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.

1. First, remove the transmission before removing the engine.
2. Remove the bonnet.
3. Remove the cowl cover and wiper arm.
4. Disconnect the negative terminal from the battery.




5. Remove the engine cover (A).




6. Remove the radiator grill upper guard (A).




7. Loosen the drain plug (A) and drain the engine coolant.




Remove the radiator cap (A) to speed draining.





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.

8. Recover refrigerant.
9. Remove the air duct (A) and the air cleaner assembly (B).




10. Disconnect the radiator upper hose (A) and lower hose (B).




11. Remove the radiator upper shroud (A).




12. Remove the cooling fan (A).




13. Remove the cooling fan clutch (A).





NOTE:
Remove the cooling fan clutch (A) after fixing the cooling fan pulley (B) by inserting a pin (C) into the hole of it.




14. Disconnect the heater hoses (A), the fuel hose (B) and the purge control solenoid valve (PCSV) hose (C).




15. Remove the engine wire harness from the fuse and relay block.
(1) Remove the ECM connector (B) and the fuse and relay block cover (A).




(2) Remove the connectors (A) and the cable (B) from the fuse and relay block (C).
(3) Remove the fuse and relay block (C).




(4) Remove the fuse and relay block connector (A) and the multi connector (B).




(5) Remove the fuse and relay block lower cover (A).




(6) Remove the connector (A) from the fuse and relay block lower cover bracket.




(7) Remove the earth cable (A) and the harness protector (B).




16. Remove the power steering pump pressure switch connector (A).




17. Remove the cable (A) from the battery.




18. Remove the air conditioner high pressure pipe (A).








19. Remove the oxygen sensor connector (A).








20. Remove the exhaust manifold heat protector (A).








21. Remove the exhaust manifold (A).








22. Remove the engine mounting bracket nuts (A) and the earth cable (B).

Tightening torque :
49.0 - 63.7Nm (5.0 - 6.5kgf.m, 36.2 - 47.0lb-ft)









23. Remove the engine assembly from the vehicle by using hoist.

NOTE:
When removing the engine 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.
- Refill engine with engine oil.
- Refill transaxle with fluid.
- Clean the battery posts and cable terminals with sandpaper assemble them, 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 lines.
- Refill radiator 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.