ENGINE REMOVAL/INSTALLATION [L3 Turbo]

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Warning
•  Fuel vapor is hazardous. It can very easily ignite, causing death, serious injury, or damage. Always keep sparks and flames away from fuel.'
•  Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can easily ignite and cause serious injury or death and damage. Fuel can also irritate skin and eyes. To prevent this, always perform the Fuel Line Safety Procedure. (See BEFORE SERVICE PRECAUTION [L3 Turbo].)

1.  Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [L3 Turbo].)

2.  Remove the charge air cooler duct. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [L3 Turbo].)

3.  Remove the air cleaner and fresh air duct component. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [L3 Turbo].)

4.  Remove the front wheel and tire.

5.  Remove the under cover, splash shield and mudguard.

6.  Drain the engine coolant (SeeENGINE COOLANT REPLACEMENT [L3 Turbo].)

7.  Drain the automatic transaxle fluid (ATF) (ATX). (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [AW6A-EL, AW6AX-EL].)

8.  Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [L3 Turbo].)

9.  Disconnect the heater hose. (See A/C UNIT REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER].)

10.  Disconnect the radiator hose. (See RADIATOR REMOVAL/INSTALLATION [L3 Turbo].)

11.  Disconnect the brake vacuum hose. (SeeVACUUM HOSE REMOVAL/INSTALLATION.)

12.  Disconnect the fuel hose and vacuum hose. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [L3 Turbo].)

13.  Disconnect the selector cable from the transaxle side (ATX). (See SELECTOR LEVER COMPONENT REMOVAL/INSTALLATION.)

14.  Disconnect the shift cable from the transaxle side (MTX). (See SHIFT MECHANISM REMOVAL/INSTALLATION [A26MX-R].)

15.  Set the clutch release cylinder out of the way (MTX). (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION.)

16.  Disconnect the wiring harnesses. (See PCM REMOVAL/INSTALLATION [L3 Turbo].)

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

18.  Remove the front pipe and HO2S. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 Turbo].)

19.  Disconnect the front drive shaft (RH) from the joint shaft side. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)

20.  Disconnect the front drive shaft (LH) from the transaxle side. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)

Note
•  Position and secure the A/C compressor out of the way with rope.

21.  Remove the A/C compressor with the pipes still connected. (See A/C COMPRESSOR REMOVAL/INSTALLATION [FULL-AUTO AIR CONDITIONER].) (See A/C COMPRESSOR REMOVAL/INSTALLATION [MANUAL AIR CONDITIONER].)

22.  Remove in the order indicated in the figure.

23.  Install in the reverse order of removal.

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

•  Air bleeding (See AIR BLEEDING.)
•  Bleed the air from the cooling system. (See ENGINE COOLANT REPLACEMENT [L3 Turbo].)
•  Runout and contact on pulley and belt
•  Leakage of engine oil, engine coolant, automatic transmission fluid, or fuel.
•  Ignition timing, idle speed and idle mixture (CO and HC)
•  Engine accessories operation

25.  Perform a road test and verify that there is no abnormal vibration or noise.

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1
No.1 engine mount
(See No.1 Engine Mount Removal Note.)
(See Engine Mount Installation Note.)
2
No.4 engine mount bracket
(See No.3 Engine Mount Rubber, No.4 Engine Mount Bracket Removal Note.)
(See Engine Mount Installation Note.)
3
No.3 engine mount rubber
(See No.3 Engine Mount Rubber, No.4 Engine Mount Bracket Removal Note.)
(See Engine Mount Installation Note.)
4
Engine and transaxle


No.1 Engine Mount Removal Note

1.  Remove the No.1 engine mount bracket from the underside of the vehicle.

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2.  Remove the No.1 engine mount rubber and the front crossmember as a single unit. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [L.H.D.].) (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [R.H.D.].)

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No.3 Engine Mount Rubber, No.4 Engine Mount Bracket Removal Note

1.  Secure the engine and transaxle using an engine jack.

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Engine Mount Installation Note

1.  Tighten the No. 3 engine mount bracket stud bolt.

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Tightening torque
7.0—13 N·m {72—132 kgf·cm, 62—115 in·lbf}

2.  Secure the engine and transaxle using an engine jack.

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3.  Temporarily tighten the No.1 engine mount bracket in the order shown in the figure.

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4.  Temporarily tighten the No.3 engine mount nuts.

5.  Tighten the No.3 engine mount nuts in the order shown in the figure.

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Tightening torque
74.5—104.9 N·m {7.6—10.6 kgf·m, 55.0—77.3 ft·lbf}

6.  Temporarily tighten the No.4 engine mount bracket in the order shown in the figure.

ATX

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MTX

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7.  Tighten the No.4 engine mount bracket in the order shown in the figure.

ATX

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MTX

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Tightening torque

Installation position

Tightening torque
1―3
74.5—93.1 N·m {7.6—9.4 kgf·m, 55.0—68.6 ft·lbf}
4
74.5—104.9 N·m {7.6—10.6 kgf·m, 55.0—77.3 ft·lbf}

Note
•  Install the No.1 engine mount dynamic damper at the angle shown in the figure. (MTX)
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8.  Tighten the No.1 engine mount bracket bolt A and B in order of A→B.

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Tightening torque
Bolt A, B: 107.5—116.6 N·m {11.0—11.8 kgf·m, 79.3—85.9 ft·lbf}

9.   Tighten bolt C.

Note
•  It may not be possible to tighten bolt C completely due to the narrow operation space. In this case, tighten nut C instead of bolt C.
•  There are two types of parts, bolt C and nut C, and each has a different tightening torque. The appearance of bolt C and nut C is same, however, the tightening torque can be determined by the bolt D size.
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Bolt C tightening torque
For bolt D (M12): 85.3—116.6 N·m {8.7—11.8 kgf·m, 63.0—85.9 ft·lbf}
For bolt D (M14): 86.1—95.1 N·m {8.8—9.6 kgf·m, 63.5—70.1 ft·lbf}
Nut C tightening torque
For bolt D (M12): 85.3—116.6 N·m {8.7—11.8 kgf·m, 63.0—85.9 ft·lbf}
For bolt D (M14): 59.3—72.5 N·m {6.0—7.3 kgf·m, 43.7—53.4 ft·lbf}