ENGINE REMOVAL/INSTALLATION (2WD)

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 Fuel Line Safety Procedure.)

1. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [L8, LF, L3].)

2. Remove the battery. (See BATTERY REMOVAL/INSTALLATION [L8, LF, L3, L3 Turbo].)

3. Remove the battery tray. (See BATTERY REMOVAL/INSTALLATION [L8, LF, L3, L3 Turbo].)

4. Remove the radiator. (See RADIATOR REMOVAL/INSTALLATION [L8, LF, L3].)

5. Drain the transaxle oil.(MTX) Drain the ATF.(ATX) (See TRANSAXLE OIL REPLACEMENT [G35M-R].) (See TRANSAXLE OIL REPLACEMENT [G66M-R].) (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [FS5A-EL].)

6. Remove the P/S oil pump with the oil hose still connected. Position the P/S oil pump so that it is out of the way. Use wire or rope to secure.(SeePOWER STEERING OIL PUMP REMOVAL/INSTALLATION [L8, LF, L3, L3 Turbo].)

7. Remove the A/C compressor with the pipes still connected. Position the A/C compressor so that it is out of the way. Use wire or rope to secure.

8. Remove the joint shaft from the front drive shaft. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION [L8, LF, L3, MZR-CD (RF Turbo)].)

9. Remove the air cleaner, intake air duct, and vacuum hose. (See INTAKE AIR SYSTEM REMOVAL/INSTALLATION [L8, LF, L3].)

10. Disconnect the shift cable and select cable from the transaxle side.(MTX) Disconnect the selector cable from the transaxle side.(ATX) (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [G35M-R].) (See MANUAL TRANSAXLE REMOVAL/INSTALLATION [G66M-R].) (See AUTOMATIC TRANSAXLE REMOVAL/INSTALLATION [FS5A-EL].)

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

12. Remove the vacuum hose and heater hose.

13. Disconnect the plastic fuel hose. (See Plastic Fuel Hose Removal Note.) (See Plastic Fuel Hose Installation Note.)

14. Disconnect the wiring harness from the engine side.

15. Remove the three way catalyst (TWC). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [L8, LF, L3 2WD].)

16. Remove in the order indicated in the table.

17. Install in the reverse order of removal.

18. Start the engine and:

• Inspect for the engine oil, engine coolant, transaxle oil and fuel leakage.

• Verify the ignition timing, idle speed and idle mixture. (See ENGINE TUNE-UP [L8, LF, L3].)

19. Perform a road test.

No.1 Engine Mount Rubber Removal Note

1. Remove the through bolt A on the No.1 engine mount bracket side.

2. Loosen the through bolt B on the front crossmember side until approximately three pitches are showing.

Note

• Do not remove the No.1 engine mount rubber from the front crossmember.

No.4 Engine Mount Bracket and No.4 Engine Mount Rubber Removal Note

1. Install the SST using the following procedure.

Caution

• Refer to the SST instruction manual for the basic handing procedure.

(1) Install the right rear shaft of the SST to the bolt of the right shock absorber as shown in the figure.

(2) Install the left rear shaft of the SST to the bolt of the left shock absorber. (Identical position to the right side)

Note

• When setting the SST on the right side, make sure it doesn't interfere with the ABS (ABS/TCS) HU/CM or the DSC HU/CM. (5 speed ATX)

(3) Install the left/right front shaft of the SST with front foot No.2 to the bolt as shown in the figure.

* :

If equipped.

(4) Adjust the positions of the SST side bars so that they are the same height (left and right) and horizontal.

(5) Make sure each joint is securely tightened.

2. Support the engine using the SST.

Note

• The SST (49E 017 5A0) can be used in place of the SST (49C 017 5A0).

3. Secure the engine and the transaxle using an engine jack and attachment as shown.

4. Remove the SST.

5. Secure the engine and the transaxle using a hoist.

No.3 Engine Joint Bracket Installation Note

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

2. Install the SST using the following procedure.

Caution

• Refer to the SST instruction manual for the basic handing procedure.

(1) Install the right rear shaft of the SST to the bolt of the right shock absorber as shown in the figure.

(2) Install the left rear shaft of the SST to the bolt of the left shock absorber. (Identical position to the right side)

Note

• When setting the SST on the right side, make sure it doesn't interfere with the ABS (ABS/TCS) HU/CM or the DSC HU/CM. (5 speed ATX)

(3) Install the left/right front shaft of the SST with front foot No.2 to the bolt as shown in the figure.

* :

If equipped.

(4) Adjust the positions of the SST side bars so that they are the same height (left and right) and horizontal.

(5) Make sure each joint is securely tightened.

3. Support the engine using the SST.

Note

• The SST (49E 017 5A0) can be used in place of the SST (49C 017 5A0).

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

7.0-13.0 N·m {71.4-132.5 kgf·cm, 62.0-115.0 in·lbf}

5. Tighten the No.3 engine joint bracket bolt and nut in the order shown.

(1) Temporarily tighten (2).

(2) Completely tighten (1).

(3) Completely tighten (2).

Tightening torque

75.4-104.9 N·m {7.6-10.6 kgf·m, 55.0-76.6 ft·lbf}

No.4 Engine Mount Bracket and No.4 Engine Mount Rubber Installation Note

1. Tighten the No.4 engine mount bracket and No.4 engine mount rubber bolts and nuts in the order shown.

(1) Temporarily tighten (1).

(2) Align (2) in position and temporarily tighten.

(3) Completely tighten (1) from the rear side.

(4) Completely tighten (2).

(5) Completely tighten (3).

(6) Temporarily tighten (4).

(7) Completely tighten in the order of (5), (6),(7).

(8) Completely tighten (4).

Tightening torque

(1)-(3) 58.8-80.4 N·m {6.0-8.1 kgf·m, 43.3-58.5 ft·lbf}

(4) 85.3-116.6 N·m {8.7-11.8 kgf·m, 63.0-85.9 ft·lbf}

(5)-(7) 66.6-93.1 N·m {6.80-9.49 kgf·m, 49.2-68.6 ft·lbf}

2. Remove the engine jack and attachment as shown.

3. Remove the hoist and secure the engine and transaxle using SST.

No.1 Engine Mount Bracket Installation Note

1. Tighten No.1 engine mount bracket bolt A.

Tightening torque:

93.1-116.6 N·m {9.50-11.8 kgf·m, 68.7-85.9 ft·lbf}

2. Tighten No.1 engine mount bracket bolt B.

Tightening torque:

93.1-116.6 N·m {9.50-11.8 kgf·m, 68.7-85.9 ft·lbf}

No.1 Engine Mount Rubber Installation Note

1. Tighten through bolt A on the No.1 engine mount bracket.

Tightening torque:

85.3-116.6 N·m {8.7-11.8 kgf·m, 62.9-85.9 ft·lbf}

2. Tighten through bolt B on the front crossmember side.

Tightening torque:

93.1-116.6 N·m {9.5-11.8 kgf·m, 68.7-85.9 ft·lbf}