Removal and Replacement
ENGINE AND TRANSAXLE ASSEMBLYCOMPONENTS:
REMOVAL
CAUTION:
^ Use fender covers to avoid damaging painted surfaces.
^ To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
NOTE:
^ Mark all wiring and hoses to avoid mis-connection.
1. Disconnect the terminals(A) from battery and remove the battery.
2. Remove the engine cover.
3. Remove the under cover(A).
4. Drain the engine coolant. Remove the radiator cap to speed draining.
5. Remove the intake air hose and air cleaner assembly.
1) Disconnect the breather hose(B) from intake air hose(D).
2) Remove the intake air hose(D) and air cleaner upper cover(C).
3) Disconnect the ECM connector(A) and ECM connector(B) (A/T only).
4) Remove the air cleaner element and air cleaner lower cover(C).
6. Remove the battery tray(A).
7. Disconnect the upper radiator hose(A) and lower radiator hose(B).
8. Disconnect the ATF oil cooler hoses(C).
9. Disconnect the heater hoses(A).
10. Disconnect the fuel hose(B).
11. Remove the accelerator cable(A) by loosening the lock-nut, then slip the cable end out of the throttle linkage.
12. Disconnect the TPS (Throttle Position Sensor) connector(B) and the MAP sensor connector(C).
13. Remove the engine wire harness connectors and wire harness clamps from cylinder head and the intake manifold.
1) Disconnect the rear oxygen sensor connector (A).
2) Disconnect the air conditioner compressor switch connector (B).
3) Disconnect the knock sensor connector (C).
4) Disconnect the injector connectors(No.3,4) (D).
5) Disconnect the injector connectors(No.1,2) (E)
6) Remove the wire harness bracket(A).
7) Disconnect the ISA (Idle Speed Actuator) connector (B).
8) Disconnect the front oxygen sensor connector(A).
9) Disconnect the CKP(Crankshaft Position Sensor) connector (B).
10) Disconnect the OCV(Oil Control Valve) connector (C).
11) Disconnect the ignition coil connector(A).
12) Disconnect the ignition coil condenser connector(B).
13) Disconnect the CMP(Camshaft Position Sensor) connector(C).
14) Disconnect the ground cable(D).
15) Remove the wire harness bracket(E).
16) Remove the ground cable(A) between engine mounting and vehicle body.
17) Remove the ground cable(A) between transaxle housing and vehicle body.
14. Remove the transaxle wire harness connectors and control cable from transaxle (NT).
1) Disconnect the transaxle range switch connector (A).
2) Disconnect the solenoid valve connector(B).
3) Disconnect the ATF oil temperature sensor connector (C).
4) Disconnect the vehicle speed sensor connector(A).
5) Disconnect the band server switch connector(B).
6) Disconnect the pulse generator(A) connector(C).
7) Disconnect the pulse generator(B) connector(D).
8) Remove the control cable nut(A) from transaxle range switch.
9) Remove the control cable(B).
15. Remove the transaxle wire harness connectors and control cable from transaxle (M/T).
1) Disconnect the vehicle speed sensor connector(A).
2) Disconnect the neutral switch connector(B).
3) Disconnect the back-up lamp switch connector(C).
4) Remove the control cable(A).
16. Move the disconnected wire harnesses to the fuse box side so as to prevent interfering with other parts.
17. Disconnect the hose(A) of the PCSV (Purge Control Solenoid Valve) side.
18. Remove the brake booster vacuum hose(B).
19. Remove the power steering oil hose(A) and drain the power steering oil.
20. Remove the power steering return hose(A).
21. Recovering refrigerant and remove the high & low pressure pipe.
22. Remove the nuts(B,D), bolt(C) and engine mounting support bracket(A).
Tightening torque:
Nut (B): 68.6 - 93.2N.m (7.0- 9.5kgf.m, 50.6 - 68.7lb-ft)
Bolt(C),Nut(D): 49.0-63.7N.m(5.0-6.5kgf.m,36.2-47.0lb-ft)
23. Remove the transaxle mounting bracket(A).
^ A/T: Remove the wire harness protector(B) on the transaxle mounting support bracket.
^ M/T: Remove the clutch release cylinder oil hose(B) on the transaxle mounting support bracket.
24. Disconnect the alternator connector(A) and "B" terminal (B).
25. Remove the front tires.
26. Remove the ABS wheel speed sensor(A).
27. Remove the caliper and hang assembly(A).
28. Remove the knuckle mounting bolts(A).
29. Remove the steering u-joint mounting bolt(A).
30. Remove the front muffler heat protector(A).
31. Remove the front muffler(B).
32. Using a floor jack, support the engine and transaxle assembly.
NOTE: After removing the sub frame mounting bolt , the engine and transaxle assembly may fall downward, and so support them securely with floor jack. Verify that the hoses and connectors are disconnected before removing the engine and transaxle assembly.
33. Remove the sub frame bolts and nuts.
34. Remove the engine and transaxle assembly by lifting vehicle.
NOTE: When remove the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.
INSTALLATION
Installation is in the reverse order of removal.
Perform the following:
^ Adjust the shift cable.
^ Adjust the throttle cable.
^ Refill the engine with engine oil.
^ Refill the transaxle with fluid.
^ Refill the radiator and reservoir tank with engine coolant.
^ Place the heater control knob on "HOT" position.
^ Bleed air from the cooling system
- Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.)
- Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system.
- Put the radiator cap on tightly, then run the engine again and check for leaks.
^ Clean the battery posts and cable terminals with sandpaper assemble them, then apply grease to prevent corrosion.
^ Inspect for fuel leakage.
- After assemble the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes.
- Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.