ENGINE REMOVAL/INSTALLATION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)]

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Warning
•  A hot engine can cause severe burns. Turn off the engine and wait until it is cool before servicing.
•  Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
•  Highly pressurized fuel may spray out if the fuel line is cut. Due to the following dangers occurring with a fuel spray, always complete the “Fuel Line Safety Procedure” to prevent the fuel from spraying.
―  Fuel may cause irritation if it comes in contact with skin and eyes.
―  If fuel ignites and causes a fire, it may lead to serious injury or death, and damage to property and facilities.
Caution
•  Secure the steering wheel using tape or a cable to prevent the steering shaft from rotating after disconnecting the steering shaft. If the steering wheel rotates after the steering shaft and the steering gear and linkage are disconnected, the internal parts of the clock spring could be damaged.
•  Applying excessive force (force of 100 N {10.2 kgf, 22.5 lbf} or more) to the electric variable valve timing motor/driver may cause a malfunction. When servicing, be careful not to apply excessive force to the electric variable valve timing motor/driver using other parts or tools.
Note
•  Perform the engine and transaxle component removal/installation from below the vehicle.

Engine Removal

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

2.  Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

3.  Remove the air cleaner, air hose and fresh air duct as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

4.  Remove the PCM component. (See PCM REMOVAL/INSTALLATION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

5.  Remove the bolts, nut and connector shown in the figure, and set the wiring harness aside.

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6.  Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

7.  Remove the bolt and clips, and set the ground cable aside.

RH

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LH

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8.  Disconnect the selector cable. (ATX) (See SELECTOR CABLE REMOVAL/INSTALLATION.)

9.  Disconnect the control cable. (MTX) (See CONTROL CABLE REMOVAL/INSTALLATION [C66M-R, C66MX-R].)

10.  Remove the clutch release cylinder with the pipe still connected. (MTX) (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION [C66M-R, C66MX-R].)

11.  Disconnect the vacuum hose. (See VACUUM HOSE REMOVAL/INSTALLATION [L.H.D. (WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5))].) (See VACUUM HOSE REMOVAL/INSTALLATION [R.H.D. (WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5))].)

12.  Disconnect the fuel hose. (See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

13.  Disconnect the evaporative hose No.3. (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

14.  Disconnect the heater hose. (See A/C UNIT REMOVAL/INSTALLATION.)

15.  Remove the front under cover No.1 and No.2. (See FRONT UNDER COVER No.1 REMOVAL/INSTALLATION.) (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

16.  Remove the front splash shield. (See SPLASH SHIELD REMOVAL/INSTALLATION.)

17.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

18.  Drain the transaxle oil (MTX) or ATF (ATX). (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [FW6A-EL, FW6AX-EL].) (See MANUAL TRANSAXLE OIL REPLACEMENT [C66M-R, C66MX-R].)

19.  Drain the transfer oil. (4WD) (See TRANSFER OIL REPLACEMENT [FW6AX-EL, GW6AX-EL].)

20.  Remove the front wheels and tires. (See WHEEL AND TIRE REMOVAL/INSTALLATION.)

21.  Remove the bracket shown in the figure from the throttle body.

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22.  Disconnect the upper radiator hose from the coolant control valve.

23.  Disconnect the lower radiator hose from the radiator.

24.  Remove the generator drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

25.  Remove the A/C compressor with the cooler hose still connected and secure it using wire or rope so that it is out of the way. (See A/C COMPRESSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

26.  Remove the TWC installation nuts (exhaust manifold side) and secure the TWC using wire or rope so that it is out of the way. (2WD) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

27.  Remove the TWC. (4WD) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

28.  Remove the propeller shaft. (4WD) (See PROPELLER SHAFT REMOVAL/INSTALLATION.)

29.  Disconnect the front drive shaft (LH) from the transaxle side and set the front drive shaft (LH) out of the way. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)

30.  Disconnect the front drive shaft (RH) from the transaxle side and set the front drive shaft (RH) out of the way.(2WD) (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)

31.  Remove the front drive shaft (RH).(4WD) (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)

32.  Disconnect the service plug. (With i-ELOOP) (See SERVICE PLUG DISCONNECTION/CONNECTION [i-ELOOP].)

33.  Disconnect the generator terminal B cable. (With i-ELOOP) (See GENERATOR REMOVAL/INSTALLATION [WITH i-ELOOP (SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION))].)

34.  Remove the clips shown in the figure and set the wiring harness aside. (With i-ELOOP).

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35.  Remove the front crossmember component and No.1 engine mount rubber as a single unit. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

36.  Remove in the order indicated in the table.

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1
No.4 engine mount bracket
(See No.3 engine mount, No.4 engine mount bracket removal note.)
2
No.3 engine mount
(See No.3 engine mount, No.4 engine mount bracket removal note.)
3
Engine, transaxle


No.3 engine mount, No.4 engine mount bracket removal note

Warning
•  When removing/installing the engine, verify that the engine and transaxle are securely supported. Otherwise, the engine may fall off and cause serious injury or death, and damage to the vehicle.
Caution
•  When supporting the engine and transaxle, insert rubber of appropriate size (approx. 20 mm {0.79 in} thickness) between the engine lifter and the oil pan, transaxle to prevent the deformation of the oil pan and damage of the transaxle.

1.  Secure the engine and transaxle using a commercially available engine lifter.

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2.  Remove the No.4 engine mount bracket.

3.  Remove the No.3 engine mount.


Engine Installation

Warning
•  When removing/installing the engine, verify that the engine and transaxle are securely supported. Otherwise, the engine may fall off and cause serious injury or death, and damage to the vehicle.
Caution
•  Slots have been adopted for the No.3 engine mount and No.4 engine mount bracket installation holes. Tighten the installation bolts and nuts so that they are centered on the slots. Otherwise, engine noise or vibration could increase.
Note
•  Retighten the engine front cover and transaxle stud bolts when the nuts of No.3 engine mount and No.4 engine mount bracket are loosened.

1.  Tighten the engine front cover stud bolts.

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Tightening torque
7—13 N·m {72—132 kgf·cm, 62—115 in·lbf}

2.  Measure the projection of the transaxle stud bolts. (MTX)

•  If the projection amount is not within the range, adjust the projection amount of the stud bolt.
Projection A of stud bolt No.1
40—42 mm {1.58—1.65 in}
Projection B of stud bolt No.2
30.7—32.7 mm {1.21—1.28 in}
Projection C of stud bolt No.3
70.7—72.7 mm {2.79—2.86 in}

3.  Tighten the transaxle stud bolts. (ATX)

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Tightening torque
15—25 N·m {1.6—2.5 kgf·m, 12—18 ft·lbf}

Caution
•  When supporting the engine and transaxle, insert rubber of appropriate size (approx. 20 mm {0.79 in} thickness) between the engine lifter and the oil pan, transaxle to prevent the deformation of the oil pan and damage of the transaxle.

4.  Secure the engine and transaxle using a commercially available engine lifter.

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5.  Return the engine and transaxle to their original positions.

6.  Temporarily tighten the No.3 engine mount installation bolts and nuts using the following procedure:

(1)  Temporarily tighten the bolts so that the bolt holes of the body are centered on the No.3 engine mount slots.
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(2)  Temporarily tighten the nuts so that the stud bolts of the engine front cover are centered on the No.3 engine mount slots.
•  If the stud bolts are deviated from the center of the slots, align the stud bolts with the center of the slots while slightly moving the engine, and temporarily tighten the installation nuts.
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7.  Temporarily tighten the No.4 engine mount bracket installation bolt and nuts using the following procedure:

(1)  Temporarily tighten the bolt shown in the figure.

MTX

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ATX

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(2)  Temporarily tighten the nuts so that the stud bolts of the transaxle are centered on the No.4 engine mount bracket slots.
•  If the stud bolts are deviated from the center of the slots, align the stud bolts with the center of the slots while slightly moving the transaxle, and temporarily tighten the installation nuts.

MTX

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ATX

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8.  Install the No.1 engine mount rubber and the front crossmember component as a single unit. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

Note
•  At this stage, only temporarily tighten the No.1 engine mount rubber, do not tighten it completely.

9.  Tighten the No.3 engine mount installation bolts and nuts in the order shown in the figure.

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Tightening torque

Installation position

Tightening torque
1
76—95 N·m {7.8—9.6 kgf·m, 57—70 ft·lbf}
2
82—95 N·m {8.4—9.6 kgf·m, 61—70 ft·lbf}
3
49—65 N·m {5.0—6.6 kgf·m, 37—47 ft·lbf}

10.  Tighten the No.4 engine mount bracket installation bolt and nuts in the order shown in the figure.

MTX

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ATX

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Tightening torque

Installation position

Tightening torque
1, 2, 3
92—116 N·m {9.4—11 kgf·m, 68—85 ft·lbf}
4
81—99 N·m {8.3—10 kgf·m, 60—73 ft·lbf}

11.  Tighten the No.1 engine mount rubber installation bolts.

2WD

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4WD

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Tightening torque

Installation position

Tightening torque
1
141—172 N·m {15—17 kgf·m, 104—126 ft·lbf}
2
130—164 N·m {14—16 kgf·m, 96—120 ft·lbf}

12.  Install the clips shown in the figure. (With i-ELOOP).

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13.  Connect the generator terminal B cable. (With i-ELOOP). (See GENERATOR REMOVAL/INSTALLATION [WITH i-ELOOP (SKYACTIV-G 2.5 (WITH CYLINDER DEACTIVATION))].)

14.  Install the service plug. (With i-ELOOP). (See SERVICE PLUG DISCONNECTION/CONNECTION [i-ELOOP].)

15.  Install the front drive shaft. (4WD) (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)

16.  Install the front drive shaft. (4WD) (See PROPELLER SHAFT REMOVAL/INSTALLATION.)

17.  Install the TWC. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

18.  Install the A/C compressor. (See A/C COMPRESSOR REMOVAL/INSTALLATION [SKYACTIV-G 2.0, SKYACTIV-G 2.5].)

19.  Install the generator drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

20.  Connect the lower radiator hose to the radiator.

21.  Install the bracket shown in the figure to the throttle body.

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22.  Connect the upper radiator hose to the coolant control valve.

23.  Install the front wheels and tires. (See WHEEL AND TIRE REMOVAL/INSTALLATION.)

24.  Connect the heater hose. (See A/C UNIT REMOVAL/INSTALLATION.)

25.  Connect the evaporative hose No.3. (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

26.  Connect the fuel hose. (See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

27.  Connect the vacuum hose. (See VACUUM HOSE REMOVAL/INSTALLATION [L.H.D. (WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5))].) (See VACUUM HOSE REMOVAL/INSTALLATION [R.H.D. (WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5))].)

28.  Install the clutch release cylinder. (MTX) (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION [C66M-R, C66MX-R].)

29.  Connect the selector cable. (ATX) (See SELECTOR CABLE REMOVAL/INSTALLATION.)

30.  Connect the control cable. (MTX) (See CONTROL CABLE REMOVAL/INSTALLATION [C66M-R, C66MX-R].)

31.  Connect the ground cable shown in the figure.

RH

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Tightening torque
9—12 N·m {92—122 kgf·cm, 80—106 in·lbf}

LH

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Tightening torque
9—12 N·m {92—122 kgf·cm, 80—106 in·lbf}

32.  Install the battery tray and battery. (See BATTERY REMOVAL/INSTALLATION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

33.  Install the PCM component. (See PCM REMOVAL/INSTALLATION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

34.  Connect the wiring harness shown in the figure.

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35.  Install the air cleaner, air hose and fresh air duct as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

36.  Connect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)

37.  Refill the transfer oil. (4WD) (See TRANSFER OIL REPLACEMENT [FW6AX-EL, GW6AX-EL].)

38.  Refill the transaxle oil (MTX) or ATF (ATX). (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [FW6A-EL, FW6AX-EL].) (See MANUAL TRANSAXLE OIL REPLACEMENT [C66M-R, C66MX-R].)

39.  Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)

40.  Start the engine, and inspect and adjust the following:

•  Front wheel alignment (See FRONT WHEEL ALIGNMENT.)
•  Leakage of engine oil, engine coolant, ATF (ATX), transaxle oil (MTX), transfer oil (AWD) and fuel.
•  Runout and contact of pulley and belt.
•  Ignition timing, idle speed and idle mixture. (See ENGINE TUNE-UP [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)
•  Engine-driven accessories operation.
Note
•  If the engine is overhauled and assembled to the vehicle, perform a road test to verify that there is no abnormal vibration and noise.

41.  Install the front splash shield. (See SPLASH SHIELD REMOVAL/INSTALLATION.)

42.  Install the front under cover No.1 and No.2. (See FRONT UNDER COVER No.1 REMOVAL/INSTALLATION.) (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

43.  Install the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [WITH CYLINDER DEACTIVATION (SKYACTIV-G 2.0, SKYACTIV-G 2.5)].)