Removal and Replacement
ENGINE REMOVAL/INSTALLATIONWarning:
^ Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
^ Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure" when servicing the fuel system.
^ After disconnecting the steering shaft joint, always set the EPS system to the neutral position to prevent system malfunction.
Caution: To allow the PCM to identify that the engine has been replaced, pump the brake pedal 20 times within 8 s after the ignition switch is turn to the ON position (engine off).
Immediately after the procedure is completed, the oil pressure gauge needle moves to right of center slightly (nearer H). This indicates that the procedure is successful. If the malfunction cannot be corrected even though the procedure is successful, the eccentric shaft position plate may have been distorted. Therefore, inspect the eccentric shaft position plate.
Note: Remove the engine, transmission, and crossmember component as a single unit from under the vehicle.
1. Remove the following parts:
(1) The front wheel and tires
(2) The engine cover
(3) The front suspension tower bar
(4) The battery cover, battery, battery box and battery tray
(5) The air cleaner, intake-air duct and air cleaner insulator
(6) The PCM
(7) The AIR pump.
2. Drain the engine coolant.
3. Disconnect the brake vacuum hose.
4. Disconnect the quick release connector going to the charcoal canister from the engine room side.
5. Disconnect the plastic fuel hose.
6. Remove the ignition coil.
7. Remove the A/C belt.
8. Remove the A/C compressor with the pipes connected and secure the A/C compressor using wire or rope so that it is out of the way.
9. Disconnect the engine wiring harness from the main fuse block side.
10. Remove the engine under cover.
11. Disconnect front ABS wheel speed sensor connector.
12. Disconnect the radiator hose, the heater hose and coolant reserve tank hose.
13. AT
^ Disconnect the selector link.
MT
^ Remove the clutch release cylinder with the pipes connected and secure the clutch release cylinder using wire or rope so that it is out of the way.
^ Remove the shift lever component.
14. Remove the engine, transmission, and crossmember component using an engine lifter in the order indicated in the table.
Warning: Remove the engine, transmission and crossmember carefully, holding it steady. If the transmission falls it could be damaged or cause injury.
15. Remove the engine and transmission from the crossmember component lifter in the order indicated in the table by suspending them with a crane.
16. Install in the reverse order of removal.
17. Start the engine and inspect and adjust the following:
^ Pulley and belt for runout, tension, and contact
^ Leakage of engine oil, engine coolant, ATF, MT oil, and fuel
^ Ignition timing, idle speed, and idle mixture (CO and HC)
^ Front wheel alignment
^ Engine-driven accessories operation
18. Perform the on-road test and verify that there is no vibration or noise.
Oil Hose Removal Note
1. Remove the clip as shown in the figure and disconnect the oil pipe.
Caution: Catch the remaining engine oil in the oil cooler using a plate pipe to prevent spillage.
Power Plant Frame, Crossmember Bolt Removal/Installation Note
1. Secure the engine, transmission, and crossmember component using an engine lifter.
Note: When installing the power plant frame, tighten the tightening bolts and nuts temporarily at this time, and after installing all parts, adjust the transmission installation positions referring to "Power Plant Frame Installation Note" and then tighten them completely.
Oil Hose Installation Note
1. Connect a new clip as shown in the figure and connect the oil hose.
Caution: Always install the oil hose with the three holes on the oil hose grooves and the three clip projections aligned.