Removal and Replacement

ENGINE ASSEMBLY


Removal and Installation












WARNING:
- Place chocks at the front and back of the rear wheels.
- For engines not equipped with slingers, attach proper slingers and bolts as described in the Parts Catalog.
- Wear electrically insulated gloves and pull out the service plug grip before inspection procedures may require disconnecting high voltage connectors. Be sure to carry the removed service plug grip because other workers install it by mistake.
- Never touch the high voltage connectors or terminals for 10 minutes after the service plug grip is removed.

CAUTION:
- Do not start working until the exhaust system and coolant are cool.
- If items or work required are not covered by the engine main body section, refer to the applicable sections.
- Use the correct supporting points for lifting and jacking. Garage Jack And Safety Stand.
- In removing the drive shaft, be careful not to damage the grease seals on the transaxle.

REMOVAL
1. Remove the inverter upper LH bracket.
2. Release fuel pressure. Testing and Inspection.
3. Disconnect the 12-volt negative battery terminal. Removal And Installation.
4. Disconnect the fuel rail at the fuel hose quick connector (engine side).
5. Drain the engine and inverter coolant. Changing Engine Coolant, Replacement.
6. Remove the engine under cover. Service and Repair.
7. Partially drain transaxle fluid. Replacement.
8. Remove engine room cover.
9. Remove the air duct and air cleaner case assembly. Service and Repair.
10. Disconnect and remove the ECM with ECM bracket.
11. Remove cowl top. Service and Repair.
12. Remove strut brace. Exploded View.
13. Disconnect and set aside the IPDM/ER and remove the IPDM/ER bracket. Service and Repair.
14. Remove upper and lower radiator hoses (engine side).

NOTE:
Cap or plug opening(s) to prevent fluid from spilling.
15. Remove the inverter with converter assembly. Removal And Installation.
16. Disconnect EVAP hose.
17. Disconnect the heater hoses.

NOTE:
Cap or plug opening(s) to prevent fluid from spilling.
18. Disconnect main harness connector and harness ground wire.
19. Disconnect remaining sensors and harness connectors from engine and transaxle.
20. Disconnect and set aside the brake ECU. Removal And Installation.

NOTE:
Cap or plug opening(s) to prevent fluid from spilling.
21. Remove front LH and RH wheels and tires. Adjustment.





22. Remove the lower side bolt of the lower shaft assembly.
23. Remove the fender protector side covers (RH) and (LH). Service and Repair.
24. Remove front exhaust tube. Exploded View.
25. Remove the left and right drive shafts. Front Drive Shaft Left Side, Front Drive Shaft Right Side.

NOTE:
Cap or plug opening(s) to prevent fluid from spilling.
26. Remove rear engine mount torque rod and bracket.
27. Remove rear engine mounting insulator and bracket.
28. Disconnect the electric compressor pipes and connectors. Service and Repair.
29. Disconnect the transaxle shift controls.





30. Install engine slingers into front left cylinder head and rear right cylinder head.
- Use the proper slingers and bolts as described in the Parts
Catalog.





31. Support engine and transaxle assembly with engine lifting equipment from the top with the vehicle raised on a hoist.
32. Remove the RH engine mount torque rod, RH engine support bracket, RH engine mounting insulator and
RH engine mounting bracket.
33. Remove the front suspension member bolts. Exploded View.
34. Lower the engine and transaxle assembly on the front suspension member from the engine compartment using Tool.

CAUTION:
- Before and during this procedure, always check if any harnesses are left connected.
- Avoid any damage to, or any oil/grease smearing or spills onto the engine mounting insulators.





35. Remove the engine and transaxle assembly from the front suspension member.
- Remove front engine mounting insulator nut.
- Remove LH engine mounting insulator nut.
36. Separate the engine from the transaxle. Removal And Installation.

INSTALLATION
Installation is in the reverse order of removal.





- Be sure the grommet (1) is installed flush with the flange plane as shown prior to mating the engine and transaxle.

CAUTION:
Do not use lubricating oil for lubricant.

NOTE:
Be careful that the edge does not protrude from the socket.
- Do not allow oil to get on mounting insulators. Be careful not to damage mounting insulators.
- If parts have a direction mark (arrow) this indicates front of the vehicle, and the parts must be installed according to the identification mark.





- Arrow Indicates Front

- Install the RH engine mounting bracket bolts in the following steps:
- First install bolts (A) and (B) loosely.
- Install and tighten the five RH engine mounting bracket bolts to specification in the order as shown.






INSPECTION AFTER INSTALLATION
- Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Recommended Chemical Products And Sealants.
- Use procedure below to check for fuel leakage.
- Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
- Run engine to check for unusual noise and vibration.
- Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oils/fluids including engine oil and engine coolant.
- Bleed air from passages in lines and hoses, such as in cooling system.
- After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to specified level, if necessary.
- Summary of the inspection items: