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.
NOTE:
Mark all wiring and hoses to avoid misconnection.
1. Disconnect the battery terminals and remove the battery.
2. Remove the engine cover (A).
3. Remove the air duct (A).
4. Disconnect the breather hose (A), ECM connector (B) and remove the air cleaner assembly (C).
Tightening torque :
7.8 - 11.8N.m (0.8 - 1.2kgf.m, 5.8 - 8.7lb-ft)
5. Remove the front wheels.
Tightening torque :
88.3 - 107.9N.m (9.0 - 11.0kgf.m, 65.1 - 79.6lb-ft)
6. Remove the under cover (A).
Tightening torque :
8.8 - 10.8N.m (0.9 - 1.1kgf.m, 6.5 - 7.9lb-ft)
7. Remove the drain plug and drain the engine coolant.
8. Remove the radiator upper hose (A) and lower hose (B).
9. Remove the heater hoses (A).
10. Disconnect the VIS connector (A), OPS connector (B), knock sensor connector (C) and A/C switch connector (D).
11. Disconnect the intake OCV connector (A).
12. Disconnect the injector connectors (A) and ignition coil connectors (B).
13. Disconnect the ETC connector (A) and MAP sensor connector (B).
14. Disconnect the CMP sensor connector (A) and fuel hose (B).
15. Disconnect the PCSV connector (A), ECT connector (B), condenser connector (C), CKP sensor connector (D), CMP sensor connector (E) and brake booster vacuum hose (F).
16. Disconnect the alternator connector (A), and 'B' terminal cable (B).
17. Disconnect the starter connector (A), and cable (B).
18. Disconnect the exhaust OCV connector (A).
19. Remove the power steering oil hose (A).
20. Disconnect the transaxle control cable and wiring connectors.
21. Recover refrigerant and remove the high & low pressure pipe. .
22. Disconnect the EPS connector (A).
23. Remove the lower arm (B) & fork (A) mounting bolt (C).
Tightening torque :
137.3 - 156.9N.m (14.0 - 16.0kgf.m, 101.3 - 115.7lb-ft)
24. Remove the lower arm ball joint mounting bolts (A).
Tightening torque :
98.1 - 117.7N.m (10.0 - 12.0kgf.m, 72.3 - 86.8lb-ft)
25. Remove the stabilizer bar link mounting nut (A).
Tightening torque :
98.1 - 117.7N.m (10.0 - 12.0kgf.m, 72.3 - 86.8lb-ft)
26. Remove the split pin and castle nut and then disconnect the tie rod end (A) with the knuckle.
Tightening torque :
23.5 - 33.3N.m (2.4 - 3.4kgf.m, 17.4 - 24.6lb-ft)
27. Disconnect the driveshaft form the axle hub.
28. Remove power steering return hose (A) and drain power steering oil.
29. Remove steering u-joint mounting bolt (A).
Tightening torque :
17.7 - 24.5N.m (1.8 - 2.5kgf.m, 13.0 - 18.1lb-ft)
30. Disconnect the O2 sensor connector (A) and remove the front muffler (B).
Tightening torque :
39.2 - 58.8N.m (4.0 - 6.0kgf.m, 28.9 - 43.4lb-ft)
31. Support the sub frame (A) with a floor jack then remove the stay (B) and sub frame mounting bolts.
Tightening torque :
137.3 - 156.9N.m (14.0 - 16.0kgf.m, 101.3 - 115.7lb-ft)
Tightening torque :
44.1 - 58.8N.m (4.5 - 6.0kgf.m, 32.5 - 43.4lb-ft)
32. Disconnect the ground line and remove the engine mounting bracket (A).
Tightening torque :
63.7 - 83.4N.m (6.5 - 8.5kgf.m, 47.0 - 61.5lb-ft)
33. Remove the transaxle mounting bracket bolt (A).
Tightening torque :
63.7 - 83.4N.m (6.5 - 8.5kgf.m, 47.0 - 61.5lb-ft)
34. Lift up the vehicle and remove the engine and transaxle assembly from the vehicle.
CAUTION:
When remove the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.
Installation
Installation is in the reverse order of removal.
Perform the followings :
- Adjust a shift cable.
- Adjust a throttle cable.
- Refill engine with engine oil.
- Refill a transaxle with fluid.
- Refill a radiator and a reservoir tank with engine coolant.
- Place a heater control knob on "HOT" position.
- 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 with sandpaper assemble them, then apply grease to prevent corrosion.
- 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.