2004 Honda ELEMENT. Submodel: Engine Type: L4 Liters: 2.4 Fuel Delivery: FI Fuel: GAS. Engine Installation. Special Tools Required
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1 2004 Honda ELEMENT Submodel: Engine Type: L4 Liters: 2.4 Fuel Delivery: FI Fuel: GAS Engine Installation Special Tools Required Engine hanger/adapter VSB02C Engine support hanger, A & Reds AAR-T Subframe adapter VSB02C These special tools are available through the Honda Tool and Equipment Program, Install the accessory brackets, and tighten their bolts to the specified torques. 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. Install the A/C compressor. 4. Attach the special tool to the subframe by hanging the belt (A) over the front of the subfame (B), then secure the belt with its stop (C). Raise the subframe up to the body with a jack. 5. Loosely install the new subframe mounting bolts. Remove the special tool.
2 6. Align the reference marks (A) with the center of the subframe mounting bolts (B), then tighten the bolts to the specified torque. 7. Loosely install the new front mount mounting bolt. 8. Tighten the rear mount mounting bolts. 9. Lower the vehicle on the hoist.
3 10. Tighten the upper engine mount bracket bolt and nut. 11. M/T model: Tighten the transmission mount bracket support bolt and nuts. 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).
4 15. A/T model: Install the transmission mount and all bolts and nuts, then tighten the bolts and nuts in the numbered sequence shown. 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 WD model: Install the propeller shaft on the transfer assembly: Manual transmission Automatic transmission 20. A/T model: Install the shift cable: 2WD 4WD 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. 23. Connect the stabilizer links.
5 24. Install the three way catalytic converter (TWC) assembly (A) using new gaskets (B). 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. 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.
6 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. 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. 36. Install the upper radiator hose (A) and heater hoses (B).
7 37. A/T model: Install the automatic transmission fluid (ATF) cooler hoses (A) and ATF filter mounting bolt (B). 38. Install the P/S pump. 39. Install the drive belt. 40. M/T model: Install the shift cables. 41. M/T model: Install the clutch slave cylinder and clutch line bracket mounting bolt. 42. Push the engine control module (ECM)/powertrain control module (PCM) connecter through the bulkhead, then install the grommet (A).
8 43. Install the harness clamps (B). 44. Connect the ECM/PCM connectors (A) and ECM/PCM wire harness connector (B). 45. Install the evaporative emission (EVAP) canister hose (A) and brake booster vacuum hose (B). 46. Connect the fuel feed hose, then install the quick-connect fitting cover (A).
9 47. Install the battery cables (A) and harness clamp (B) to the under-hood fuse/relay box. 48. Install the ground cable (C). 49. Install the throttle cable, then adjust it. 50. Install the cruise control actuator cable, then adjust it. 51. Install the battery base (A), then install the harness clamps (B). 52. Install the air cleaner housing. 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).
10 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. 59. Refill the transmission with fluid: Manual transmission Automatic transmission 60. Refill the radiator with engine coolant, and bleed air from the cooling system with the heater valve open. 61. Do the ECM/PCM reset procedure. 62. Do the ECM/PCM idle learn procedure. 63. Do the crankshaft position (CKP) pattern clear/ckp pattern learn procedure. 64. Inspect the idle speed. 65. Inspect the ignition timing. 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. 68. Set the clock.
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