Removal and Installation
ENGINE AND TRANSAXLE ASSEMBLYREMOVAL
1. Remove the battery.
2. Detach the air cleaner.
3. Disconnect the engine harness connectors.
1. Engine wiring connectors (alternator, starter, etc.)
2. TPS connector
3. Power steering switch connector, oil pressure gauge connector.
4. Back up lamp switch connector.
5. A/T solenoid, inhibitor switch connector.
6. Coolant temperature sensor.
7. Ignition coil, power TR connector.
8. Idle speed control valve (ISC) connector.
9. MAP and ATS connectors.
10. Oxygen sensor connector.
4. Drain the engine coolant.
5. For a vehicle with automatic transaxles, disconnect the transaxle oil cooler hoses.
NOTE: When disconnecting hoses, make identification marks to avoid making any mistake when installing them again.
CAUTION: Be careful not to spill any of oil or fluid out of the hoses. Plug the openings to prevent the entry of foreign material.
6. Disconnect the radiator upper and lower hoses on the engine side then remove the radiator assembly.
7. Disconnect the engine ground.
8. Disconnect the brake booster vacuum hose.
9. Disconnect the heater hoses (inlet and outlet) on the engine side.
10. Disconnect the accelerator cable at the engine side.
11. Using a special tool, remove the main fuel line at the delivery pipe (supply/return).
12. Disconnect the speedometer cable from the transaxle.
13. Disconnect the clutch cable or control cable from the transaxle.
14. Disconnect the power steering suction hose and return hose from the pump.
15. Detach the steering dust cover in the engine compartment and then disconnect the gear box universal joint bolt.
NOTE: Make sure to make identification marks between the universal joint and the gear box for reassembly.
16. Raise the vehicle and then remove the front tire.
17. Attaching the wheel speed sensor and caliper to the body, disconnect the lower arm and the fork, and then separate the upper arm and knuckle.
18. Drain the transaxle oil.
19. Remove the front muffler bolts.
20. Remove the transaxle control rod and extension rod (M/T only).
21. Put the special fixture on the T/M jack and then adjust it to the sub-frame.
NOTE: Check that all the cables, harness connector and hose are disconnected from the engine and transaxle assembly.
22. Remove the engine mounting bracket and the transaxle mounting bracket.
23. Remove the sub-frame installation bolts.
24. Using the special tool 09624 - 38100, remove the cross member stud bolt.
With holding the stud bolt using a special tool in order not to loosen the stud bolt, remove the lock nut using a ring wrench.
25. After removing the drive shaft, lower the engine and transaxle assembly on the jack then, remove the front roll stopper and the rear roll stopper.
26. Remove the engine and transaxle assembly as a unit.
INSTALLATION
1. When installing the engine and transaxle, check the connections of harnesses, pipes, hoses, etc. make sure that none of them are caught, damaged,etc.
2. Install the front roll stopper to the bracket roughly.
Tightening torque
Service standard: 50 - 65 Nm (500 - 650 kg-cm, 36 - 47 ft. lbs.)
3. Install the rear roll stopper to the bracket.
Tightening torque
Service standard: 50 - 65 Nm (500 - 650 kg-cm, 36 - 47 ft. lbs.)
4. Install the engine/transaxle to the sub-frame assembly. Use the T/M jack to raise the assembly slowly adjust it to the vehicle body.
5. Install the transaxle mounting bracket.
Tightening torque
Service standard: 90 - 110 Nm (900 - 1100 kg-cm, 65 - 80 ft. lbs.)
6. Install the engine bracket (right side).
Tightening torque
Service standard: 60 - 80 Nm (600 - 800 kg-cm, 43 - 58 ft. lbs.)
7. To install all of parts, follow the removal procedures in the reverse order.
8. Refill the coolant and then check for leaks.
9. Refill the transaxle oil and check for leaks, then test its operation.
10. Check the operation of the transaxle control cable and accelerator cable.
11. Check the proper operation of each gauge.