Removal and Replacement

Engine Assembly Removal and Installation

Engine Mountings Components

Removal

1) Relieve fuel pressure. Service and Repair
2) Disconnect negative and positive cables at battery.
3) Disconnect ECM connectors.
4) Remove battery and battery tray with ECM.
5) Remove right and left side engine under covers.
6) Remove accessory drive belt. Removal and Installation
7) Remove front bumper. [1][2]Diagrams
8) Drain the following oils and fluids if necessary.
- Engine oil: Service and Repair
- Manual transaxle oil (M/T model): Removal and Replacement
- CVT fluid (CVT model): Removal and Replacement
- P/S fluid (Hydraulic P/S model): Removal and Replacement
- Transfer oil (4WD model): Removal and Replacement
9) Remove air cleaner assembly. Air Cleaner Assembly Removal and Installation
10) Remove radiator. Radiator Removal and Installation
11) With hose connected, detach A/C compressor from its bracket.
- Manual A/C model: Removal and Installation
- Auto A/C model: Removal and Installation

NOTE:
The A/C compressor may be damaged if it hits against or interferes with other parts.

Suspend the removed A/C compressor in a place where no damage will be caused during removal and installation of the engine assembly.

12) Disconnect P/S fluid reservoir hose (1) and P/S gear low pressure hose (2) (Hydraulic P/S model).






13) Disconnect the following electric wires / connectors and each clamp.
- Connectors (1) in main fuse box
- Connector (2) in fuse box No.1
- Ground terminal (3) from vehicle body
- Battery ground cable (4) from transaxle
- Ground terminal (5) from exhaust manifold
- Torque sensor (6) (EPS model)
- P/S motor (7) (EPS model)











14) Disconnect TCM connectors (1), and then pull out engine harness to engine compartment.





15) Disconnect the following cables, and remove control cable bracket (1).
- Gear select control cable (2) (M/T model)
- Gear shift control cable (3) (M/T model)
- Select cable with select cable bracket (4) (CVT model)











16) Disconnect the following hoses.
- Brake booster hose (1) from brake booster
- Heater inlet and outlet hoses (2) from water outlet cap and heater outlet pipe
- Fuel feed hose (3) from fuel feed pipe
- Purge hose (4) from purge valve
- Clutch hose (5) from clutch fluid pipe (6) (M/T model)





17) Remove right and left drive shaft. Front Drive Shaft Assembly Removal and Installation
18) Remove exhaust No.1, No.2 and center pipe. Exhaust System Components
19) Disconnect propeller shaft from transfer (4WD model). Propeller Shaft Assembly Removal and Installation
20) Disconnect steering lower shaft from pinion shaft. Steering Lower Shaft Removal and Installation
21) Fix A/C condenser to vehicle body with rope so that A/C condenser does not fall off while lowering engine front mounting member.
22) Fix transaxle to suspension frame with rope so that engine assembly does not incline while lowering engine assembly.





23) Support front suspension frame and engine front mounting member putting jack at hatched parts (1) indicated in figure.






24) Remove engine right mounting nuts (1) and engine left mounting bracket bolt and nuts (2).





25) Remove suspension frame mounting bolts (1) and engine front mounting member No.1 and No.2 bolts (2).





26) Lower engine with transaxle, transfer (4WD model), steering gear case, CVT fluid cooler, front suspension frame and engine front mounting member.

NOTE:
The A/C compressor may be damaged if there is not adequate clearance when the engine is lowered.

Before lowering the engine, move the A/C compressor to vehicle body side to ensure that there is adequate clearance when the engine is lowered.

27) Disconnect steering gear case from suspension frame, if necessary.
- Hydraulic P/S model: Steering Gear Case Assembly Removal and Installation
- EPS model: Steering Gear Case Assembly Removal and Installation
28) Remove engine with transaxle, transfer (4WD model) from front suspension frame and front lower cross member.
29) Remove engine harness.
30) Disconnect transfer (4WD model).
31) Disconnect transaxle from engine.
32) Remove clutch cover and clutch disk, if necessary (M/T model). Clutch Cover and Clutch Disc Removal and Installation

Installation

1) Install clutch cover and clutch disk, if removed (M/T model). Clutch Cover and Clutch Disc Removal and Installation
2) Connect transaxle to engine, if removed.
- M/T model: Manual Transaxle Unit Dismounting and Remounting
- CVT model: CVT Assembly Dismounting and Remounting
3) Connect transfer to transaxle, if removed (4WD model). Removal and Replacement
4) Install engine harness, and then tighten bolts and nuts to specified torque.

Tightening torque
Starting motor terminal nut (a): 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
Generator terminal nut (b): 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
Ground terminal bolt (c): 11 Nm (1.1 kgf-m, 8.5 lbf-ft)
Ground terminal bolt (d): 25 Nm (2.5 kgf-m, 18.5 lbf-ft)





5) Install engine with transaxle, transfer (4WD model) to front suspension frame and engine front mounting member. [1][2]Diagrams
6) Connect steering gear case to suspension frame, if removed.
- Hydraulic P/S model: Steering Gear Case Assembly Removal and Installation
- EPS model: Steering Gear Case Assembly Removal and Installation
7) Lift engine with transaxle, transfer (4WD model), steering gear case, CVT fluid cooler, front suspension frame and engine front mounting member into engine compartment with jack.

NOTE:
The A/C compressor may be damaged if there is not adequate clearance when the engine is raised.

Before raising the engine, move the A/C compressor to vehicle body side to ensure that there is adequate clearance when the engine is raised.

8) Tighten suspension frame mounting bolts and engine front mounting member bolts, and then tighten bolts to specified torque.

Tightening torque
Suspension frame mounting bolt (a): 95 Nm (9.7 kgf-m, 70.0 lbf-ft)
Engine front mounting member No.1 bolt (b): 55 Nm (5.6 kgf-m, 40.5 lbf-ft)
Engine front mounting member No.2 bolt (c): 59 Nm (6.0 kgf-m, 43.5 lbf-ft)





9) Tighten engine right mounting nuts, engine left mounting bolts and nuts to specified torque. [1][2]Diagrams
10) Remove jack.
11) Connect steering lower shaft to pinion shaft. Steering Lower Shaft Removal and Installation
12) Connect propeller shaft (4WD model). Propeller Shaft Assembly Removal and Installation
13) Install exhaust No.1, No.2 and center pipe. Exhaust System Components
14) Install right and left drive shafts. Front Drive Shaft Assembly Removal and Installation
15) Reverse disconnection of hoses, cables and electric wires for connection noting the following.

Tighten bolts and nuts to specified torque.

Tightening torque
Battery ground bolt (a): 25 Nm (2.5 kgf-m, 18.5 lbf-ft) ((M/T model))
Battery ground bolt (b): 55 Nm (5.6 kgf-m, 40.5 lbf-ft) ((CVT model))









16) Connect P/S fluid reservoir hose (1) and P/S gear low pressure hose (2) (Hydraulic P/S model).





17) Install A/C compressor to cylinder block.
- Manual A/C model: Removal and Installation
- Auto A/C model: Removal and Installation
18) Install radiator, radiator outlet hose, CVT fluid cooler inlet and outlet hoses. Radiator Removal and Installation
19) Install A/C condenser cooling fan to radiator.
- Manual A/C model: Removal and Installation
- Auto A/C model: Removal and Installation
20) Install radiator cooling fan assembly and radiator inlet hose. Removal and Replacement
21) Install air cleaner assembly. Air Cleaner Assembly Removal and Installation
22) Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
23) Install accessory drive belt. Removal and Installation
24) Install front bumper. [1][2]Diagrams
25) Install battery and battery tray with ECM.
26) Connect ECM connectors.
27) Connect negative and positive cable at battery.
28) Refill cooling system with coolant. Cooling System Refilling
29) Fill all drained oils and fluids.
- Engine oil: Service and Repair
- Manual transaxle oil (M/T model): Removal and Replacement
- CVT fluid (CVT model): Removal and Replacement
- P/S fluid (Hydraulic P/S model): Removal and Replacement
- Transfer oil (4WD model): Removal and Replacement
30) Verify that there is no fuel leakage, coolant leakage, oil leakage and exhaust gas leakage at each connection.
31) Install right and left side engine under covers.