the bracket, then connect ECM/PCM connectors A, B, and C.
    NOTE: ECM/PCM connectors A, B, and C have symbols (A=□, B= , C=◦) embossed on them for identification.
    Fig 24: Locating ECM/PCM Connectors A, B, And C With Torque Specifications
    G06949301Courtesy of AMERICAN HONDA MOTOR CO., INC.
  55. Install the harness clamps (D) and auxiliary under-hood relay box A (E).
  56. CVT model: Install the harness clamp (F).
  57. Install the starter cable (A) and the harness clamp (B).
    Fig 25: Locating Starter Cable And Harness Clamp (M/T Model) With Torque Specifications
    G06949302Courtesy of AMERICAN HONDA MOTOR CO., INC.
    Fig 26: Locating Starter Cable And Harness Clamp (CVT Model) With Torque Specifications
    G06949303Courtesy of AMERICAN HONDA MOTOR CO., INC.
  58. Install the air cleaner (see AIR CLEANER ELEMENT INSPECTION/REPLACEMENT ).
  59. Install the front bumper center upper beam (see FRONT BUMPER CENTER UPPER BEAM REPLACEMENT ).
  60. Install the cowl cover and the under-cowl panel (see COWL COVER REPLACEMENT ).
  61. Do the 12 volt battery installation procedure (see 12 VOLT BATTERY REMOVAL AND INSTALLATION ).
  62. Turn the battery module switch ON (see DISCONNECTING THE IMA MOTOR POWER CABLE CONNECTOR FROM THE MOTOR STATOR ).
  63. 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.
  64. Refill the engine with engine oil (see ENGINE OIL REPLACEMENT ).
  65. Refill the transmission fluid.
  66. M/T model: Check that the transmission shifts into all gears smoothly.
  67. CVT model: Move the shift lever to each gear, and verify that the CVT gear position indicator follows the transmission range switch.
  68. Refill the radiator with engine coolant, and bleed air from the cooling system (see COOLANT REPLACEMENT ).
  69. Do the ECM/PCM reset procedure (see IF THE MIL DID NOT STAY ON ).
  70. Do the CKP pattern clear/CKP pattern learn procedure (see CKP PATTERN CLEAR/CKP PATTERN LEARN ).
  71. Do the IMA motor rotor position calibration procedure (see IMA MOTOR ROTOR POSITION CALIBRATION ).
  72. Inspect the idle speed (see IDLE SPEED INSPECTION ).
  73. Inspect the ignition timing (see IGNITION TIMING INSPECTION ).
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