ENGINE REMOVAL/INSTALLATION [ZJ, ZY]

Warning

• Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

• Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure". (See BEFORE REPAIR PROCEDURE.)

Note

• Perform the engine and transaxle component removal/installation from below the vehicle.

1. Remove the battery and the battery bracket. (See BATTERY REMOVAL/INSTALLATION [ZJ, ZY].)

2. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [ZJ, ZY].)

3. Disconnect the radiator hose.

4. Remove the air cleaner, intake-air duct, accelator cable, and vacuum hose. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [WITHOUT WU-TWC].) (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [WITH WU-TWC].)

5. Remove the ATF hose, selector cable, and wiring harness. (ATX) (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [FN4A-EL].)

6. Remove the shift cable. (MTX) (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [F35M-R].)

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

8. Remove the drive belt. (See DRIVE BELT REPLACEMENT [ZJ, ZY].)

9. Disconnect the P/S oil pump hose and pipe from the pump side. (See POWER STEERING OIL PUMP REMOVAL/INSTALLATION.)

10. Remove the A/C compressor with the pipes still connected.

Note

• Secure the A/C compressor using wire or rope so that it is out of the way.

11. Drain the transaxle oil.

12. Remove the joint shaft. (See JOINT SHAFT REMOVAL/INSTALLATION.)

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

14. Disconnect the vacuum hose and the heater hose.

15. Disconnect the fuel hose. (See BEFORE REPAIR PROCEDURE.) (See FUEL HOSE (ENGINE ROOM SIDE) REMOVAL/INSTALLATION.)

16. Disconnect the wiring harness from the engine side.

17. Remove the front pipe. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [WITHOUT WU-TWC].) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [WITH WU-TWC].)

18. Remove the front cross member component. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION.)

19. Remove in the order indicated in the table.

20. Install in the reverse order of removal.

21. Start the engine. and inspect and adjust the following.

22. Inspect the following and adjust them if necessary.

• Pulley and belt for runout and contact .

• Leakage of engine oil, engine coolant, ATF, MT oil, and fuel.

• Ignition timing and idle speed. Verify the amount of CO, HC. (See IGNITION TIMING INSPECTION [ZJ, ZY].) (See IDLE SPEED ADJUSTMENT [ZJ, ZY (WITHOUT WU-TWC)].) (See IDLE SPEED ADJUSTMENT [ZJ, ZY (WITH WU-TWC)].) (See IDLE MIXTURE INSPECTION [ZJ, ZY].)

• Engine-driven accessories operation

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

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

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

No.3 Engine Mount, No.4 Engine Mount Rubber Installation Note

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

2. Install the No.3 engine mount, and then temporarily tighten the installation bolts and nuts.

3. Tighten the installation bolts in the order shown in the figure.

62-76 N·m {6.4-7.7 kgf·m, 46-56 ft·lbf}

4. Align the No.4 engine mount rubber in the direction shown in the figure, and then temporarily tighten the installation bolts and nuts.

5. Tighten the No.4 Engine mount rubber installation bolts and nuts in the order shown in the figure.

6. Remove the engine jack and attachment.