ENGINE REMOVAL/INSTALLATION [SKYACTIV-D 2.2]
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Operation After Replacing Engine
1. After replacing the engine, perform the following procedure.
STEP |
ACTION |
PAGE/CONDITION |
---|---|---|
1
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Perform KOEO self-test procedure.
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2
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Start the engine.
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—
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3
|
Verify that the check engine light does not illuminate.
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—
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4
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Perform KOER self-test procedure.
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5
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Perform fuel injector injection amount correction.
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6
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Perform timing chain learning procedure.
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7
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Clear the DTCs.
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8
|
Switch the ignition off.
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—
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9
|
Wait for 20 s or more.
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—
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Engine Removal
1. Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)
2. Remove the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
3. Remove the air cleaner, air hose and fresh air duct as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
4. Remove the bolts, nut and connector shown in the figure, and set the wiring harness aside.
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5. Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
6. Disconnect the ground cable shown in the figure.
RH
ac5wzw00009306
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LH
ac5wzw00009307
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7. Remove the following parts as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
8. Disconnect the selector cable. (ATX) (See SELECTOR CABLE REMOVAL/INSTALLATION.)
9. Disconnect the control cable. (MTX) (See CONTROL CABLE REMOVAL/INSTALLATION [D66M-R, D66MX-R].)
10. Remove the clutch release cylinder with the pipe still connected. (MTX) (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION [D66M-R, D66MX-R].)
11. Disconnect the vacuum hose. (See VACUUM HOSE REMOVAL/INSTALLATION [L.H.D. (SKYACTIV-D 2.2)].) (See VACUUM HOSE REMOVAL/INSTALLATION [R.H.D. (SKYACTIV-D 2.2)].)
12. Disconnect the fuel main hose and fuel return hose No.1. (See LOWER CASE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
13. Remove the front wheels and tires. (See WHEEL AND TIRE REMOVAL/INSTALLATION.)
14. 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.)
15. Remove the front splash shield. (See SPLASH SHIELD REMOVAL/INSTALLATION.)
16. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-D 2.2].)
17. Drain the transaxle oil (MTX) or ATF (ATX). (See MANUAL TRANSAXLE OIL REPLACEMENT [D66M-R, D66MX-R].) (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [GW6A-EL, GW6AX-EL].)
18. Drain the transfer oil. (4WD) (See TRANSFER OIL REPLACEMENT [C66MX-R, D66MX-R].) (See TRANSFER OIL REPLACEMENT [FW6AX-EL, GW6AX-EL].)
19. Disconnect the upper radiator hose and water hose (upper side of radiator).
20. Disconnect the ATF oil hose from the radiator. (If equipped) (See OIL COOLER REMOVAL/INSTALLATION [GW6A-EL, GW6AX-EL (SKYACTIV-D 2.2)].)
21. Remove the front crossmember component and the No.1 engine mount rubber as a single unit. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)
22. Disconnect the heater hose. (See A/C UNIT REMOVAL/INSTALLATION.)
23. Remove the lower radiator hose.
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24. Remove the charge air cooler outlet hose and charge air cooler outlet pipe as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].) (See CHARGE AIR COOLER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
25. Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
26. Remove the front crossmember extension (RH).
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27. Remove the A/C compressor with the pipes connected and secure the A/C compressor using wire or rope so that it is out of the way. (See A/C COMPRESSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
28. Remove the middle pipe installation nut (catalytic converter side) and secure the middle pipe using wire or rope so that it is out of the way. (2WD) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
29. Remove the middle pipe. (4WD) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
30. Remove the propeller shaft. (4WD) (See PROPELLER SHAFT REMOVAL/INSTALLATION.)
31. Disconnect the front drive shaft (LH) from the transaxle side and set it aside. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)
32. Disconnect the front drive shaft (RH) from the transaxle side and set it aside. (2WD) (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)
33. Remove the front drive shaft (RH). (4WD) (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)
34. Remove in the order indicated in the table.
ac5wzw00009310
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1
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No.4 engine mount bracket
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2
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No.3 engine mount
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3
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Engine, transaxle
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No.3 engine mount, No.4 engine mount bracket removal note
1. Set the PCM wiring harness and PCM component aside using the following procedure:
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ac5wzw00009312
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2. Set the connector and cooler hose shown in the figure and remove the wiring harness bracket.
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3. Remove the seal plate installed to the underside of the oil pan. (See OIL PAN REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
4. Secure the engine and transaxle using a commercially available engine lifter.
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5. Remove the No.4 engine mount bracket.
6. Remove the No.3 engine mount.
Engine Installation
1. Tighten the engine front cover stud bolts.
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2. Tighten the transaxle stud bolts.
MTX
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ATX
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3. Secure the engine and transaxle using a commercially available engine lifter.
ac5wzw00009314
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4. Return the engine and transaxle to their original position.
5. Temporarily tighten the No.3 engine mount installation bolts and nuts using the following procedure:
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ac5wzw00009317
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6. Temporarily tighten the No.4 engine mount bracket installation bolt and nuts using the following procedure:
MTX
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ATX
ac5wzw00009319
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MTX
ac5wzw00009320
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ATX
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7. Install the front drive shafts. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)
8. Install the propeller shaft. (4WD) (See PROPELLER SHAFT REMOVAL/INSTALLATION.)
9. Install the middle pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
10. Install the A/C compressor. (See A/C COMPRESSOR REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
11. Install the front crossmember extension (RH).
ac5wzw00009309
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12. Install the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
13. Install the charge air cooler outlet hose and charge air cooler outlet pipe as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].) (See CHARGE AIR COOLER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
14. Install the lower radiator hose.
ac5wzw00009308
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15. Connect the heater hose. (See A/C UNIT REMOVAL/INSTALLATION.)
16. Install the No.1 engine mount rubber and the front crossmember component as a single unit. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)
17. 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}
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2
|
82—95 N·m {8.4—9.6 kgf·m, 61—70 ft·lbf}
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3
|
49—65 N·m {5.0—6.6 kgf·m, 37—47 ft·lbf}
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18. Tighten the No.4 engine mount bracket installation bolt and nuts in the order shown in the figure.
MTX
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Tightening torque
Installation position |
Tightening torque |
---|---|
1, 2, 3, 4
|
92—116 N·m {9.4—11 kgf·m, 68—85 ft·lbf}
|
5
|
81—99 N·m {8.3—10 kgf·m, 60—73 ft·lbf}
|
ATX
ac5wzw00009324
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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}
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19. Tighten the No.1 engine mount rubber installation bolts in the order shown in the figure.
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}
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20. Install the seal plate. (See OIL PAN REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
21. Install the wiring harness bracket, cooler hose and connector.
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22. Install the PCM component using the following procedure:
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ac5wzw00009329
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23. Connect the ATF oil hose to the radiator. (If equipped) (See OIL COOLER REMOVAL/INSTALLATION [GW6A-EL, GW6AX-EL (SKYACTIV-D 2.2)].)
24. Connect the upper radiator hose and water hose (upper side of radiator).
25. Install the front wheels and tires. (See WHEEL AND TIRE REMOVAL/INSTALLATION.)
26. Connect the fuel main hose and fuel return hose No.1. (See LOWER CASE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
27. Connect the vacuum hose. (See VACUUM HOSE REMOVAL/INSTALLATION [L.H.D. (SKYACTIV-D 2.2)].) (See VACUUM HOSE REMOVAL/INSTALLATION [R.H.D. (SKYACTIV-D 2.2)].)
28. Install the clutch release cylinder. (MTX) (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION [D66M-R, D66MX-R].)
29. Connect the selector cable. (ATX) (See SELECTOR CABLE REMOVAL/INSTALLATION.)
30. Connect the control cable. (MTX) (See CONTROL CABLE REMOVAL/INSTALLATION [D66M-R, D66MX-R].)
31. Install the following parts as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
32. Connect the ground cable shown in the figure.
RH
ac5wzw00009306
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LH
ac5wzw00009307
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33. Install the battery tray and battery. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
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 [SKYACTIV-D 2.2].)
36. Connect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION.)
37. Refill the transfer oil. (4WD) (See TRANSFER OIL REPLACEMENT [C66MX-R, D66MX-R].) (See TRANSFER OIL REPLACEMENT [FW6AX-EL, GW6AX-EL].)
38. Refill the transaxle oil (MTX) or ATF (ATX). (See MANUAL TRANSAXLE OIL REPLACEMENT [D66M-R, D66MX-R].) (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [GW6A-EL, GW6AX-EL].)
39. Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-D 2.2].)
40. If the engine is replaced, perform “Operation After Replacing Engine”. (See Operation After Replacing Engine.)
41. Start the engine, and inspect and adjust the following:
42. Install the front splash shield. (See SPLASH SHIELD REMOVAL/INSTALLATION.)
43. 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.)
44. Install the engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)