ENGINE REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0]

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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 transmission component removal/installation from the lower side of the vehicle after removing the front crossmember component.

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

2.  Remove the front wheels and tires. (See GENERAL PROCEDURES (SUSPENSION).)

3.  Remove the front mudguard No.1 and No.2. (See FRONT MUDGUARD REMOVAL/INSTALLATION.)

4.  Remove the front splash shield No.1 and No.2. (See FRONT SPLASH SHIELD No.1 REMOVAL/INSTALLATION.) (See FRONT SPLASH SHIELD No.2 REMOVAL/INSTALLATION.)

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

6.  Remove the front under cover. (See FRONT UNDER COVER REMOVAL/INSTALLATION.)

7.  Remove the plate. (With plate) (See PLATE REMOVAL/INSTALLATION.)

8.  Remove the front crossmember under cover. (See FRONT CROSSMEMBER UNDER COVER REMOVAL/INSTALLATION.)

9.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

10.  Drain the ATF. (AT) (See AUTOMATIC TRANSMISSION FLUID (ATF) REPLACEMENT [SJ6A-EL].)

11.  Disconnect the connectors shown in the figure and set the wiring harness aside.

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12.  Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

13.  Remove the following intake air system related parts as a single unit. (With resonance chamber No.2) (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

•  Resonance chamber No.2

•  Resonance duct

•  Air intake hose No.1

•  Air intake hose No.2

•  Air intake hose No.3

14.  Remove the air cleaner, air hose and resonance chamber No.1 as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

15.  Disconnect the upper radiator hose, heater hose and secure the upper radiator hose, heater hose using wire or rope so that it is out of the way.

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16.  Remove the bolt shown in the figure and set the cooler pipe, heater hose and bracket aside.

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17.  Disconnect the heater hose from the water outlet component side.

18.  Disconnect the lower radiator hose from the thermostat side. (See THERMOSTAT REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

19.  Remove the generator drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

20.  Remove the PCM and PCM bracket component. (See PCM REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

21.  Set aside the engine wiring harness on the engine.

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22.  Remove the bolt and clips shown in the figure and set the wiring harness aside.

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23.  Disconnect the ground cable shown in the figure.

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24.  Disconnect the vacuum hose. (See VACUUM HOSE REMOVAL/INSTALLATION [L.H.D.].) (See VACUUM HOSE REMOVAL/INSTALLATION [R.H.D.].)

25.  Disconnect the evaporative hose. (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

26.  Disconnect the fuel hose from the engine side. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

27.  Disconnect the selector lever. (AT) (See AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION [SJ6A-EL].)

28.  Remove the shift lever. (MT) (See TRANSMISSION REMOVAL/INSTALLATION [M66M-D].)

29.  Remove the clutch release cylinder with the pipe still connected. (MT) (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION.)

30.  Disconnect the engine wiring harness from the capacitor. (With i-ELOOP) (See CAPACITOR (i-ELOOP) REMOVAL/INSTALLATION [i-ELOOP].)

31.  Disconnect the oil hoses from the radiator using the following procedure: (AT)

Note

•  ATF drains from the radiator and oil hoses when the oil hoses are disconnected.

(1)  Place a container under the vehicle to collect drained ATF.

(2)  Disconnect the oil hoses from the radiator.

(3)  Secure the oil hoses using rope or equivalent with the hose ends facing upward so that ATF does not drain.

32.  Remove in the order indicated in the table.

33.  Install in the reverse order of removal.

34.  Refill the ATF. (AT) (See AUTOMATIC TRANSMISSION FLUID (ATF) REPLACEMENT [SJ6A-EL].)

35.  Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

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

•  Front wheel alignment (See FRONT WHEEL ALIGNMENT.)

•  Leakage of engine oil, engine coolant, ATF (AT) and fuel.

•  Runout and contact of pulley and belt.

•  Ignition timing, idle speed and idle mixture. (See ENGINE TUNE-UP [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

•  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.

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1	Center under cover (With center under cover) (See CENTER UNDER COVER REMOVAL/INSTALLATION.)
2	Member bracket (MT) (See POWER PLANT FRAME REMOVAL [M66M-D].) (See POWER PLANT FRAME INSTALLATION [M66M-D].)
3	Tunnel member (See POWER PLANT FRAME REMOVAL [M66M-D].) (See POWER PLANT FRAME INSTALLATION [M66M-D].)
4	TWC (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].) (See TWC Installation Note.)
5	Front crossmember component (See Front Crossmember Component Removal/Installation Note.)
6	Propeller shaft (See PROPELLER SHAFT REMOVAL/INSTALLATION.)
7	Power plant frame (See POWER PLANT FRAME REMOVAL [M66M-D].) (See POWER PLANT FRAME INSTALLATION [M66M-D].)
8	Engine, transmission (See Engine, Transmission Removal/Installation Note.)

Front Crossmember Component Removal/Installation Note

1.  Remove the bracket.

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2.  Remove the front ABS wheel speed sensor from the wheel hub component.

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3.  Remove the front ABS wheel speed sensor wiring harness from the bracket and front upper arm and set it aside so that it does not interfere with the servicing.

4.  Remove the front brake hose from the front upper arm and front crossmember and set it aside so that it does not interfere with the servicing.

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5.  Remove the front brake caliper component and secure the front brake caliper component using wire or rope so that it is out of the way. (See FRONT BRAKE DISC REMOVAL/INSTALLATION [WITH 4-POT OPPOSED PISTON CALIPER].) (See FRONT BRAKE DISC REMOVAL/INSTALLATION [WITH SINGLE PISTON FLOATING CALIPER].)

6.  Remove the front disc plate. (See FRONT BRAKE DISC REMOVAL/INSTALLATION [WITH 4-POT OPPOSED PISTON CALIPER].) (See FRONT BRAKE DISC REMOVAL/INSTALLATION [WITH SINGLE PISTON FLOATING CALIPER].)

7.  Remove the seal plate. (See SEAL PLATE REMOVAL/INSTALLATION.)

8.  Remove the horn LO component. (See HORN REMOVAL/INSTALLATION.)

9.  Remove the bumper stiffener lower. (See BUMPER STIFFENER LOWER REMOVAL/INSTALLATION.)

10.  Remove the front crossmember extension. (See FRONT STABILIZER REMOVAL/INSTALLATION.)

11.  Remove the oil pipe No.3 bracket from the front crossmember. (AT) (See OIL COOLER REMOVAL/INSTALLATION [SJ6A-EL].)

12.  Remove the coolant reserve tank. (See COOLANT RESERVE TANK REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

13.  Remove the upper mount rubber bracket (LH). (See RADIATOR REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

14.  Suspend the cooling fan component with rope through the upper mount rubber bracket (LH) hole as shown in the figure.

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15.  Remove the center mount rubber bracket and lower mount rubber bracket of the radiator. (See RADIATOR REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

16.  Disconnect the intermediate shaft from the steering gear and linkage. (See INTERMEDIATE SHAFT REMOVAL/INSTALLATION.)

17.  Disconnect the EPS connector. (See STEERING GEAR AND LINKAGE REMOVAL/INSTALLATION.)

18.  Disconnect the lower radiator hose and clip.

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19.  Install the SST to the position shown in the figure using the following bolt.

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20.  Remove the bolt shown in the figure and set the ground cable aside.

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21.  Set the SSTs as shown in the figure.

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Note

•  When removing the engine, use 2 SSTs (49 E017 503) as shown in the figure to lift up the engine on the left and right sides equally. If only 1 SST (49 E017 503) is available, make arrangements for 1 more.

22.  Rotate the shafts of the SSTs (49 E017 503) to support the engine.

23.  Remove the engine mount rubber installation bolts (front crossmember side). (See ENGINE MOUNT DISASSEMBLY/ASSEMBLY [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)

24.  Lift up the engine until the engine mount rubber is slightly raised above the front crossmember and verify again that the engine is securely hung.

25.  Remove the front suspension tower bar. (With front suspension tower bar) (See FRONT SUSPENSION TOWER BAR REMOVAL/INSTALLATION.)

26.  Remove the front shock absorber upper side nuts. (See FRONT SHOCK ABSORBER AND COIL SPRING REMOVAL/INSTALLATION.)

27.  Loosen the front shock absorber lower side nuts.

Caution

•  With the front shock absorber secured, the front crossmember may come in contact with it during front crossmember removal/installation which may lead to part damage. Loosen the front shock absorber lower nut until the front shock absorber can move.

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28.  Disconnect the front stabilizer control link from the front lower arm. (See FRONT STABILIZER REMOVAL/INSTALLATION.)

29.  Remove the front stabilizer bracket installation nuts and suspend the front stabilizer component. (See FRONT STABILIZER REMOVAL/INSTALLATION.)

30.  Support the front crossmember component using a transmission jack.

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31.  Remove the front crossmember installation bolts and nuts. (See FRONT STABILIZER REMOVAL/INSTALLATION.)

32.  Lower the transmission jack slowly and remove the front crossmember component. (See FRONT STABILIZER REMOVAL/INSTALLATION.)

33.  Install in the reverse order of removal.

Engine, Transmission Removal/Installation Note

1.  Remove the bolt shown in the figure.

SKYACTIV-G 1.5

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SKYACTIV-G 2.0

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2.  Disconnect the A/C compressor connector.

3.  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.)

Caution

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

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

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5.  Remove the power plant frame. (See POWER PLANT FRAME REMOVAL [M66M-D].)

6.  Remove the SST (49 E017 5A0) from the engine.

7.  Lower the engine lifter and remove the engine, transmission.

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8.  Install in the reverse order of removal.

TWC Installation Note

1.  Temporarily remove the installed tunnel member when installing the power plant frame.

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2.  Install the TWC. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 1.5, SKYACTIV-G 2.0].)