Removal and Replacement

Engine Replacement

Removal Procedure

1. Release the fuel pressure. Refer to Fuel Pressure Relief (Service and Repair).
2. Disconnect the fuel pipe from the fuel rail.
3. Disconnect the EVAP hose from the EVAP canister solenoid valve.
4. Drain the engine coolant. Refer to Cooling System Draining and Filling (Service and Repair).
5. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).
6. Remove the battery and tray. Refer to Battery Tray Replacement (Service and Repair).
7. Remove the fuse box bolts.




8. Discharge the A/C system, if equipped. Refer to Refrigerant Recovery and Recharging (Service and Repair).
9. Remove the A/C inlet/outlet pipe bolt (1) from the A/C compressor.




10. Drain the power steering oil if equipped. Refer to Power Steering Pump Replacement (1.2L LMU Engine) (Power Steering Pump Replacement (1.4L LDT and 1.6L LXV Engines))Power Steering Pump Replacement (1.4L L95 and 1.5L LV8 Engines) (Power Steering Pump Replacement (1.4L LDT and 1.6L LXV Engines))Power Steering Pump Replacement (1.4L LDT and 1.6L LXV Engines) (Power Steering Pump Replacement (1.4L LDT and 1.6L LXV Engines)).
11. Remove the power steering pump pressure line union nut. Refer to Power Steering Pump Replacement (1.2L LMU Engine) (Power Steering Pump Replacement (1.4L LDT and 1.6L LXV Engines))Power Steering Pump Replacement (1.4L L95 and 1.5L LV8 Engines) (Power Steering Pump Replacement (1.4L LDT and 1.6L LXV Engines))Power Steering Pump Replacement (1.4L LDT and 1.6L LXV Engines) (Power Steering Pump Replacement (1.4L LDT and 1.6L LXV Engines)).
12. Remove the power steering pressure pipe retaining clamp bolt (1) from the intake manifold.
13. Disconnect the power steering hose from the power steering pump.
14. Disconnect the following:

* Oil switch wiring connector
* A/C compressor connector

15. Disconnect the following:

* Intake air temperature sensor connector
* A/C pressure sensor (ACP) connector
* Cam position solenoid valve connector
* Electric throttle controller (ETC) connector
* Manifold air pressure (MAP) sensor connector
* EVAP solenoid valve connector
* Injector connectors

16. Disconnect the following

* Ignition coil connector
* Camshaft position sensor (CPS) connectors (right/left)
* Coolant temperature sensor connector
* Oxygen sensor connector
* Ground bolt
* Thermostat heater connector

17. Disconnect the following and pull the engine harness aside.

* Crankshaft position (CKP) sensor connector
* Knock sensor connector
* Alternator connector
* Alternator B+ nut
* Oil level switch connector, if equipped
* Starter solenoid B+ nut
* Ground tightening nut
* Starter solenoid ground nut




18. Disconnect the coolant hose (1) from water pump.
19. Disconnect the coolant hose (2) from the thermostat housing.
20. Disconnect the heater core coolant inlet/outlet hoses (3) from the coolant distributor.
21. Disconnect the ETC-to-coolant tank hose (4).
22. Disconnect the brake boost hose (5) from the intake manifold.
23. Remove and disconnect the cables and wiring harness related to the automatic transaxle.
24. Disconnect the auto transaxle fluid cooler inlet/outlet hoses.




25. Remove and disconnect the cables and wiring harness related to the manual transaxle.




26. Remove the reaction rod (1).
27. Remove the exhaust front pipe. Refer to Front Pipe Replacement (Service and Repair).
28. Remove the drive axle shafts. Refer to Front Drive Axle Inner Shaft Replacement (Service and Repair)
29. Raise the vehicle.
30. Locate suitable supporter under the vehicle engine and transaxle.
31. Lower the vehicle until engine assembly is on the supporter.
32. Remove the engine mount. Refer to Engine Mount Replacement (Service and Repair).
33. Remove the transaxle mount.




34. Separate the engine and the transaxle.

Installation Procedure




1. Assemble the engine to the transaxle.
2. Place the engine assembly on the supporter.
3. Raise the vehicle.
4. Locate the engine assembly with the supporter.
5. Lower the vehicle.
6. Install the engine mount. Refer to Engine Mount Replacement (Service and Repair).
7. Install the transaxle mount.




8. Install the drive axle shafts. Refer to Front Drive Axle Inner Shaft Replacement (Service and Repair).
9. Install the exhaust front pipe. Refer to Front Pipe Replacement (Service and Repair).




10. Install the reaction rod (1).
11. Install and connect the cables and wiring harness related to the automatic transaxle.
12. Connect the auto transaxle fluid cooler inlet/outlet hoses.




13. Install and connect the cables and wiring harness related to the manual transaxle.




14. Connect the coolant hose (1) to the water pump.
15. Connect the coolant hose (2) to the thermostat housing.
16. Connect the heater core coolant inlet/outlet hoses (3) to the coolant distributor.
17. Connect the ETC-to-coolant tank hose (4).
18. Connect the brake boost hose (5) to the intake manifold.

Caution: Refer to Fastener Caution (Fastener Caution).

19. Position the engine harness and connect the following connectors.

* Crankshaft position (CKP) sensor connector
* Knock sensor connector
* Alternator connector
* Alternator B+ nut
* Oil level switch connector, if equipped
* Starter solenoid B+ nut
* Ground nut
* Starter solenoid ground nut

- Tighten the alternator B+ nut to 15 Nm (11 lb ft).
- Tighten the starter solenoid B+ nut to 10.5 Nm (7.7 lb ft).
- Tighten the ground nut to 12 Nm (8.8 lb ft).
- Tighten the starter solenoid ground nut to 38 Nm (28 lb ft).

20. Connect the following:

* Ignition coil connector
* Camshaft position sensor (CPS) connectors (right/left)
* Coolant temperature sensor connector
* Oxygen sensor connector
* Ground bolt

Tighten the ground bolt to 12 Nm (8.8 lb ft).

* Thermostat heater connector

21. Connect the following:

* Oil switch wiring connector
* A/C compressor connector




22. Install the power steering pump pressure line union nut.
23. Install the power steering pressure pipe retaining clamp bolt (1) to the intake manifold.
24. Connect the power steering hose to the power steering pump.




25. Install the A/C inlet/outlet pipe bolt (1) from the A/C compressor if equipped.
26. Charge the A/C system. Refer to Refrigerant Recovery and Recharging (Service and Repair).
27. Install the fuse box bolts.
28. Install the battery and tray. Refer to Battery Tray Replacement (Service and Repair).
29. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement (Service and Repair).
30. Connect the fuel pipe to the fuel rail.
31. Connect the EVAP hose to the EVAP canister solenoid valve.