Removal and Replacement

Removal

CAUTION:
- Use fender covers to avoid damaging painted surfaces.
- To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

WARNING:
For release the fuel pressure, start the engine and wait until fuel in fuel line is exhausted.
After the engine stop turn the ignition switch OFF.

NOTE:
Mark all wiring and hoses to avoid misconnection.

1. Disconnect the battery negative cable (A).
2. Remove the transmission system before removing the engine system.
3. Remove the strut bar (B).




4. Remove the drain plug (A) and drain the engine coolant.




5. After recovering refrigerant, remove the high & low pressure pipe.
6. Disconnect the breather hose (A), vacuum hose (B). And remove the air duct (C) and air cleaner assembly (D).

Tightening torque :
Bolt : 7.8 - 9.8N.m (0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)
Clamp : 2.9 - 4.9N.m (0.3 - 0.5kgf.m, 2.2 - 3.6lb-ft)




7. Remove the radiator upper hose (A).




8. Remove the intercooler inlet hose (A) and radiator lower hose (B).

Tightening torque :
Bolt : 14.7 - 19.6N.m (1.5 - 2.0kgf.m, 10.8 - 14.4lb-ft)
Clamp : 4.9 - 6.8 N.m (0.5 - 0.7kgf.m, 3.6 - 5.1lb-ft)




9. Remove the intercooler outlet hose (B) after disconnecting the BPS connector (A).




10. Remove the cooling fan.
(1) Remove the cooling fan connector (A).
(2) Remove the reservoir tank (B).
(3) Remove the fan assembly (C).




11. Disconnect the oil pressure (OPS) sensor (A) and remove the power steering oil hoses (B).




12. Disconnect the ECM connectors (A), brake oil level sensor connector (B) and ground (C).




13. Disconnect the brake booster vacuum hose (A), PCSV hose (B) and fuel hose (C).




14. Remove the alternator cable.
15. Disconnect the the battery (+) cable (A), wirings (B) and heater hoses (C).




16. Remove the engine mounting bracket nut (A) and bolt (B).

Tightening torque :
66.7 - 83.4N.m (6.8 - 8.5kgf.m, 49.2 - 61.5lb-ft)








17. Remove the hood.
18. Remove the engine assembly by lifting the engine jack.

CAUTION:
When removing the engine assembly, be careful not to damage any surrounding parts or body components.





Installation

Installation is in the reverse order of removal.

Perform the following :
- Adjust a shift cable.
- Adjust a throttle cable.
- Refill engine with engine oil.
- Refill a transaxle with fluid.
- Refill power steering fluid.
- Refill a radiator and a reservoir tank with engine coolant.
- Place a heater control knob on "HOT" position.
- Inspect for fuel leakage.
- After assemble the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes.
- Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
- Bleed air from the cooling system.
- Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.)
- Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system.
- Put radiator cap on tightly, then run the engine again and check for leaks.
- Clean battery posts and cable terminals and assemble.