Repair procedures
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 misconnection.
- For release the fuel system pressure before remove the engine assembly, start the engine without fuel pump relay. And then turn off the ignition switch after engine stops.
1. Remove the engine cover.
2. Remove the battery and battery tray.
3. Remove the under cover.
4. Drain the engine coolant.
5. Disconnect the radiator upper hose (A).
6. Disconnect the radiator lower hose (A).
NOTE:
When installing radiator hoses, install as shown in illustrations.
7. Recover the refrigerant and then remove the high pressure pipe and low pressure pipe.
8. Remove the transaxle wire harness connectors and control cable from the transaxle.
9. Disconnect the brake booster vacuum hose (A) and the heater hoses (B).
NOTE:
When installing the heater hoses, install as shown in illustrations.
10. Disconnect the fuel hose (A) and the purge control solenoid valve (PCSV) hose (B).
11. Remove the engine wirings from the engine room.
(1) Remove the (+) cable nut (A).
(2) Disconnect the EMS block (B).
(3) Disconnect the fuse box connector (C).
(4) Disconnect the battery sensor connector (D).
(5) Remove the ground bolts (E).
(6) Remove the engine wirings from the engine room.
12. Remove the front muffler.
13. Remove the roll rod bracket (A).
Tightening torque
Nut (B):
107.9 - 127.5 N.m (11.0 - 13.0 kgf.m, 79.6 - 94.0 lb-ft)
Bolts (C):
49.0 - 63.7 N.m (5.0 - 6.5 kgf.m, 36.2 - 47.0 lb-ft)
14. Remove the roll rod mounting support bracket (A).
Tightening torque:
49.0 - 68.6 N.m (5.0 - 7.0 kgf.m, 36.2 - 50.6 lb-ft)
15. Remove the sub frame.
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.
16. Disconnect the ground cable (A), and then remove the engine mounting bracket (B).
Tightening torque
Ground line bolt (A):
10.8 - 13.7 N.m (1.1 - 1.4 kgf.m, 8.0 - 10.1 lb-ft)
Nut (C):
63.7 - 83.4 N.m (6.5 - 8.5 kgf.m, 47.0 - 61.5 lb-ft)
Bolt (D) and nuts (E):
58.8 - 73.5 N.m (6.0 - 7.5 kgf.m, 43.4 - 54.2 lb-ft)
17. Disconnect the ground line (A), and then slowly loosen the transaxle mounting bolts (B).
Tightening torque:
88.3 - 107.9 N.m (9.0 - 11.0 kgf.m, 65.1 - 79.8 lb-ft)
18. Remove the engine and transaxle assembly by lifting vehicle.
CAUTION:
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 shift cable.
- Adjust throttle cable.
- Refill engine with engine oil.
- Refill transaxle with fluid.
- Refill radiator and reservoir tank with engine coolant.
- Place 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 radiator cap on tightly, then run the engine again and check for leaks.
- Clean 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.