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ENGINE REMOVAL/INSTALLATION (4WD)

id011000801900

  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".

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. (SeeAUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [JA5AX-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.

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 propeller shaft from the transfer. (See PROPELLER SHAFT REMOVAL/INSTALLATION [A26MX-R].)(SeePROPELLER SHAFT REMOVAL/INSTALLATION [JA5AX-EL].)

9. Remove the joint shaft. (See JOINT SHAFT REMOVAL/INSTALLATION [L8, LF, L3, MZR-CD (RF Turbo)].)

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

11. Remove the air cleaner, intake air duct, and vacuum hose.

12. Remove the ATF hose and selector cable.

13. Remove the vacuum hose and heater hose.

14. Disconnect the selector cable from the transaxle side. (See AUTOMATIC TRANSAXLE AND TRANSFER REMOVAL/INSTALLATION [JA5AX-EL].)

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

16. Disconnect the wiring harness from the engine side.

17. Remove the three way catalyst (TWC). (See EXHAUST SYSTEM REMOVAL/INSTALLATION [L3 4WD].)

18. Remove in the order indicated in the table.

19. Install in the reverse order of removal.

20. 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].)

21. Perform a road test.

1 | No.1 Engine mount rubber (See No.1 Engine Mount Rubber Removal Note) (See No.1 Engine Mount Rubber Installation Note)
2 | No.1 Engine mount bracket (See No.1 Engine Mount Bracket Installation Note)
3 | No.4 Engine mount bracket and No.4 Engine mount rubber (See No.4 Engine Mount Bracket and No.4 Engine Mount Rubber Removal Note) (See No.4 Engine Mount Bracket and No.4 Engine Mount Rubber Installation Note)
4 | Engine ground
5 | No.3 Engine joint bracket (See No.3 Engine Joint Bracket Installation Note)
6 | Engine, transaxle

## No.1 Engine Mount Rubber Removal Note

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

2. Loosen 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.

  Tightening torque
  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 as shown.

  (1) Temporarily tighten (2).
  (2) Completely tighten (1).
  (3) Completely tighten (2).

  Tightening torque
  74.5-104.9 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 {9.5-11.8 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 {9.5-11.8 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}