Engine Assembly Removal and Installation

NOTICE:

For A/C model, 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.

Removal

1)Relieve fuel pressure.

2)Remove battery and battery tray.

3)Hoist vehicle and remove engine undercover.

4)Remove front fender lining, if necessary.

5)Drain the following oils.

•Engine oil:

•Manual transaxle oil (M/T model):

•Transfer oil (4WD model):

6)Drain coolant.

7)Remove air cleaner assembly.

8)For M/T model, disconnect clutch hose from clutch pipe joint.

9)Disconnect the following electric wires/connectors and each clamp.

•ECM connector (1)
•Battery ground cable (M/T model) (2)
•Connectors (3) in main fuse box
•Connector (4) in individual circuit fuse box No.1
•Battery ground cable (A/T model) (5)

10)Disconnect the following cables.

•M/T model: Gear shift and select control cables

•A/T model: Select cable

11)Disconnect the following hoses.

•Radiator inlet hose (1)
•Radiator outlet hose (2)
•Brake booster hose (3)
•Heater inlet hose (4)
•Heater outlet hose (5)
•Fuel feed hose (6)
•Canister purge hose (7)

12)For A/C model, with hose connected, detach A/C compressor from its bracket.

•Manual A/C model:

•Auto A/C model:

13)Disconnect steering lower shaft from pinion shaft.

14)Remove stabilizer bar joints from stabilizer bar.

15)Disconnect tie-rod end from steering knuckle.

16)Disconnect right and left drive shaft joints from steering knuckle.

17)Disconnect suspension arm from steering knuckle.

18)Remove exhaust No.1 pipe and center pipe.

19)For 4WD model, remove propeller shaft.

20)Remove suspension frame.

21)Support transaxle and engine assembly using jack.

22)Remove engine right mounting (1).

NOTE:

As engine mounting stud bolts (2) are installed at an angle on the engine, removal of engine right mounting facilitates dismounting the engine.

[A]:	Nut and bolt – tightening engine right mounting
[B]:	Nut – tightening engine right mounting

23)Remove engine left mounting No.2 bracket bolt (1) and nuts (2).

24)Before removing engine, check that all hoses, electric wires and cables are disconnected from engine.

25)Lower engine, transaxle and drive shafts all together.

26)Remove engine harness from engine and transaxle, if necessary.

27)For 4WD model, remove transfer, if necessary.

28)Disconnect transaxle from engine, if necessary.

•M/T model:

•A/T model:

29)For M/T model, remove clutch cover and clutch disc, if necessary.

30)For M/T model, remove flywheel, if necessary.

31)For A/T model, remove drive plate, if necessary.

32)Remove engine left mounting No.1 bracket, if necessary.

Installation

1)Install engine left mounting No.1 bracket, if removed.

2)For M/T model, tighten engine left mounting No.1 bracket bolts in numerical order as shown in figure.

a)Temporarily engine left mounting No.1 bracket bolts (1).

b)Tighten engine left mounting No.1 bracket bolts to specified torque in numerical order (“1 – “2”).

Tightening torque

Engine left mounting No.1 bracket bolt* (a): 55 N·m (5.6 kgf-m, 40.5 lbf-ft)

3)For M/T model, install flywheel, if removed.

4)For A/T model, install drive plate, if removed.

5)For M/T model, install clutch cover and clutch disc, if removed.

6)Install transaxle to engine, if removed.

•M/T model:

•A/T model:

7)For 4WD model, install transfer, if removed.

8)Install engine harness to engine and then tighten engine harness ground bolts to specified torque, if removed.

Tightening torque

Engine harness ground bolt (a): 11 N·m (1.1 kgf-m, 8.5 lbf-ft)

9)Lift up engine, transaxle and drive shafts all together.

10)Install engine right mounting (1) and tighten the following bolts and nuts to specified torque.

Tightening torque

Engine right mounting bolt (a): 55 N·m (5.6 kgf-m, 40.5 lbf-ft)
Engine right mounting nut (b): 55 N·m (5.6 kgf-m, 40.5 lbf-ft)
Engine right mounting nut (c): 70 N·m (7.1 kgf-m, 52.0 lbf-ft)

[A]:	Nut and bolt – tightening engine right mounting
[B]:	Nut – tightening engine right mounting

11)Tighten engine left mounting No.2 bracket bolt and nuts to specified torque.

Tightening torque

Engine left mounting No.2 bracket bolt (a): 55 N·m (5.6 kgf-m, 40.5 lbf-ft)
Engine left mounting No.2 bracket nut (b): 55 N·m (5.6 kgf-m, 40.5 lbf-ft)

12)Install suspension frame.

13)For 4WD model, install propeller shaft.

14)Install exhaust No.1 pipe and center pipe.

15)Connect suspension arm to steering knuckle.

16)Connect right and left drive shaft joints to steering knuckle.

17)Connect tie-rod end to steering knuckle.

18)Install stabilizer bar joints to stabilizer bar.

19)Connect steering lower shaft to pinion shaft.

20)Install all other removed electric wires, connectors and hoses to original positions.

21)Tighten battery ground cable bolt (1) to specified torque.

Tightening torque

Battery ground cable bolt (a): 25 N·m (2.5 kgf-m, 18.5 lbf-ft)

M/T model

A/T model

22)Connect the following cables.

•M/T model: Gear shift and select control cables

•A/T model: Select cable

23)For A/C model, install A/C compressor to its bracket.

•Manual A/C model:

•Auto A/C model:

24)Install battery and battery tray.

25)Install air cleaner assembly.

26)Check that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.

27)Refill engine, transaxle and transfer with oil.

•Engine oil:

•Manual transaxle oil (M/T model):

•Transfer oil (4WD model):

28)For M/T model, install clutch fluid pipe.

29)Connect positive (+) and negative (–) cables at battery.

30)Refill cooling system with coolant.

31)Check for leakage of fuel, coolant, oil and exhaust gas.

•Fuel leakage:

•Coolant leakage:

32)Install front fender lining, if removed.

33)Install engine undercover.