Engine Assembly

Removal & Installation

2.4L Engine

To Remove:

CAUTION
Parts marked with * should be hand-tightened initially, then completely tightened once the vehicle is on the ground with the full engine weight on the vehicle body.

1. Remove the hood.
2. Relieve the fuel system pressure.
3. Drain the engine oil.
4. Drain the engine coolant.
5. Remove the strut tower bar if equipped.
6. Remove the air cleaner.
7. Remove the thermostat case assembly.
8. Remove the reserve tank and radiator.
9. Remove the front exhaust pipe.
10. Disconnect the accelerator cable.
11. Disconnect the purge hose.
12. Disconnect the brake booster vacuum hose.
13. Disconnect the cruise control vacuum hose if equipped.
14. Disconnect the ignition coil connector.
15. Disconnect the injector.
16. Disconnect the manifold absolute pressure sensor.
17. Disconnect the throttle position sensor.
18. Disconnect the front heated oxygen sensor.
19. Disconnect the capacitor connector.
20. Disconnect the camshaft position sensor.
21. Disconnect the idle air control motor.
22. Disconnect the evaporative emission purge solenoid valve connector.
23. Disconnect the EGR vacuum regulator solenoid valve.
24. Disconnect the fuel high-pressure hose.
25. Disconnect the fuel return hose.
26. Disconnect the pressure hose.
27. Remove the oil dipstick and dipstick guide.
28. Disconnect the pressure hose.
29. Disconnect the heater hose.
30. Disconnect the generator connector.
31. Disconnect the oil pressure switch.
32. Remove the (power steering oil pump and A/C compressor) drive belt.
33. Remove the (generator) drive belt.
34. Disconnect the crankshaft position sensor.
35. Disconnect the power steering pressure switch.
36. Remove the power steering pump and bracket. Do not disconnect the fluid line and secure the pump out of the way.
37. Remove the A/C compressor. Do not disconnect the refrigerant line and secure the compressor out of the way.
38. Remove the transaxle assembly.
39. Remove the engine mount bracket.
40. Remove the engine mount stopper.
41. Attach a floor crane to the engine and remove the engine. When removing the engine assembly, make sure all the hoses, cables, and harness connectors are no longer connected to the engine, lift the chain block slowly to remove the engine assembly up from the engine compartment.

To Install:

CAUTION
Parts marked with * should be hand-tightened initially, then completely tightened once the vehicle is on the ground with the full engine weight on the vehicle body.

1. Install the engine assembly and make sure all hoses, cables, and harness connectors are not pinched or bent.
2. When installing the engine mount stopper, make sure to clamp it so the arrow points in the direction shown.

   Engine mount stopper installation

3. Install the engine mount bracket.
4. Remove the floor crane and support the engine assembly with an engine hanger such as special tool #MB991895.
5. Install the transaxle assembly.
6. Install the A/C compressor.
7. Install the power steering oil pump and bracket assembly.
8. Connect the power steering pressure switch.
9. Connect the crankshaft position sensor.
10. Install the (generator) drive belt.
11. Install the (power steering oil pump and A/C compressor) drive belt.
12. Connect the oil pressure switch.
13. Connect the generator.
14. Connect the heater hose.
15. Connect the pressure hose.
16. Install the oil dipstick and dipstick guide.
17. Connect the pressure hose.
18. Connect the fuel return hose.

    CAUTION
    Do not let any engine oil to get into the fuel rail.

19. When installing the fuel high-pressure hose, do the following:
    • Step 1: Put a small amount of clean engine oil onto the O-ring.
    • Step 2: As you rotate the fuel high-pressure hose to the right and left, install it onto the fuel rail, and be cautious not to damage the O-ring. After installation, make sure the hose turns smoothly.
    • Step 3: In the event the hose does not turn smoothly, the O-ring is most likely pinched. Disconnect the fuel high-pressure hose and examine the O-ring for damage. If necessary, replace the O-ring with a new one.
    • Step 4: Insert the fuel rail and make sure the hose turns smoothly.
20. Connect the EGR vacuum regulator solenoid valve.
21. Connect the evaporative emission purge solenoid valve.
22. Connect the idle air control motor.
23. Connect the engine coolant temperature gauge unit.
24. Connect the knock sensor.
25. Connect the camshaft position sensor.
26. Connect the engine coolant temperature sensor.
27. Connect the capacitor.
28. Connect the front heated oxygen sensor.
29. Connect the throttle position sensor.
30. Connect the manifold absolute pressure sensor.
31. Connect the injector.
32. Connect the ignition coil.
33. Connect the vacuum hose.
34. Connect the brake booster vacuum hose.
35. Connect the purge hose.
36. Connect the accelerator cable.
37. Install the front exhaust pipe.
38. Install the reserve tank and radiator.
39. Install the air cleaner.
40. Install the strut tower bar.
41. Check the drive belt tension.
42. Refill the engine oil.
43. Refill the engine coolant.
44. Adjust the accelerator cable.
45. Install the hood.

3.0L Engine

To Remove:

CAUTION
Parts marked with * should be hand-tightened initially, then completely tightened once the vehicle is on the ground with the full engine weight on the vehicle body.

1. Remove the hood.
2. Drain the engine oil.
3. Drain the engine coolant.
4. Remove the strut tower bar.
5. Remove the air cleaner.
6. Remove the reserve tank and radiator.
7. Remove the front exhaust pipe.
8. Disconnect the accelerator cable.
9. Disconnect the manifold absolute pressure sensor.
10. Disconnect the control wiring harness and power steering wiring harness combination connector.
11. Disconnect the EGR vacuum regulator solenoid valve.
12. Disconnect the evaporative emission purge solenoid valve connector.
13. Disconnect the knock sensor.
14. Disconnect the crankshaft position sensor.
15. Disconnect the right bank heated oxygen sensor.
16. Disconnect the injector.
17. Disconnect the distributor.
18. Disconnect the control wiring harness and injector wiring harness combination connector.
19. Disconnect the throttle position sensor.
20. Disconnect the idle air control motor.
21. Disconnect the ground wire.
22. Disconnect the engine coolant temperature gauge unit.
23. Disconnect the engine coolant temperature sensor.
24. Disconnect the left bank heated oxygen sensor.
25. Disconnect the starter.
26. Disconnect the ground wire.
27. Disconnect the generator.
28. Disconnect the oil pressure switch.
29. Disconnect the A/C compressor.
30. Disconnect the vacuum hose.
31. Disconnect the brake booster vacuum hose.
32. Disconnect the fuel high-pressure hose.
33. Disconnect the fuel return hose.
34. Disconnect the heater hose.
35. Disconnect the suction hose.
36. Remove the (generator and A/C compressor) drive belt.
37. Remove the (power steering oil pump) drive belt.
38. When removing the A/C compressor from the bracket, keep the hose attached.

    NOTE: After removing, put the A/C compressor in a place where it will not get in the way during the rest of the procedure, and secure it with a cord.

39. Disconnect the power steering pressure switch.
40. When removing the power steering oil pump and bracket assembly, keep the hose attached.

    NOTE: After removing, put the power steering oil pump in a place where it will not get in the way during the rest of the procedure, and secure it with a cord.

41. Disconnect the engine mount stay.

    CAUTION
    Be sure not to remove the flywheel mounting bolt because this will cause the flywheel to become out of balance and damaged.

42. When removing the transaxle assembly, do the following:
    • Step 1: Use an engine lifter (special tool #MZ203827) to remove the transaxle assembly.
    • Step 2: Using an engine hanger (special tool #MB991895 or #MB991928) to loosely fit the two radiator support upper insulator mounting bolts to the vehicle body.
    • Step 3: Remove the transaxle assembly.
    • When removing the engine mount bracket, do the following:
    • Step 1: Safely lift and support the engine with a jack.
    • Step 2: If using engine lifter (special tool #MZ203827), remove the engine hanger attachment set (special tool #MB991453) and the engine lifter (special tool #MZ203827), which were attached while the transaxle assembly was removed.
    • Step 4: If using engine hanger (special tool #MB991895), remove the engine hanger balancer (special tool #MB991454 [includes #MB991453]) and the engine hanger (special tool #MB991895) which were attached when the transaxle assembly was removed.
    • Step 5: If using engine hanger (special tool #MB991928), remove the engine hanger balancer (special tool #MB991454 [includes #MB991453]) and the engine hanger (special tool #MB991928) which were attached when the transaxle assembly was removed.
    • Step 6: Hold the engine assembly with a chain block or similar tool.
    • Step 7: Put a jack against the engine oil pan with a piece of wood in between, jack up the engine so that the weight of the engine is no longer being applied to the engine mount bracket, and then remove the engine mount bracket.
43. Remove the engine mount stopper.
44. When removing the engine assembly, make sure all the hoses, cables, and harness connectors are no longer connected to the engine, lift the chain block slowly to remove the engine assembly up from the engine compartment.

To Install:

CAUTION
Parts marked with * should be hand-tightened initially, then completely tightened once the vehicle is on the ground with the full engine weight on the vehicle body.

1. Install the engine assembly and make sure all hoses, cables, and harness connectors are not pinched or bent.
2. When installing the engine mount stopper, make sure to clamp it so the arrow points in the direction shown.

   Engine mount stopper installation

3. When installing the engine mount bracket, do the following:
   • Step 1: Put a jack against the engine oil pan with a piece of wood in between, and install the engine mount bracket while adjusting the position of the engine.
   • Step 2: Safely lift and support the engine with a jack.
   • Step 3: If you used engine lifter (special tool #MZ203827), remove the chain block and support the engine assembly with an engine hanger attachment set (special tool #MB991453) and an engine lifter (special tool #MZ203827).
   • Step 4: If you use engine hanger (special tool #MB991895), remove the chain block and support the engine assembly using an engine hanger (special tool #MB991895).
   • Step 5: If you use engine hanger (special tool #MB991928), assemble the engine hanger (#MB991928). Put the following parts onto the base hanger:
     1. Slide bracket
     2. Foot (short) (#MB991933)
     3. Foot (standard) (#MB991932)
     4. Joint (50) (#MB991929)
     5. Joint (90) (#MB991930)
     6. Joint (140) (#MB991931)
4. Remove the chain block and support the engine assembly an engine hanger (special tool #MB991895).
5. Install the transaxle assembly.
6. Install the engine mount stay.
7. Install the power steering oil pump.
8. Connect the power steering pressure switch.
9. Install the A/C compressor.
10. Install the (power steering oil pump) drive belt.
11. Install the (generator and A/C compressor) drive belt.
12. Connect the suction hose connector.
13. Connect the heater hose.
14. Connect the fuel return hose.

    CAUTION
    Do not let any engine oil to get into the fuel rail.

15. When installing the fuel high-pressure hose, do the following:
    • Step 1: Put a small amount of clean engine oil onto the O-ring.
    • Step 2: As you rotate the fuel high-pressure hose to the right and left, install it onto the fuel rail, and be cautious not to damage the O-ring. After installation, make sure the hose turns smoothly.
    • Step 3: In the event the hose does not turn smoothly, the O-ring is most likely pinched. Disconnect the fuel high-pressure hose and examine the O-ring for damage. If necessary, replace the O-ring with a new one.
    • Step 4: Insert the fuel rail and make sure the hose turns smoothly.
16. Connect the brake booster vacuum hose.
17. Connect the vacuum hose.
18. Connect the A/C compressor.
19. Connect the engine oil pressure switch.
20. Connect the generator.
21. Connect the ground wire.
22. Connect the starter.
23. Connect the left bank heated oxygen sensor.
24. Connect the engine coolant temperature sensor.
25. Connect engine coolant temperature gauge unit.
26. Connect the ground wire.
27. Connect the idle air control motor.
28. Connect the throttle position sensor.
29. Connect the control wiring harness combination connector.
30. Connect the distributor.
31. Connect the injector.
32. Connect the right bank heated oxygen sensor.
33. Connect the crankshaft position sensor.
34. Connect the knock sensor.
35. Connect the evaporative emission purge solenoid valve.
36. Connect the EGR vacuum regulator solenoid valve.
37. Connect the control wiring harness and power steering wiring harness combination connector.
38. Connect the manifold absolute pressure sensor.
39. Connect the accelerator cable.