Engine: Service and Repair
ENGINE AND TRANSAXLE ASSEMBLYREMOVAL
1. Remove the engine cover.
2. Disconnect the battery terminals.
3. Remove the battery and the battery tray.
4. Disconnect the air flow sensor connector and the vacuum hose from the air intake hose.
5. Remove the air cleaner assembly after removing the air intake hose clamp and fixing bolt (3ea).
6. Drain the engine coolant.
7. Drain the engine oil.
8. Drain the transaxle oil.
9. Disconnect the alternator B terminal, the alternator connector and the oil pressure switch connector.
10. Disconnect the crank angle sensor connector, the cam angle sensor connector, the injector harness connector, the power steering switch connector, the variable intake motor connector (2ea), the accelerator position sensor connector and the EGR solenoid connector.
11. Disconnect the injector connector after removing the injector harness bracket bolt (2ea).
CAUTION: When disconnect the injector connector, lift the fuel delivery pipe and injector assembly upward appropriately. At this time unscrew the mounting bolt to lift the fuel delivery pipe.
Reinstall the delivery pipe and injector assembly.
12. Disconnect the ignition coil harness connector, the oxygen sensor (front) connector and the knock sensor connector.
13. Disconnect the throttle position sensor connector, the Electronic Throttle System (ETS) motor connector, the limp-home connector and the purge solenoid valve connector.
14. Disconnect the water temperature sensor connector.
15. Disconnect the radiator upper hose and lower hose.
16. Remove the ground wire from the fuse box and the body frame.
17. Disconnect the inhibitor switch connector, the A/T solenoid connector, the input sensor, the output sensor and the speed sensor connector from the transaxle.
18. Remove the shift cable after removing the clip and nut.
19. Remove the ground wire from the transaxle assembly.
20. Remove the ground wire from the dash board panel.
21. Disconnect the heater hose from surge tank, and disconnect the heater hose(in, out) from dash board panel.
22. Remove the mounting nut between the front muffler and the catalytic converter.
23. Remove the mounting nut between the center muffler and the rear muffler. Remove the front muffler and center muffler assembly.
24. Disconnect the starter motor B terminal and connect after removing the starter motor cover.
25. Disconnect the power steering gear connector and remove the intermediate shaft.
26. Remove the wheel and tire.
27. Remove the drive shaft nut after removing a split pin from the front hub.
28. Remove the lower arm ball joint mounting bolt (2ea) from the knuckle.
29. Remove the tie rod end ball joint and sensor.
30. Remove the drive shaft from axle hub.
31. Remove the drive shaft from the transaxle.
32. Remove the under cover (bolt 3ea) in the right tire side.
33. Loosen the fixing bolt of the drive belt tensioner.
34. Loosen the drive belt tension by screwing the adjusting bolt of the drive belt tensioner.
35. Fix the air conditioner compressor to the body frame by using a wire after removing air conditioner compressor mounting bolt (4ea).
36. Remove the radiator upper member mounting bolt and the bonnet release cable.
37. Remove the radiator upper member from engine room, after disconnecting the horn connector.
38. Disconnect the cooling fan connector and the air condenser fan connector. Remove the fan assembly from engine room, after removing the fan assembly mounting bolt.
39. Remove the radiator mounting bolt (4ea) from the air conditioner condenser.
40. Remove the radiator from engine room, after disconnecting the radiator reserve hose.
41. Disconnect the fuel hoses.
42. Remove the sub frame mounting bolts and nuts.
43. Support the sub frame with a floor jack.
CAUTION: After removing the mounting bolt (engine and transaxle), the engine and transaxle assembly may fall downward, and so support them securely with floor jack.
Verify that the hoses and connectors are disconnected before removing the engine and the transaxle assembly.
44. Remove the engine mounting bolt and nut.
45. Remove the transaxle mounting bolt and nut.
46. Remove the sub frame, engine and transaxle assembly by lifting vehicle.
INSTALLATION
1. Install the sub frame, engine and transaxle assembly to engine room.
2. Install the transaxle mounting bolt and nut.
Tightening torque: 58.8 - 78.5 Nm (6 - 8 kg-m, 43.4 - 57.9 ft. lbs.)
3. Install the engine mounting bolt and nut.
Tightening torque: 58.8 - 78.5 Nm (6 - 8 kg-m, 43.4 - 57.9 ft. lbs.)
4. Install the sub frame bolt and nut.
Tightening torque: 98.1 - 117.7 Nm (10 - 12 kg-m, 72.3 - 86.8 ft. lbs.)
5. Reconnect the fuel hoses.
6. Install the radiator to vehicle and reconnect the radiator reserve hose.
7. Install the radiator mounting bolts(4ea) to the air conditioner condenser.
8. Install the cooling fan and the air conditioner condenser fan. And then reconnect the connectors.
9. Install the radiator upper member to vehicle, and then reconnect the horn connector.
10. Install the air conditioner compressor to the engine. (mounting bolt 4ea)
11. Install the drive belt and then apply tension by screwing the tension adjusting bolt.
12. Tighten the fixing bolt of the drive belt tensioner.
13. Install the under cover (bolt 3ea).
14. Install the drive shaft to the transaxle.
15. Install the drive shaft to the axle hub.
16. Install the tie rod end ball joint to the Buckle.
Tightening torque: 23.5 - 33.3 Nm (2.4 - 3.4 kg-m, 17.4 - 24.6 ft. lbs.)
17. Install the lower arm ball joint mounting bolt (2ea) to the knuckle.
Tightening torque: 98.1 - 117.7 Nm (10 - 12 kg-m, 72.3 - 86.8 ft. lbs.)
18. Install the drive shaft nut and install a split pin to the front hub.
Tightening torque: 196.1 - 274.6 Nm (20 - 28 kg-m, 144.7 - 202.5 ft. lbs.)
19. Install the intermediate shaft and reconnect the power steering gear connector.
20. Reconnect the starter motor B terminal and connector, and then install the starter motor cover.
21. Install the front muffler and center muffler assembly. And tighten the mounting nut between the center muffler and the rear muffler
Tightening torque: 39.2 - 58.8 Nm (4 - 6 kg-m, 28.9 - 43.4 ft. lbs.)
22. Tighten the mounting nut between the catalytic converter and the front muffler.
Tightening torque: 39.2 - 58.8 Nm (4 - 6 kg-m, 28.9 - 43.4 ft. lbs.)
23. Reconnect the heater hose to surge tank, and reconnect the heater hose(in, out) to dash board panel.
24. Install the ground wire to the dash board panel.
25. Install the ground wire to the transaxle assembly.
26. Install the shift cable with the clip and nut.
27. Reconnect the inhibitor switch connector, the A/T solenoid connector, the input sensor, the output sensor and the speed sensor connector to the transaxle.
28. Install the ground wire to the fuse box and the body frame.
29. Reconnect the radiator upper hose and lower hose.
30. Reconnect the water temperature sensor connector.
31. Reconnect the throttle position sensor connector, the Electronic Throttle System(ETS) motor connector, the limp home connector and the purge solenoid valve connector.
32. Reconnect the ignition coil harness connector, the oxygen sensor (front) connector and the knock sensor connector.
33. Reconnect the injector connector and install the injector harness bracket bolt (2ea).
34. Reconnect the crank angle sensor connector, the cam angle sensor connector, the injector harness connector, the power steering switch connector, the variable intake motor connector (2ea), the accelerator position sensor connector and the EGR solenoid connector.
35. Reconnect the alternator B terminal, the alternator connector and the oil pressure switch connector.
36. Install the air cleaner assembly with the air intake hose clamp and fixing bolt (3ea).
37. Reconnect the air flow sensor connector and the vacuum hose to the air intake hose.
38. Install the battery and the battery tray.
39. Refill the engine coolant, the engine oil and the transaxle oil.
40. Reconnect the battery terminal.
41. Install the engine cover.