Engine Assembly Removal and Installation

Engine Assembly Removal

Tools Required:
DW110-060 Engine Assembly Lift Support
DW010-010 Power Pack Stand

1. Remove the fuel pump fuse.
2. Start the engine and repeat cranking until the remaining fuel in the fuel line is all consumed.
3. Disconnect the negative battery cable.
4. Drain the engine coolant.
5. Drain the engine oil.
6. Drain the transaxle oil.
7. Drain the power steering oil.
8. Recover the refrigerant.
9. Remove the engine beautification cover.





10. Remove the air filter snorkel.





11. Remove the air filter housing assembly.
12. Remove the breather hose.





13. Disconnect the throttle cable from the throttle body assembly.
14. Disconnect the coolant reservoir hoses.





15. Remove the coolant reservoir.
16. Disconnect the power steering pump outlet pipe.





17. Disconnect the fuel rail hose and fuel feeding/return pipe.





18. Disconnect the connectors on the O2S, EGR, charcoal canister purge solenoid valve, MAP sensor, Throttle body, engine oil pressure sensor, CMP sensor, knock sensor, VIS, and the engine coolant temperature sensor.





19. Detach wiring harness from the wiring harness bracket on the cylinder block.





20. Disconnect the engine block ground by removing the engine block ground bolts.





21. Remove the battery.
22. Disconnect the automatic transaxle cable.
23. Disconnect the inhibit switch connector.
24. Disconnect the connectors on the transaxle.





25. Disconnect the alternator connector and wiring harness.
26. Remove the upper and lower radiator hoses.
27. Remove the front wheels.





28. Remove the engine under covers.
29. Remove the front axle shaft.





30. Remove the front muffler.





31. Support the engine assembly using the engine assembly lift support DW110-060.





32. Remove the impact beam.





33. Remove the front engine mount bracket-to-damper bush bolt/nut and the rear transaxle mount bracket-to-damper bush bolt/nut.





34. Remove the center front suspension member bolts and the center front suspension member.
35. Disconnect the connector on the compressor.





36. Disconnect the refrigerant suction and discharge pipe block from the compressor.





37. Remove the oil filter.





38. Support the engine and transaxle with the power pack stand DWO10-010.





39. Remove the engine mount bracket (RH).
40. Remove the engine mount bracket (LH).





41. Separate the engine and transaxle assembly from the engine compartment.





42. Remove the starter.





43. Remove three (3) transaxle torque converter bolts.





44. Remove the transaxle-to-engine block bolts.
45. Remove the rear transaxle mount bracket.





46. Remove the front damper bush bracket.





47. Remove the engine block-to-transaxle bolts.





48. Remove the engine assembly from the transaxle.

CAUTION: Be careful not to damage the torque converter when removing the transaxle.

Engine Assembly Installation
1. Installation should follow the removal procedure in the reverse order.





2. Tighten the engine block-to-transaxle bolts near the rear transaxle bracket.
Tighten the engine block-to-transaxle bolts to 60 - 85 Nm (44 - 63 ft. lbs.).





3. Tighten the engine block-to-transaxle bolts near the front engine mount bracket.
Tighten the engine block- to-transaxle bolts to 60 - 85 Nm (44 - 63 ft. lbs.).





4. Tighten the transaxle-to-engine block bolts near the rear support bracket.
Tighten the transaxle-to-engine block bolts to 60 - 85 Nm (44 - 63 ft. lbs.).





5. Tighten the three (3) flexible plate-to-torque converter retaining bolts.
Tighten the transaxle torque converter bolts to40 - 50 Nm (30 - 37 ft. lbs.).





6. Install the rear transaxle mount bracket.
Tighten the rear transaxle mount bracket bolts to 55 - 75 Nm (26 - 55 ft. lbs.).





7. Install the front damper bush bracket.
Tighten the front damper bush bracket bolts to 55 - 75 Nm (26 - 55 ft. lbs.).
8. Install the starter.





9. Install the engine and transaxle assembly using the power pack stand DW010-010.





10. Install the engine mount bracket (LH).





11. Install the engine mount bracket (RH).
12. Support the engine and transaxle assembly using the engine assembly lift support DW110-060.





13. Remove the power pack stand DW010-010.





14. Install the oil filter.
Tighten the oil filter to 12 - 16 Nm (9 - 12 inch lbs.).





15. Install the center front suspension member.
Tighten the center front suspension member bolts to 80 - 100 Nm (59 - 74 ft. lbs.).





16. Tighten the front engine mount bracket-to-damper bush bolt/nut and the rear transaxle mount bracket-to-damper bush bolt/nut.
Tighten the front engine mount bracket-to-damper bush bolt/nut to 70 - 90 Nm (52 - 66 ft. lbs.)
Tighten the rear transaxle mount bracket-to-damper bush bolt/nut to 70 - 90 Nm (52 - 66 ft. lbs.).





17. Install the front muffler.
18. Install the axle shaft.





19. Install the engine under cover.
Tighten the engine under cover bolts to 17 - 27 Nm (13 - 20 ft. lbs.).
20. Connect the connectors and cables on the transaxle.
21. Connect the Mining harness, hoses, pipes, and connectors to the engine assembly.





22. Install the coolant reservoir.
Tighten the coolant reservoir bolts to 3.5 - 4.5 Nm (31 - 40 inch lbs.).





23. Install the air filter housing.
Tighten the air filter housing bolt to 8 - 12 Nm (71 - 106 inch lbs.).





24. Install the air filter snorkel.
Tighten the air filter snorkel retaining bolt to 5 - 7 Nm (44 - 62 inch lbs.).
25. Install the engine beautification cover.
Tighten the engine beautification cover bolts to 8 - 12 Nm (71 - 106 inch lbs.).
26. Connect the connectors and hoses.
27. Recharge the refrigerant.
28. Fill the power steering oil.
29. Fill the transaxle oil.





30. Fill the engine oil.