Removal and Replacement
Engine Assembly Removal and Installation
Removal
1) Relieve fuel pressure. Service and Repair
2) Disconnect negative (-) and positive (+) cables at battery.
3) Disconnect ECM connectors.
4) Remove ECM, battery, battery tray and battery bracket. Service and Repair
5) Remove right and left side engine undercovers.
6) Remove right and left side front fender lower linings.
7) Remove front bumper and front bumper lower cover. Service and Repair
8) Remove engine cover.
9) Drain coolant. Draining
10) Drain the following oils and fluid if necessary.
- Engine oil: Service and Repair
- Manual transaxle oil (M/T model): Removal and Replacement
- CVT fluid (CVT model): Removal and Replacement
- Transfer oil (4WD model): Removal and Replacement
11) Disconnect the following electric wires, connectors and clamp:
- Connector (1) in main fuse box
- Connector (2) in fuse box No.1
- Connector (3) in fuse box No.2
- Engine harness connector to main harness connector (4) (CVT model)
- Battery ground cable (5)
- Engine harness clamp (6)
- Front height sensor connector (7)
12) Disconnect the following hoses:
- Brake booster hose (1)
- Heater inlet and outlet hoses (2)
- Fuel hose (3)
- EVAP canister purge hose (4)
- Radiator inlet hose (5)
- CVT Fluid Cooler No.1 Hose (6) (CVT model)
- CVT Fluid Cooler No.2 Hose (7) (CVT model)
13) Remove radiator outlet hose, thermostat cap and thermostat. Thermostat Removal and Installation
14) Remove battery ground terminal bolt (1) after disconnecting the following cables:
- Gear select control cable (2) (M/T model): Manual Transaxle Unit Components
- Gear shift control cable (3) (M/T model): Manual Transaxle Unit Components
- Battery ground terminal bolt (M/T model): Manual Transaxle Unit Components
- Select cable (4) (CVT model): Select Cable Components
15) Remove accessory drive belt. Removal and Installation
16) With A/C hoses connected, remove A/C compressor from bracket. A/C Compressor Assembly 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.
17) Remove front brake caliper and brake pads. Front Brake Pad Removal and Installation
18) Remove front wheel speed sensor harness clamp bolt, and then detach front speed sensor harness from strut bracket. Front Wheel Speed Sensor Removal and Installation
19) Remove front strut nuts and bolts referring to steps 1) to 5) in "removal" under Front Strut Assembly Removal and Installation Front Strut Assembly Removal and Installation.
20) Remove floor tunnel front brace (1).
21) Remove exhaust pipe No.1 and heat protector panel No.1. Exhaust System Components
22) For 4WD model, remove propeller shaft assembly. Propeller Shaft Assembly Removal and Installation
23) Remove steering lower shaft referring to steps 4) to 7) in "removal" under Steering Column Removal and Installation Steering Column Removal and Installation.
24) Remove P/S control module cover after turning over passenger side carpet, disconnect P/S control module connector (1) and remove ground bolt (2). Then, pull the harness (3) out to engine compartment.
25) Disconnect ground cable (1) from suspension frame rear mounting bracket and body.
26) Support suspension frame (1) and engine assembly (2) using engine lifter.
27) Remove suspension frame mounting brackets. Front Suspension Frame Components
28) Remove engine left mounting bracket (1).
29) Remove engine right mounting bracket nuts (1), then loosen engine right mounting bolts (2).
30) Before lowering engine, make sure that all hoses, electric wires and cables are disconnected from engine.
31) Lower engine assembly with transaxle, transfer (4WD model), front drive shafts and suspension frame all together.
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.
NOTE:
Prior to removing engine rear mounting bracket No.1 on 4WD model, it is necessary to remove transfer and disconnect engine rear mounting bracket No.2.
32) Remove front drive shaft assembly if necessary. Front Drive Shaft Assembly Removal and Installation
33) For 4WD model, remove transfer if necessary. Removal and Replacement
34) Remove engine mounting bracket from engine assembly if necessary. [1][2]Diagrams
35) Remove transaxle if necessary.
- M/T model: Manual Transaxle Unit Dismounting and Remounting
- CVT model: CVT Assembly Dismounting and Remounting
36) For M/T model, remove clutch cover and clutch disc if necessary. Clutch Cover and Clutch Disc Removal and Installation
37) For M/T model, remove flywheel if necessary. Flywheel / Drive Plate Removal and Installation
For CVT model, remove drive plate if necessary. Flywheel / Drive Plate Removal and Installation
38) Remove engine harness from engine assembly if necessary.
Installation
1) Install engine harness to engine assembly if removed.
2) For M/T model, install flywheel if removed. Flywheel / Drive Plate Removal and Installation
3) For CVT model, install drive plate if removed. Flywheel / Drive Plate Removal and Installation
4) For M/T model, install clutch cover and clutch disc if removed. Clutch Cover and Clutch Disc Removal and Installation
5) Install transaxle to engine if removed.
- For M/T model: Manual Transaxle Unit Dismounting and Remounting
- For CVT model: CVT Assembly Dismounting and Remounting
6) Install engine mounting bracket to engine assembly if removed. [1][2]Diagrams
7) For 4WD model, install transfer if removed. Removal and Replacement
8) Install front drive shaft assembly if removed. Front Drive Shaft Assembly Removal and Installation
9) Lift up engine assembly together with transaxle, transfer (4WD model), front drive shafts and suspension frame into engine compartment using engine lifter.
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.
10) Tighten engine right mounting bracket bolts and nuts to specified torque. [1][2]Diagrams
11) Install left mounting bracket, then tighten left mounting bracket bolts and nuts to specified torque. [1][2]Diagrams
12) Install suspension frame mounting brackets, then tighten suspension frame mounting bracket bolts to specified torque. Front Suspension Frame Components
13) Connect ground cable to suspension frame mounting bracket and body, then tighten ground cable bolts (1) to specified torque.
Tightening torque
Ground cable bolt (a): 9.0 Nm (0.92 kgf-m, 7.0 lbf-ft)
14) Insert EPS harness (3) into cabin, connect P/S control module connector (1), tighten ground bolt (2) to specified torque, and then install P/S control module cover.
Tightening torque
P/S control module ground bolt (a): 9.0 Nm (0.92 kgf-m, 7.0 lbf-ft)
15) Connect steering lower shaft to pinion shaft, then tighten lower joint bolt to specified torque. Steering Column Removal and Installation
16) For 4WD model, install propeller shaft assembly. Propeller Shaft Assembly Removal and Installation
17) Install exhaust pipe No.1 and heat protector panel No.1. Exhaust System Components
18) Install floor tunnel front brace (1).
19) Tighten front strut bolts and nuts to specified torque. Front Strut Assembly Removal and Installation
20) Connect front wheel speed sensor harness to strut bracket, then tighten front wheel speed sensor harness clamp bolt. Front Wheel Speed Sensor Removal and Installation
21) Install brake pads and caliper. Front Brake Pad Removal and Installation
22) Install A/C compressor to bracket. A/C Compressor Assembly Removal and Installation
23) Install accessory drive belt. Removal and Installation
24) For M/T model, connect gear select control cable, gear shift control cable, then tighten battery ground terminal bolt to specified torque. Manual Transaxle Unit Components
25) For CVT model, connect select cable. Select Cable Components
26) Install thermostat, thermostat cap and radiator outlet hose. Thermostat Removal and Installation
27) Install engine harness clamps.
28) Install all other removed electric wires, connectors and hoses to original locations.
29) Tighten battery ground terminal bolts (1) to specified torque.
Tightening torque
Battery ground terminal bolts (a): 9.0 Nm (0.92 kgf-m, 7.0 lbf-ft)
30) Install air cleaner assembly. Air Cleaner Assembly Removal and Installation
31) Refill oils and fluid.
- Engine oil: Service and Repair
- Manual transmission oil (M/T model): Removal and Replacement
- CVT fluid (CVT model): Removal and Replacement
- Transfer oil (4WD model): Removal and Replacement
32) Refill cooling system with coolant. Refilling
33) Install right and left side engine undercovers.
34) Install battery bracket, battery tray, battery and ECM. Service and Repair
35) Connect ECM connectors.
36) Connect positive (+) cables and negative (-) at battery.
37) Check any leakage of fuel, coolant, oil and exhaust.
- Fuel leak: Fuel Leakage Check Procedure
- Coolant leak: Initial Inspection and Diagnostic Overview
38) Install engine cover.
39) Install front bumper and front bumper lower cover. Service and Repair
40) Install right and left side front fender lower linings.