Engine Assembly Removal and Installation
Engine Assembly Removal and InstallationRemoval
1) Relieve fuel pressure.
2) Disconnect negative (-) and positive (+) cables at battery.
3) Disconnect ECM connectors.
4) Remove ECM, battery, battery tray and battery bracket.
5) Remove right and left side engine under covers.
6) Remove right and left side front fender lower linings.
7) Remove front bumper and front bumper lower cover.
8) Remove engine cover.
9) Drain coolant.
10) Drain the following oils and fluid if necessary.
^ Engine oil:
^ Manual transaxle oil (M/T model):
^ CVT fluid (CVT model):
^ Transfer oil (4WD model):
11) Disconnect the following electric wires, connectors and clamp:
^ Connector (1) in main fuse box
^ Connector (2) in fuse box No.1
^ Connector (3) in fuse box No.2
^ Engine harness connector to main harness connector (4) (CVT model)
^ Battery ground cable (5)
^ Engine harness clamp (6)
^ Front height sensor connector (7)
12) Disconnect the following hoses:
^ Brake booster hose (1)
^ Heater inlet and outlet hoses (2)
^ Fuel hose (3)
^ EVAP canister purge hose (4)
^ Radiator inlet hose (5)
^ CVT Fluid Cooler No.1 Hose (6) (CVT model)
^ CVT Fluid Cooler No.2 Hose (7) (CVT model)
13) Remove radiator outlet hose, thermostat cap and thermostat.
14) Remove battery ground terminal bolt (1) after disconnecting the following cables:
^ Gear select control cable (2) (M/T model):
^ Gear shift control cable (3) (M/T model):
^ Battery ground terminal bolt (M/T model):
^ Select cable (4) (CVT model):
15) Remove accessory drive belt.
16) With A/C hoses connected, remove A/C compressor from bracket.
CAUTION:
Secure the A/C compressor to the body with a rope or the like so that it does not get damaged during removal and installation of engine assembly.
17) Remove front brake caliper and brake pads.
18) Remove front wheel speed sensor harness clamp bolt, and then detach front speed sensor harness from strut bracket.
19) Remove front strut nuts and bolts referring to steps 1) to 5) in "removal" under Front Strut Assembly Removal and Installation.
20) Remove floor tunnel front brace (1).
21) Remove exhaust pipe No.1 and heat protector panel No.1.
22) For 4WD model, remove propeller shaft assembly.
23) Remove steering lower shaft referring to steps 4) to 7) in "removal" under Steering Column Removal and Installation.
24) Remove EPS controller cover after turning over passenger side carpet, disconnect EPS controller connector (1) and remove ground bolt (2). Then, pull the harness (3) out to engine compartment.
25) Disconnect ground cable (1) from suspension frame rear mounting bracket and body.
26) Support suspension frame (1) and engine assembly (2) using engine lifter.
27) Remove suspension frame mounting brackets.
28) Remove engine left mounting bracket (1).
29) Remove engine right mounting bracket nuts (1), then loosen engine right mounting bolts (2).
30) Before lowering engine, make sure that all hoses, electric wires and cables are disconnected from engine.
31) Lower engine assembly with transaxle, transfer (4WD model), front drive shafts and suspension frame all together.
NOTE:
^ When removing engine assembly, CVT assembly, transfer (4WD model), front drive shafts or suspension frame from vehicle, maintain clearance with A/C compressor.
^ Prior to removing engine rear mounting bracket No.1 on 4WD model, it is necessary to remove transfer and disconnect engine rear mounting bracket No.2.
32) Remove front drive shaft assembly if necessary.
33) For 4WD model, remove transfer if necessary.
34) Remove engine mounting bracket from engine assembly if necessary.
35) Remove transaxle if necessary.
^ M/T model:
^ CVT model:
36) For M/T model, remove clutch cover and clutch disc if necessary.
37) For M/T model, remove flywheel if necessary.
For CVT model, remove drive plate if necessary.
38) Remove engine harness from engine assembly if necessary.
Installation
1) Install engine harness to engine assembly if removed.
2) For M/T model, install flywheel if removed.
3) For CVT model, install drive plate if removed.
4) For M/T model, install clutch cover and clutch disc if removed.
5) Install transaxle to engine if removed.
^ For M/T model:
^ For CVT model:
6) Install engine mounting bracket to engine assembly if removed.
7) For 4WD model, install transfer if removed.
8) Install front drive shaft assembly if removed.
9) Lift up engine assembly together with transaxle, transfer (4WD model), front drive shafts and suspension frame into engine compartment using engine lifter.
NOTE:
When removing engine chassis, CVT chassis, transfer (4WD model), front drive shafts or suspension frame from vehicle, maintain clearance with A/C compressor.
10) Tighten engine right mounting bracket bolts and nuts to specified torque.
11) Install left mounting bracket, then tighten left mounting bracket bolts and nuts to specified torque.
12) Install suspension frame mounting brackets, then tighten suspension frame mounting bracket bolts to specified torque.
13) Connect ground cable to suspension frame mounting bracket and body, then tighten ground cable bolts (1) to specified torque.
Tightening torque
Ground cable bolt (a): 9.0 Nm (0.92 kg-m, 7.0 lbf-ft)
14) Insert EPS harness (3) into cabin, connect EPS controller connector (1), tighten ground bolt (2) to specified torque, and then install EPS controller cover.
Tightening torque
EPS controller ground bolt (a): 9.0 Nm (0.92 kg-m, 7.0 lbf-ft)
15) Connect steering lower shaft to pinion shaft, then tighten lower joint bolt to specified torque.
16) For 4WD model, install propeller shaft assembly.
17) Install exhaust pipe No.1 and heat protector panel No.1.
18) Install floor tunnel front brace (1).
19) Tighten front strut bolts and nuts to specified torque.
20) Connect front wheel speed sensor harness to strut bracket, then tighten front wheel speed sensor harness clamp bolt.
21) Install brake pads and caliper.
22) Install A/C compressor to bracket.
23) Install accessory drive belt.
24) For M/T model, connect gear select control cable, gear shift control cable, then tighten battery ground terminal bolt to specified torque.
25) For CVT model, connect select cable.
26) Install thermostat, thermostat cap and radiator outlet hose.
27) Install engine harness clamps.
28) Install all other removed electric wires, connectors and hoses to original locations.
29) Tighten battery ground terminal bolts (1) to specified torque.
Tightening torque
Battery ground terminal bolts (a): 9.0 Nm (0.92 kg-m, 7.0 lbf-ft)
30) Install air cleaner assembly.
31) Refill oils and fluid.
^ Engine oil:
^ Manual transmission oil (M/T model):
^ CVT fluid (CVT model):
^ Transfer oil (4WD model):
32) Refill cooling system with coolant.
33) Install right and left side engine under covers.
34) Install battery bracket, battery tray, battery and ECM.
35) Connect ECM connectors.
36) Connect positive (+) cables and negative (-) at battery.
37) Check any leakage of fuel, coolant, oil and exhaust.
^ Fuel leak:
^ Coolant leak:
38) Install engine cover.
39) Install front bumper and front bumper lower cover.
40) Install right and left side front fender lower linings.