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Home >> Honda >> 2004 >> Element DX, 2.4 YH1, Standard >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine >> Engine Installation

Engine Installation

Special Tools Required 

These special tools are available through the Honda Tool and Equipment Program, 1-888-424-6857.

  1. Install the accessory brackets, and tighten their bolts to the specified torques.
    Fig 1: Installing Accessory Brackets And Torque Specifications
    G03677093Courtesy of AMERICAN HONDA MOTOR CO., INC.
  2. Position the engine/transmission under the vehicle. Attach the engine support hanger to the engine, then lift the engine into position in the vehicle.
    NOTE: Reinstall the mounting bolts/support nuts in the sequence given. Failure to follow this sequence may cause excessive noise and vibration, and reduce bushing life.
  3. Tighten the upper engine mount bracket bolt and nut.
    Fig 2: Tightening Upper Engine Mount Bracket Bolt And Nut With Specified Torques
    G03677094Courtesy of AMERICAN HONDA MOTOR CO., INC.
  4. Install the A/C compressor.
    Fig 3: Installing A/C Compressor And Torque Specifications
    G03677095Courtesy of AMERICAN HONDA MOTOR CO., INC.
  5. Attach the special tool to the subframe by hanging the belt (A) over the front of the subframe (B), then secure the belt with its stop (C). Raise the subframe up to the body with a jack.
    Fig 4: Attaching Special Tool To Subframe
    G03677096Courtesy of AMERICAN HONDA MOTOR CO., INC.
  6. Loosely install the new subframe mounting bolts. Remove the special tool.
  7. Align the reference marks (A) with the center of the subframe mounting bolts (B), then tighten the bolts to the specified torque.
    Fig 5: Aligning Reference Marks And Torque Specifications
    G03677097Courtesy of AMERICAN HONDA MOTOR CO., INC.
  8. Loosely install the new front mount mounting bolt.
    Fig 6: Installing Front Mount Mounting Bolt
    G03677098Courtesy of AMERICAN HONDA MOTOR CO., INC.
  9. Tighten the rear mount mounting bolts.
    Fig 7: Tightening Rear Mount Mounting Bolts And Torque Specifications
    G03677099Courtesy of AMERICAN HONDA MOTOR CO., INC.
  10. Lower the vehicle on the hoist.
  11. M/T model: Tighten the transmission mount bracket support bolt and nuts.
    Fig 8: Tightening Transmission Mount Bracket Support Bolt And Nuts (M/T Model) With Specified Torques
    G03677100Courtesy of AMERICAN HONDA MOTOR CO., INC.
  12. A/T model: Support the transmission with a jack and wood block.
  13. Remove the engine support hanger.
  14. A/T model: Loosen the transmission mount bracket support bolt and nuts (A).
    Fig 9: Loosening Transmission Mount Bracket Support Bolt And Nuts (A/T Model)
    G03677101Courtesy of AMERICAN HONDA MOTOR CO., INC.
  15. A/T model: Install the transmission mount and all bolts and nuts, then tighten the bolts and nuts in the numbered sequence shown.
    Fig 10: Installing Transmission Mount And Bolts And Nuts (A/T Model) With Specified Torques
    G03677102Courtesy of AMERICAN HONDA MOTOR CO., INC.
  16. A/T model: Remove the jack and wood block.
  17. Raise the vehicle on the hoist to full height.
  18. Tighten the front mount mounting bolt.
    Fig 11: Tightening Front Mount Mounting Bolt And Torque Specifications
    G03677103Courtesy of AMERICAN HONDA MOTOR CO., INC.
  19. 4WD model: Install the propeller shaft on the transfer assembly:
  20. A/T model: Install the shift cable:
  21. Install a new set ring on the end of the left driveshaft and the intermediate shaft then install the driveshafts. Make sure the ring "clicks" into place on the differential and the right driveshaft.
  22. Connect the suspension lower arm ball joints (see LOWER ARM REPLACEMENT ).
  23. Connect the stabilizer links (see STABILIZER LINK REMOVAL/INSTALLATION ).
  24. Install the three way catalytic converter (TWC) assembly (A) using new gaskets (B).
    Fig 12: Installing Three Way Catalytic Converter Assembly Using New Gaskets And Torque Specifications
    G03677104Courtesy of AMERICAN HONDA MOTOR CO., INC.
  25. Connect the air fuel ratio (A/F) sensor connector (C) and the secondary heated oxygen sensor (secondary HO2S) connector (D).
  26. Install the splash shield.
    Fig 13: Installing Splash Shield
    G03677105Courtesy of AMERICAN HONDA MOTOR CO., INC.
  27. Install the front wheels.
  28. Lower the vehicle on the hoist.
  29. A/T model: Tighten the bolt securing the power steering (P/S) line.
    Fig 14: Tightening Bolt Securing Power Steering Line (A/T Model) And Torque Specifications
    G03677106Courtesy of AMERICAN HONDA MOTOR CO., INC.
  30. Check the quick connector (A) and set ring (B) for cracks or damage. If the connector and/or set ring are cracked or damaged, replace the connector.
    Fig 15: Checking Quick Connector And Set Ring
    G03677107Courtesy of AMERICAN HONDA MOTOR CO., INC.
  31. Make sure the set ring is in place inside the quick connector. If the set ring is off the connector, replace the quick connector.
  32. Replace the O-ring (C) in the quick connector.
  33. Check the lock (D) for damage or deformation. If the lock is damaged or deformed, replace it. When installing the new lock to the connector, push it straight down along the groove.
  34. Clean the connecting surface of the thermostat cover (E), then apply clean engine coolant around the connecting surface.
  35. Push the lock (A) down, then push the quick connector (B) onto the thermostat cover until you hear it click.
    Fig 16: Pushing Lock Down Onto Thermostat Cover
    G03677108Courtesy of AMERICAN HONDA MOTOR CO., INC.
  36. Install the upper radiator hose (A) and heater hoses (B).
    Fig 17: Installing Upper Radiator Hose And Heater Hoses
    G03677109Courtesy of AMERICAN HONDA MOTOR CO., INC.
  37. A/T model: Install the automatic transmission fluid (ATF) cooler hoses (A) and ATF filter mounting bolt (B).
    Fig 18: Installing Automatic Transmission Fluid Cooler Hoses And ATF Filter Mounting Bolt (A/T Model) With Specified Torques
    G03677110Courtesy of AMERICAN HONDA MOTOR CO., INC.
  38. Install the P/S pump.
    Fig 19: Installing Power Steering Pump And Torque Specifications
    G03677111Courtesy of AMERICAN HONDA MOTOR CO., INC.
  39. Install the drive belt (see DRIVE BELT INSPECTION ).
  40. M/T model: Install the shift cables (see step 22 on TRANSMISSION INSTALLATION ).
  41. M/T model: Install the clutch slave cylinder and clutch line bracket mounting bolt (see step 21 on TRANSMISSION INSTALLATION ).
  42. Push the engine control module (ECM)/powertrain control module (PCM) connector through the bulkhead, then install the grommet (A).
    Fig 20: Installing Grommet
    G03677112Courtesy of AMERICAN HONDA MOTOR CO., INC.
  43. Install the harness clamps (B).
  44. Connect the ECM/PCM connectors (A) and ECM/PCM wire harness connector (B).
    Fig 21: Connecting ECM/PCM Connectors And Wire Harness Connector
    G03677113Courtesy of AMERICAN HONDA MOTOR CO., INC.
  45. Install the evaporative emission (EVAP) canister hose (A) and brake booster vacuum hose (B).
    Fig 22: Installing Evaporative Emission Canister Hose And Brake Booster Vacuum Hose
    G03677114Courtesy of AMERICAN HONDA MOTOR CO., INC.
  46. Connect the fuel feed hose (see FUEL LINE/QUICK-CONNECT FITTING INSTALLATION ), then install the quick-connect fitting cover (A).
    Fig 23: Connecting Fuel Feed Hose And Installing Quick-Connect Fitting Cover
    G03677115Courtesy of AMERICAN HONDA MOTOR CO., INC.
  47. Install the battery cables (A) and harness clamp (B) to the under-hood fuse/relay box.
    Fig 24: Installing Battery Cables And Harness Clamp To Under-Hood Fuse/Relay Box With Specified Torques
    G03677116Courtesy of AMERICAN HONDA MOTOR CO., INC.
  48. Install the ground cable (C).
  49. Install the throttle cable (see THROTTLE CABLE REMOVAL/INSTALLATION ), then adjust it (see RESONATOR REMOVAL/INSTALLATION ).
  50. Install the cruise control actuator cable (see CRUISE CONTROL ACTUATOR/CABLE REPLACEMENT ), then adjust it (see CRUISE CONTROL ACTUATOR CABLE ADJUSTMENT ).
  51. Install the battery base (A), then install the harness clamps (B).
    Fig 25: Installing Battery Base And Install Harness Clamps And Specified Torques
    G03677117Courtesy of AMERICAN HONDA MOTOR CO., INC.
  52. Install the air cleaner housing (see AIR CLEANER REMOVAL/INSTALLATION ).
  53. Install the air intake duct (A), then connect the intake air temperature (IAT) sensor connector (B), and install the vacuum hose (C) and breather pipe (D).
    Fig 26: Installing Air Intake Duct, Vacuum Hose And Breather Pipe
    G03677118Courtesy of AMERICAN HONDA MOTOR CO., INC.
  54. Install the battery. Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion.
  55. A/T model: Move the shift lever to each gear, and verify that the A/T gear position indicator follows the transmission range switch.
  56. M/T model: Check that the transmission shifts into gear smoothly.
  57. Inspect for fuel leaks. Turn the ignition switch ON (II) (do not operate the starter) so the fuel pump runs for about 2 seconds and pressurizes the fuel line. Repeat this operation two or 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 ).
  59. Refill the transmission with fluid:
  60. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open (see step 7 on COOLANT REPLACEMENT ).
  61. Do the ECM/PCM reset procedure (see ECM/PCM RESET ).
  62. Do the ECM/PCM idle learn procedure (see ECM/PCM IDLE LEARN PROCEDURE ).
  63. Do the crankshaft position (CKP) pattern clear/CKP pattern learn procedure (see CRANK (CKP) PATTERN CLEAR/CRANK (CKP) PATTERN LEARN ).
  64. Inspect the idle speed (see IDLE SPEED INSPECTION ).
  65. Inspect the ignition timing (see IGNITION TIMING INSPECTION ).
  66. Enter the anti-theft codes for the radio, then enter the customer's audio presets.
  67. Do the power window control unit reset procedure (see RESETTING THE POWER WINDOW CONTROL UNIT ).
  68. Set the clock.
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