Engine Assembly Removal and Installation
Precautions: General safety (00)
Removal
1)Relieve fuel pressure. 
2)Remove battery and bracket.
3)Remove ECM and ECM bracket.
4)Hoist vehicle and remove engine undercover.
5)Remove front fender linings.
6)Drain the following oils.
•Engine oil:
•Manual transaxle oil (M/T model):
•Transfer oil (4WD model):
•Manual transaxle oil (M/T model):
•Transfer oil (4WD model):
7)Drain coolant.
8)Disconnect steering lower shaft from pinion shaft.
9)Remove air cleaner assembly and air cleaner outlet hose.
10)For M/T model, disconnect clutch fluid pipe from clutch pipe joint.
11)Disconnect the following cables.
•M/T model: Gear shift and select control cables
•A/T model: Select cable
•A/T model: Select cable
12)Disconnect the following connectors and cable including the related clamps.
•Connectors (1) in main fuse box
•Connector (2) in individual circuit fuse box No.1
•Battery ground cable (3)
•Connector (2) in individual circuit fuse box No.1
•Battery ground cable (3)
| [A]: | M/T model | [B]: | A/T model |
13)Disconnect the following hoses.
•EVAP canister purge valve hose (1)
•Heater inlet hose (2)
•Heater outlet hose (3)
•Brake vacuum pump hose (4)
•Fuel feed hose No.1 (5)
•Turbocharger water outlet hose (6)
•Intercooler inlet hose (7)
•Intercooler outlet hose No.1 (8)
•Radiator inlet hose No.2 (9)
•Radiator outlet hose No.2 (10)
•Heater inlet hose (2)
•Heater outlet hose (3)
•Brake vacuum pump hose (4)
•Fuel feed hose No.1 (5)
•Turbocharger water outlet hose (6)
•Intercooler inlet hose (7)
•Intercooler outlet hose No.1 (8)
•Radiator inlet hose No.2 (9)
•Radiator outlet hose No.2 (10)
14)With hoses connected, detach A/C compressor from cylinder block.
15)Remove stabilizer bar joints from stabilizer bar.
16)Disconnect tie-rod end from steering knuckle at each of right and left sides.
17)Disconnect suspension arm joint from steering knuckle at each of right and left sides.
18)Disconnect right and left drive shaft joints from steering knuckle.
19)Remove exhaust No.1 pipe and center pipe.
20)For 4WD model, remove propeller shaft.
21)Support front suspension frame (1), transaxle case (2) and oil pan (3) using jack.
22)Remove front suspension frame bolts (4).
23)Remove engine right mounting bolt (1) and nuts (2).
24)Remove engine left mounting bolt (1) and nuts (2).
25)Before removing engine, check that all hoses, electric wires and cables are disconnected from engine.
26)Lower engine assembly with transaxle, front suspension frame, drive shafts, steering gear case all together.
NOTICE:
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 of the engine assembly.
27)Remove WGV-VSV.
28)Remove intercooler outlet pipe.
29)Remove engine cover bracket No.1 (1).
30)Install a suitable hook (1) with bolt and nut as shown in figure and lift engine, if necessary, with transaxle and suspension frame assembled, using this hook and another hook (2) on transaxle.
| [A]: | M/T model | [B]: | A/T model |
31)Remove front drive shaft assemblies, if necessary.
32)Remove front suspension frame, if necessary.
33)Install a suitable hook (1) with bolt and nut as shown in figure and lift engine assembly, if necessary, using this hook and another hook (2) on engine.
34)Remove the following components from engine assembly, if necessary.
•Engine harness
•Transfer (4WD model):
•Transaxle
•Flywheel (M/T model):
•Drive plate (A/T model):
•Transfer (4WD model):
•Transaxle
—M/T model:
—A/T model:
•Clutch cover and disc (M/T model): —A/T model:
•Flywheel (M/T model):
•Drive plate (A/T model):
Installation
1)Install the following components to engine, if removed.
•Flywheel (M/T model):
•Drive plate (A/T model):
•Clutch disc and cover (M/T model):
•Transaxle
•Engine harness
•Drive plate (A/T model):
•Clutch disc and cover (M/T model):
•Transaxle
—M/T model:
—A/T model:
•Transfer (4WD model): —A/T model:
•Engine harness
2)Set engine harness ground cable to its original position and tighten engine harness ground bolt (1) to specified torque, if removed.
3)Install front suspension frame, if removed.
4)Install front drive shaft assemblies, if removed.
5)Install engine cover bracket No.1 (1).
6)Install intercooler outlet pipe.
7)Install WGV-VSV.
8)Lift up engine assembly with transaxle, front suspension frame, drive shafts and P/S gear case all together.
NOTICE:
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 installation of the engine assembly.
9)Tighten engine left mounting nuts (1) and bolt (2) to specified torque.
Engine left mounting bolt (b): 55 N·m (5.6 kgf-m, 40.5 lbf-ft)
Tightening torque
Engine left mounting nut (a): 55 N·m (5.6 kgf-m, 40.5 lbf-ft)Engine left mounting bolt (b): 55 N·m (5.6 kgf-m, 40.5 lbf-ft)
10)Tighten new engine right mounting nuts (1) and new bolt (2) to specified torque.
Engine right mounting bolt (b): 90 N·m (9.2 kgf-m, 66.5 lbf-ft)
Tightening torque
Engine right mounting nut (a): 90 N·m (9.2 kgf-m, 66.5 lbf-ft)Engine right mounting bolt (b): 90 N·m (9.2 kgf-m, 66.5 lbf-ft)
11)Tighten front suspension frame bolts to specified torque.
12)Remove jack.
13)For 4WD model, install propeller shaft.
14)Install exhaust No.1 pipe and center pipe.
15)Connect right and left drive shaft joints to steering knuckle.
16)Connect suspension arm joint to steering knuckle at each of right and left sides.
17)Connect tie-rod end to steering knuckle at each of right and left sides.
18)Install stabilizer bar joints to stabilizer bar.
19)Install all other removed electric wires, connectors and hoses to original positions.
20)Tighten battery ground cable bolt (1) to specified torque.
M/T model
A/T model
21)Connect the following cables.
•M/T model: Gear shift and select control cables
•A/T model: Select cable
•A/T model: Select cable
22)Install A/C compressor to cylinder block.
23)Check that removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
24)Refill engine, transaxle and transfer with oil.
•Engine oil:
•Manual transaxle oil (M/T model):
•Transfer oil (4WD model):
•Manual transaxle oil (M/T model):
•Transfer oil (4WD model):
25)For M/T model, connect clutch fluid pipe to clutch pipe joint.
26)Install ECM and ECM bracket.
27)Install battery and bracket.
28)Install air cleaner assembly and air cleaner outlet hose.
29)Connect steering lower shaft to pinion shaft.
30)Connect positive (+) and negative (–) cables at battery.
31)Refill cooling system with coolant.
32)Check for leakage of fuel, coolant, oil and exhaust gas.
•Fuel leakage:
•Coolant leakage:
•Coolant leakage:
33)Install front fender linings.
34)Install engine undercover.