ENGINE REMOVAL/INSTALLATION [SKYACTIV-D 2.2]

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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.
Note
•  Perform the engine and transaxle component removal/installation from the lower side of the vehicle after removing the front crossmember component.

Operation After Replacing Engine

Note
•  Because there will be a new timing chain if the engine is replaced, perform the same procedure as “Operation After Replacing Timing Chain”.

1.  After replacing the engine, perform the following procedure.

STEP

ACTION

PAGE/CONDITION
1
Perform KOEO self-test procedure.
(See KOEO/KOER SELF TEST [PCM (SKYACTIV-D 2.2)].)
2
Start the engine.
—
3
Verify that the check engine light does not illuminate.
—
4
Perform KOER self-test procedure.
(See KOEO/KOER SELF TEST [PCM (SKYACTIV-D 2.2)].)
5
Perform fuel injector injection amount correction.
(See FUEL INJECTOR INJECTION AMOUNT CORRECTION [SKYACTIV-D 2.2].)
6
Perform timing chain learning procedure.
(See TIMING CHAIN LEARNING [SKYACTIV-D 2.2].)
7
Clear the DTCs.
(See OBD READ/CLEAR DIAGNOSTIC TEST RESULTS [PCM (SKYACTIV-D 2.2)].)
8
Switch the ignition off.
—
9
Wait for 30 s or more.
—


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

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LH

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7.  Remove the following parts as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  Turbocharger air outlet pipe component
•  Charge air cooler inlet hose

8.  Disconnect the selector cable. (See AUTOMATIC TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION.)

9.  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)].)

10.  Disconnect the fuel main hose and fuel return hose No.1. (See LOWER CASE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

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

12.  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.)

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

14.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-D 2.2].)

15.  Drain the ATF. (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [GW6A-EL, GW6AX-EL].)

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

17.  Disconnect the upper radiator hose from the engine.

18.  Disconnect the water hose from the upper side of radiator.

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

20.  Remove the No.1 engine mount bracket and the bracket plate No.2 as a single unit. (2WD) (See ENGINE MOUNT DISASSEMBLY/ASSEMBLY [SKYACTIV-D 2.2].)

21.  Disconnect the heater hose from the engine. (See HEATER HOSE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

22.  Remove the lower radiator hose.

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23.  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].)

24.  Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

25.  Remove the front crossmember extension (RH).

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26.  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].)

27.  Remove the middle pipe installation nuts (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].)

28.  Remove the middle pipe. (4WD) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

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

30.  Disconnect the front drive shaft (LH) from the transaxle side and set it aside. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)

31.  Disconnect the front drive shaft (RH) from the transaxle side and set it aside. (2WD) (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)

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

33.  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.

1.  Set the PCM wiring harness and PCM component aside using the following procedure:

(1)  Disconnect the PCM connector (140 pin side) from the PCM. (See PCM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)
(2)  Remove the bolt shown in the figure and set aside the PCM wiring harness to the engine upper side.
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(3)  Disconnect the active bonnet actuator connector (RH). (See ACTIVE BONNET ACTUATOR REMOVAL/INSTALLATION.)
(4)  Remove the bolts shown in the figure and set aside the PCM component with the PCM connector (60 pin side) connected.
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2.  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].)

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 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.  Remove the No.4 engine mount bracket.

6.  Remove the No.3 engine mount.

7.  Remove the engine and transaxle.


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
40—52 N·m {4.1—5.3 kgf·m, 30—38 ft·lbf}

2.  Tighten the transaxle stud bolts.

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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 deformation of the oil pan and damage of the transaxle.

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

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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:

(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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6.  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.
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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.
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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).

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Tightening torque
8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}

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.

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Tightening torque
8—10 N·m {82—101 kgf·cm, 71—88 in·lbf}

15.  Connect the heater hose. (See HEATER HOSE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

16.  Install the No.1 engine mount bracket and the bracket plate No.2 as a single unit and temporarily tighten the installation bolts. (2WD) (See ENGINE MOUNT DISASSEMBLY/ASSEMBLY [SKYACTIV-D 2.2].)

17.  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.

18.  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}

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

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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}

20.  Tighten the bolts in the order shown in the figure. (2WD)

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Tightening torque
131—153 N·m {14—15 kgf·m, 97—112 ft·lbf}

21.  Tighten the bolts shown in the figure.

2WD

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Tightening torque
Bolt A: 130—151 N·m {14—15 kgf·m, 96—111 ft·lbf}
Bolt B: 130—164 N·m {14—16 kgf·m, 96—120 ft·lbf}

4WD

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Tightening torque
Bolt A: 55—69 N·m {5.7—7.0 kgf·m, 41—50 ft·lbf}
Bolt B: 140—163 N·m {15—16 kgf·m, 104—120 ft·lbf}
Bolt C: 130—164 N·m {14—16 kgf·m, 96—120 ft·lbf}

22.  Install the seal plate. (See OIL PAN REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

23.  Install the wiring harness bracket.

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Tightening torque
6.9—9.8 N·m {71—99 kgf·cm, 62—86 in·lbf}

24.  Install the PCM component using the following procedure:

(1)  Temporarily tighten the bolt shown in the figure.
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(2)  Tighten the PCM component installation bolts in the order shown in the figure.
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Tightening torque
9—10 N·m {92—101 kgf·cm, 80—88 in·lbf}
(3)  Connect the active bonnet actuator connector (RH). (See ACTIVE BONNET ACTUATOR REMOVAL/INSTALLATION.)
(4)  Install the bolt shown in the figure.
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Tightening torque
9—12 N·m {92—122 kgf·cm, 80—106 in·lbf}
(5)  Connect the PCM connector (140 pin side) to the PCM. (See PCM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

25.  Connect the upper radiator hose and water hose (upper side of radiator).

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

27.  Connect the fuel main hose and fuel return hose No.1. (See LOWER CASE REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

28.  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)].)

29.  Connect the selector cable. (See AUTOMATIC TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION.)

30.  Install the following parts as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

•  Turbocharger air outlet pipe component
•  Charge air cooler inlet hose

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 [SKYACTIV-D 2.2].)

33.  Connect the wiring harness shown in the figure.

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34.  Install the air cleaner, air hose and fresh air duct as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)

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

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

37.  Refill the ATF. (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [GW6A-EL, GW6AX-EL].)

38.  Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-D 2.2].)

39.  If the engine is replaced, perform “Operation After Replacing Engine”. (See Operation After Replacing Engine.)

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

•  Front wheel alignment (See FRONT WHEEL ALIGNMENT.)
•  Leakage of engine oil, engine coolant, ATF, transfer oil (4WD) and fuel.
•  Runout and contact of pulley and belt.
•  Idle speed (See ENGINE TUNE-UP [SKYACTIV-D 2.2].)
•  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 engine cover. (See ENGINE COVER REMOVAL/INSTALLATION [SKYACTIV-D 2.2].)