Engine Assembly Removal and Installation
Engine Assembly Removal and InstallationReference: Engine Mountings Components
Removal
1) Relieve fuel pressure.
2) Disconnect negative and positive cables at battery.
3) Disconnect ECM connectors.
4) Remove battery and battery tray with ECM.
5) Remove right and left side engine under covers.
6) Remove accessory drive belt.
7) Remove front bumper..
8) Drain the following oils and fluids if necessary.
^ Engine oil:
^ Manual transaxle oil (M/T model):
^ CVT fluid (CVT model):
^ P/S fluid (Hydraulic P/S model):
^ Transfer oil (4WD model):
9) Remove air cleaner assembly.
10) Remove radiator.
11) With hose connected, detach A/C compressor from its bracket.
^ Manual A/C model:
^ Auto A/C model:
CAUTION:
Suspend removed A/C compressor at a place where no damage will be caused during removal and installation of engine assembly.
12) Disconnect P/S fluid reservoir hose (1) and P/S gear low pressure hose (2) (Hydraulic P/S model).
13) Disconnect the following electric wires / connectors and each clamp.
^ Connectors (1) in main fuse box
^ Connector (2) in fuse box No.1
^ Ground terminal (3) from vehicle body
^ Battery ground cable (4) from transaxle
^ Ground terminal (5) from exhaust manifold
^ Torque sensor (6) (EPS model)
^ P/S motor (7) (EPS model)
14) Disconnect TCM connectors (1), and then pull out engine harness to engine compartment.
15) Disconnect the following cables, and remove control cable bracket (1).
^ Gear select control cable (2) (M/T model)
^ Gear shift control cable (3) (M/T model)
^ Select cable with select cable bracket (4) (CVT model)
16) Disconnect the following hoses.
^ Brake booster hose (1) from brake booster
^ Heater inlet and outlet hoses (2) from water outlet cap and heater outlet pipe
^ Fuel feed hose (3) from fuel feed pipe
^ Purge hose (4) from purge valve
^ Clutch hose (5) from clutch fluid pipe (6) (M/T model)
17) Remove right and left drive shaft.
18) Remove exhaust No.1, No.2 and center pipe.
19) Disconnect propeller shaft from transfer (4WD model).
20) Disconnect steering lower shaft from pinion shaft.
21) Fix A/C condenser to vehicle body with rope so that A/C condenser does not fall off while lowering engine front mounting member.
22) Fix transaxle to suspension frame with rope so that engine assembly does not incline while lowering engine assembly.
23) Support front suspension frame and engine front mounting member putting jack at hatched parts (1) indicated in figure.
24) Remove engine right mounting nuts (1) and engine left mounting bracket bolt and nuts (2).
25) Remove suspension frame mounting bolts (1) and engine front mounting member No.1 and No.2 bolts (2).
26) Lower engine with transaxle, transfer (4WD model), steering gear case, CVT fluid cooler, front suspension frame and engine front mounting member.
CAUTION:
When lowering engine, in order to avoid damage to A/C compressor, make clearance by raising A/C compressor.
27) Disconnect steering gear case from suspension frame, if necessary.
^ Hydraulic P/S model:
^ EPS model:
28) Remove engine with transaxle, transfer (4WD model) from front suspension frame and front lower cross member.
29) Remove engine harness.
30) Disconnect transfer (4WD model).
31) Disconnect transaxle from engine.
32) Remove clutch cover and clutch disk, if necessary (M/T model).
Installation
1) Install clutch cover and clutch disk, if removed (M/T model).
2) Connect transaxle to engine, if removed.
^ M/T model:
^ CVT model:
3) Connect transfer to transaxle, if removed (4WD model).
4) Install engine harness, and then tighten bolts and nuts to specified torque.
Tightening torque
Starting motor terminal nut (a): 11 Nm (1.1 kg-m, 8.5 lbf-ft)
Generator terminal nut (b): 11 Nm (1.1 kg-m, 8.5 lbf-ft)
Ground terminal bolt (c): 11 Nm (1.1 kg-m, 8.5 lbf-ft)
Ground terminal bolt (d): 25 Nm (2.5 kg-m, 18.5 lbf-ft)
5) Install engine with transaxle, transfer (4WD model) to front suspension frame and engine front mounting member.
6) Connect steering gear case to suspension frame, if removed.
^ Hydraulic P/S model:
^ EPS model:
7) Lift engine with transaxle, transfer (4WD model), steering gear case, CVT fluid cooler, front suspension frame and engine front mounting member into engine compartment with jack.
CAUTION:
When lifting engine, in order to avoid damage to A/C compressor, make clearance by raising A/C compressor.
8) Tighten suspension frame mounting bolts and engine front mounting member bolts, and then tighten bolts to specified torque.
Tightening torque
Suspension frame mounting bolt (a): 95 Nm (9.7 kg-m, 70.0 lbf-ft)
Engine front mounting member No.1 bolt (b): 55 Nm (5.6 kg-m, 40.5 lbf-ft)
Engine front mounting member No.2 bolt (c): 59 Nm (6.0 kg-m, 43.5 lbf-ft)
9) Tighten engine right mounting nuts, engine left mounting bolts and nuts to specified torque.
10) Remove jack.
11) Connect steering lower shaft to pinion shaft.
12) Connect propeller shaft (4WD model).
13) Install exhaust No.1, No.2 and center pipe.
14) Install right and left drive shafts.
15) Reverse disconnection of hoses, cables and electric wires for connection noting the following.
Tighten bolts and nuts to specified torque.
Tightening torque
Battery ground bolt (a): 25 Nm (2.5 kg-m, 18.5 lbf-ft) ((M/T model))
Battery ground bolt (b): 55 Nm (5.6 kg-m, 40.5 lbf-ft) ((CVT model))
16) Connect P/S fluid reservoir hose (1) and P/S gear low pressure hose (2) (Hydraulic P/S model).
17) Install A/C compressor to cylinder block.
^ Manual A/C model:
^ Auto A/C model:
18) Install radiator, radiator outlet hose, CVT fluid cooler inlet and outlet hoses.
19) Install A/C condenser cooling fan to radiator.
^ Manual A/C model:
^ Auto A/C model:
20) Install radiator cooling fan assembly and radiator inlet hose.
21) Install air cleaner assembly.
22) Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
23) Install accessory drive belt.
24) Install front bumper.
25) Install battery and battery tray with ECM.
26) Connect ECM connectors.
27) Connect negative and positive cable at battery.
28) Refill cooling system with coolant.
29) Fill all drained oils and fluids.
^ Engine oil:
^ Manual transaxle oil (M/T model):
^ CVT fluid (CVT model):
^ P/S fluid (Hydraulic P/S model):
^ Transfer oil (4WD model):
30) Verify that there is no fuel leakage, coolant leakage, oil leakage and exhaust gas leakage at each connection.
31) Install right and left side engine under covers.