Removal and Replacement

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 transmission before removing the engine.
2. Disconnect the battery negative cable (A).

Tightening torque :
3.9 - 5.9 N.m (0.4 - 0.6 kgf.m, 2.9 - 4.3 lb-ft)




3. Remove the engine cover (A), engine side covers (B) and the radiator grill upper cover (C).




4. Loosen the drain plug and drain the engine coolant.

WARNING:
Never remove the radiator cap when the engine is hot. Serious scalding could be caused by hot fluid under high pressure escaping from the radiator.




5. After recovering refrigerant, remove the high & low pressure pipe.
6. Remove the intake air hose and air cleaner assembly.
(1) Remove the air duct (A).
(2) Disconnect the MAFS connector (B).
(3) Disconnect the breather hose (C).
(4) Disconnect the vacuum hose (D).
(5) Remove the intake air hose (E) and air cleaner assembly (F).

Tightening torque
Hose clamp bolt :
2.9 - 4.9 N.m (0.3 - 0.5 kgf.m, 2.2 - 3.6 lb-ft)
Air cleaner assembly bolts :
7.8 - 9.8 N.m (0.8 - 1.0 kgf.m, 5.8 - 7.2 lb-ft)




7. Remove the front wheels.
8. Remove the under cover.
9. Remove the radiator upper hose (A) and lower hose (B).








10. Disconnect the ATF cooler hoses (A).




11. Disconnect the heater hoses (A).




12. Disconnect the ECM connector (A), TCM connector (B), IDB connector (C), front connector (D) and the ground (E).

Tightening torque
Ground (E) :
10.8 - 13.7 N.m (1.1 - 1.4 kgf.m, 7.9 - 10.1 lb-ft)




13. Remove the fuse box cover (A).




14. Disconnect the wirings (A) from the fuse box.




15. Remove the jump cable cover.
16. Disconnect the wiring (A) from the jump cable.




17. Remove the fuse & relay box cover.
18. Remove the fuse & relay box mounting bolts (A) and wiring mounting bolts (B).




19. Remove the fuse & relay box (A) after disconnect from the connector (B).




20. Remove the connector (A) and wirings.




21. Disconnect the fuel hose (A), PCSV hose (B) and the intensifier hose (C).




22. Disconnect the vacuum pump hose (A), the pump connector (B) and the ground (C).

Tightening torque
Ground (C) :
10.8 - 13.7 N.m (1.1 - 1.4 kgf.m, 7.9 - 10.1 lb-ft)




23. Remove the tie rod end ball joint (A).

24. Remove the lower arm ball joint (B).

25. Remove the stabilizer bar link (C).

26. Remove the shock absorber lower mounting bolt and nut (D).
27. Remove the height level sensor mounting bolt (E).
28. Remove the lower arm mounting bolt & nut (F) from the sub frame.




29. Remove the stabilizer bar.
30. Remove the wheel housing under cover (A).
31. Disconnect the power steering fluid return hose (B) and then drain the power steering fluid.




32. Remove the steering column U-joint bolt (A).




33. Support the sub frame (A) securely with a floor jack, and then remove the mounting bolts (B).

Tightening torque :
137.3 - 156.9N.m(14.0 - 16.0kgf.m, 101.3 - 115.7lb-ft)

NOTE:
- Check that all the cables, harness connector and hoses are disconnected from the engine and transaxle assembly.





[Front]





[Center]





[Rear]




34. Remove the engine assembly and sub frame by lifting vehicle.





CAUTION:
- When removing the engine and transmission 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 a shift cable.
- Refill engine with engine oil.
- Refill a transmission with fluid.
- Clean battery posts and cable terminals with sandpaper. Reassemble, then apply grease to prevent corrosion.
- Inspect for fuel leakage.
- After assembling 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.
- Refill a radiator and a reservoir tank with engine coolant.
- 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.