Honda Jazz/Fit 2004 · Service Manual

Engine Installation (With ETCS)

Engine Installation

1.	Position the engine under the vehicle. Attach the chain hoist to the engine, then lift the engine into position in the vehicle. 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.

2.	Install the front subframe (A), then secure the under covers with the clips (B). BBA14 x 1.5 mm 93 N·m (9.5 kgf·m, 69 lbf·ft) Replace.

3.	Install the left front mount/bracket assembly. 10 x 1.25 mm 44 N·m (4.5 kgf·m, 32 lbf·ft)10 x 1.25 mm 39 N·m (4.0 kgf·m, 29 lbf·ft)

4.	Install the rear mount mounting bolts. 10 x 1.25 mm 59 N·m (6.0 kgf·m, 43 lbf·ft)10 x 1.25 mm 58 N·m (5.9 kgf·m, 43 lbf·ft)

5.	Lower the hoist.

6.	Install the side engine mount/bracknt assembly (A), then tighten the mounting bolts and support nuts in the numbered sequence shown. A6 x 1.0 mm 9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)B10 x 1.25 mm 59 N·m (6.0 kgf·m, 43 lbf·ft)(1)10 x 1.25 mm 54 N·m (5.5 kgf·m, 40 lbf·ft)(2)

7.	Install the ground cable (B).

8.	Install the transmission mount bracket (A), then tighten the support bolt/nuts and mounting bolt in the numbered sequence shown. AB10 x 1.25 mm 49 N·m (5.0 kgf·m, 36 lbf·ft)10 x 1.25 mm 44 N·m (4.5 kgf·m, 33 lbf·ft)(2)(1)6 x 1.0 mm 9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)

9.	Install the ground cable (B).

10.	Remove the chain hoist from the engine.

11.	Raise the hoist to full height.

12.	Install the steering gearbox on the front subframe.

13.	Install a new set ring on the end of each driveshaft, then install the driveshafts. Make sure each ring ‘‘clicks'' into place in the differential and intermediate shaft.

14.	Connect the suspension lower arm ball joints.

15.	Connect the stabilizer links.

16.	Install the three way catalytic converter (TWC) (A); use new gaskets (B) and new self locking nuts (C). DAEC 10 x 1.25 mm 31 N·m (3.2 kgf·m, 23 lbf·ft)8 x 1.25 mm 22 N·m (2.2 kgf·m, 16 lbf·ft)BB

17.	Connect the primary heated oxygen sensor (primary HO2S) connector (D).

18.	Connect the secondary heated oxygen sensor (secondary HO2S) connector (E).

19.	If the A/C compressor is equipped, install the condenser fan shroud.

20.	Install the A/C compressor (A), then connect the compressor clutch connector (B). BA8 x 1.25 mm 24 N·m (2.4 kgf·m, 17 lbf·ft)

21.	Install the splash shield.

22.	Lower the hoist.

23.	Install the upper radiator hose (A) and lower radiator hose (B). AB

24.	Install the heater hoses.

25.	Install the select cable (A) and shift cable (B) using the plastic washers (C), washers (D), and new cotter pins (E). EB8 x 1.25 mm 27 N·m (2.8 kgf·m, 20 lbf·ft)EDCCDA

26.	Install the clutch slave cylinder (A) and clutch line bracket mounting bolt (B). A8 x 1.25 mm 22 N·m (2.2 kgf·m, 16 lbf·ft)B 6 x 1.0 mm 9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)

27.	Install the evaporative emission (EVAP) canister hose (A) and brake booster vacuum hose (B). AB

28.	Install the battery cables (A) on the under-hood fuse/relay box, then install the harness clamp(s) (B). LHD models: CBA RHD models: ABC

29.	Connect the wire harness connector (C).

30.	Push the engine control module (ECM) connectors through the bulkhead, then install the grommet (A). LHD models: BCBA RHD models: BACB

31.	Install the harness clamps (B).

32.	Connect the accelerator pedal position (APP) sensor connector (C).

33.	Connect the ECM connectors (A) and main wire harness connector (B). LHD models: BA RHD models: AB

34.	Install the battery base (A), then install the harness clamps (B). AB8 x 1.25 mm 22 N·m (2.2 kgf·m, 16 lbf·ft)

35.	Install air cleaner housing.

36.	Install the battery.

37.	Install the fuel feed hose.

38.	Install the drive belt and adjust it, refer to the 2002 Jazz/Fit Shop Manual.

39.	Clean the battery posts and cable terminals with sandpaper, then assemble them and apply grease to prevent corrosion.

40.	Check that the transmission shifts into gear smoothly.

41.	Inspect for fuel leaks. Turn the ignition switch ON (II) (do not operate the starter) so that 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.

42.	Refill the engine with engine oil, refer to the 2002 Jazz/Fit Shop Manual.

43.	Refill the transmission with fluid.

44.	Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open, refer to the 2002 Jazz/Fit Shop Manual.

45.	Perform the ETCS learn procedure.

46.	Inspect the idle speed.

47.	Inspect the ignition timing.

48.	Check the wheel alignment.