Engine Assembly

Removal & Installation

2.0L Engine

To Remove:

1. Relieve the fuel system pressure.
2. Drain the coolant and engine oil.
3. Remove the under cover.
4. Remove the air cleaner.
5. Remove the hood.
6. Remove the radiator.
7. Remove the front exhaust pipe.
8. Remove the battery and tray.
9. Disconnect the accelerator cable.
10. Disconnect the electrical connectors from the following;
    • A/C compressor clutch
    • power steering pressure switch
    • crankshaft position sensor
    • manifold absolute pressure sensor
    • EVAP purge solenoid
    • EGR solenoid valve
    • ignition coils
    • fuel injectors
    • throttle position sensor
    • idle air control motor
    • engine coolant temperature sensor and gauge unit
    • camshaft position sensor
    • knock sensor
    • oxygen sensor
    • starter and generator
    • oil pressure switch
11. Disconnect the brake booster vacuum hose.
12. Remove the drive belt.
13. Remove the power steering pump without disconnecting the fluid lines. Secure the pump out of the way.
14. Remove the A/C compressor without disconnecting the refrigerant lines. Secure the compressor out of the way.
15. Disconnect the radiator hoses and remove the radiator.
16. Disconnect the heater hoses.
17. Disconnect the purge hose.
18. Disconnect the fuel lines.
19. Remove the transaxle.
20. Support the engine with a floor jack and replace the engine support (used during transaxle removal) with a suitable floor crane.
21. Remove the engine mount insulator.
22. Make sure all hoses, cables and wiring are disconnected from the engine and then carefully lift the engine from the vehicle.

To Install:

1. Carefully lower the engine into the vehicle. Support the engine with a floor jack and a block of wood. Remove the engine crane and install the engine support fixture.
2. Install the engine mount insulator.
3. Install the transaxle.
4. Connect the fuel lines.
5. Connect the purge hose.
6. Connect the heater hoses.
7. Connect the radiator hoses and remove the radiator.
8. Install the A/C compressor and power steering pump.
9. Install the drive belt.
10. Connect the brake booster vacuum hose.
11. Connect the electrical connectors to the following;
    • oil pressure switch
    • starter and generator
    • oxygen sensor
    • knock sensor
    • camshaft position sensor
    • engine coolant temperature sensor and gauge unit
    • idle air control motor
    • throttle position sensor
    • fuel injectors
    • ignition coils
    • EGR solenoid valve
    • EVAP purge solenoid
    • manifold absolute pressure sensor
    • crankshaft position sensor
    • power steering pressure switch
    • A/C compressor clutch
12. Connect the accelerator cable.
13. Install the battery and tray.
14. Install the front exhaust pipe.
15. Install the radiator.
16. Install the hood.
17. Install the air cleaner.
18. Install the under cover.
19. Refill the cooling system and add the correct amount of oil to the engine.
20. Check and adjust the transaxle fluid as necessary.

2.0L Turbo Engine

To Remove:

1. Relieve the fuel system pressure.
2. Remove the hood.
3. Remove the under cover and side cover.
4. Drain the coolant and engine oil.
5. Remove the strut tower bar.
6. Remove the air cleaner and air duct.
7. Remove the battery and tray.
8. Disconnect the accelerator cable.
9. Remove the center cover from the rocker cover.
10. Remove the radiator.
11. Remove the front axle crossmember bar.
12. Remove the front exhaust pipe.
13. Remove the air outlet fitting.
14. Disconnect the electrical connectors from the following;
    • ignition coils
    • oxygen sensor
    • crankshaft position sensor
    • manifold differential pressure sensor
    • fuel pressure solenoid
    • knock sensor
    • EVAP purge solenoid
    • throttle position sensor
    • idle air control motor
    • fuel injectors
    • camshaft position sensor
    • engine coolant temperature sensor
    • engine and transaxle wiring harness combination
15. Disconnect the ground cable.
16. Disconnect the generator wiring.
17. Disconnect the EGR vacuum regulator solenoid.
18. Disconnect the engine oil pressure switch.
19. Remove the turbo wastegate actuator bolts.
20. Remove the drive belt.
21. Disconnect the brake booster vacuum hose and EVAP purge hose.
22. Disconnect the power steering pressure switch.
23. Remove the heat shield from the power steering pump and then remove the pump without disconnecting the fluid lines. Secure the pump out of the way.
24. Remove the A/C compressor without disconnecting the refrigerant lines. Secure the compressor out of the way.
25. Disconnect the engine oil cooler.
26. Disconnect the heater hoses.
27. Disconnect the fuel lines.
28. Remove the transfer case and transaxle.
29. Support the engine with a floor jack and replace the engine support (used during transaxle removal) with a suitable floor crane.
30. Remove the engine mount insulator and cushion stopper assembly.
31. Make sure all hoses, cables and wiring are disconnected from the engine and then carefully lift the engine from the vehicle.

To Install:

1. Carefully lower the engine into the vehicle. Support the engine with a floor jack and a block of wood. Remove the engine crane and install the engine support fixture.
2. Install the engine mount insulator and cushion stopper assembly as shown.

Engine mount stopper installation direction

3. Install the transfer case and transaxle.
4. Connect the fuel lines.
5. Connect the heater hoses.
6. Connect the engine oil cooler.
7. Install the A/C compressor.
8. Install the power steering pump and shield.
9. Connect the power steering pressure switch.
10. Connect the brake booster vacuum hose and EVAP purge hose.
11. Install the drive belt.
12. Install the turbo wastegate actuator bolts.
13. Connect the engine oil pressure switch.
14. Connect the EGR vacuum regulator solenoid.
15. Connect the generator wiring.
16. Connect the ground cable.
17. Connect the electrical connectors to the following;
    • ignition coils
    • oxygen sensor
    • crankshaft position sensor
    • manifold differential pressure sensor
    • fuel pressure solenoid
    • knock sensor
    • EVAP purge solenoid
    • throttle position sensor
    • idle air control motor
    • fuel injectors
    • camshaft position sensor
    • engine coolant temperature sensor
    • engine and transaxle wiring harness combination
18. Install the air outlet fitting.
19. Install the front exhaust pipe.
20. Install the front axle crossmember bar.
21. Install the radiator.
22. Install the center cover on the rocker cover.
23. Connect the accelerator cable.
24. Install the battery and tray.
25. Install the air cleaner and air duct.
26. Install the strut tower bar.
27. Drain the coolant and engine oil.
28. Install the under cover and side cover.
29. Install the hood.
30. Refill the cooling system.
31. Check and adjust the transaxle and transfer case fluid.

2.4L Engine

To Remove:

1. Remove the under cover.
2. Relieve the fuel system pressure.
3. Drain the coolant and engine oil.
4. Drain the transaxle fluid.
5. Remove the hood.
6. Remove the strut tower brace.
7. Remove the engine cover.
8. Remove the air cleaner.
9. Remove the battery and tray.
10. Disconnect the accelerator cable.
11. Remove the radiator.
12. Remove the front exhaust pipe.
13. Remove the engine control wiring harness.
14. Remove the battery wiring harness.
15. Disconnect the EVAP hose connection.
16. Disconnect the brake booster vacuum hose.
17. Remove the drive belt.
18. Remove the power steering pump without disconnecting the fluid lines. Secure the pump out of the way.
19. Remove the A/C compressor without disconnecting the refrigerant lines. Secure the compressor out of the way.
20. Disconnect the heater hoses.
21. Disconnect the fuel lines.
22. Remove the transaxle.
23. Disconnect the ground cable.
24. Support the engine with a floor jack and replace the engine support (used during transaxle removal) with a suitable floor crane.
25. Remove the engine mount insulator.
26. Make sure all hoses, cables and wiring are disconnected from the engine and then carefully lift the engine from the vehicle.

To Install:

1. Carefully lower the engine into the vehicle. Support the engine with a floor jack and a block of wood. Remove the engine crane and install the engine support fixture.
2. Install the engine mount insulator. Do not tighten the insulator to final torque until the procedure is completed and the vehicle is resting on the suspension.
3. Install the transaxle.
4. Connect the ground cable.
5. Connect the fuel lines.
6. Connect the heater hoses.
7. Install the A/C compressor and power steering pump.
8. Install the drive belt.
9. Connect the brake booster vacuum hose.
10. Connect the EVAP hose.
11. Install the battery wiring harness.
12. Install the engine control wiring harness.
13. Install the front exhaust pipe.
14. Install the radiator.
15. Connect the accelerator cable.
16. Install the battery and tray.
17. Install the air cleaner.
18. Install the engine cover.
19. Install the strut tower brace.
20. Install the hood.
21. Install the under cover.
22. Refill the cooling system and add the correct amount of oil to the engine.
23. Check and adjust the transaxle fluid as necessary.