ENGINE REMOVAL/INSTALLATION[L3]

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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 SERVICE PRECAUTION[L3].)
Note
•  Perform the engine and transaxle component removal/installation from below the vehicle.
Note
•  If the engine is overhauled and installed to the vehicle, perform the road test and verify that there is no abnormality.

1.  Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION[L3])

2.  Remove the front wheel and tire (RH). (See WHEEL AND TIRE REMOVAL/INSTALLATION)

3.  Remove the splash shield.

4.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT[L3])

5.  Drain the ATF. (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT[GF4AX-EL])

6.  Remove the air cleaner, intake air duct, brake vacuum hose and bracket. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION[L3])

7.  Remove the front bumper. (See FRONT BUMPER REMOVAL/INSTALLATION)

8.  Remove the cooling fan component. (SeeFAN MOTOR REMOVAL/INSTALLATION[L3])

9.  Disconnect the heater hose from the body.

10.  Disconnect the upper radiator hose from the water outlet.

11.  Disconnect the Quick release connector from the fuel distributor. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION[L3])

12.  Disconnect the vacuum hose of the purge solenoid valve from the intake manifold.

13.  Remove the ATF filler tube and selector cable.

14.  Disconnect the PCM connector. (See PCM REMOVAL/INSTALLATION[L3])

15.  Disconnect the wiring harnesses.

16.  Remove the transverse member. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION)

17.  Disconnect the front drive shaft. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION)

18.  Disconnect the propeller shaft on the transfer side.

19.  Remove the air guide plate. (SeeAUTOMATIC TRANSAXLE AND TRANSFER REMOVAL/INSTALLATION[GF4AX-EL])

20.  Remove the TWC. (See EXHAUST SYSTEM REMOVAL/INSTALLATION[L3])

21.  Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION[L3])

22.  Disconnect the lower radiator hose from the radiator.

23.  Disconnect the ATF oil hose.

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

Note
•  Position and secure the A/C compressor out of the way with rope or wire.

25.  Remove the P/S oil pump. Position the P/S oil pump out of the way with the hoses and pipes still connected.

26.  Remove in the order indicated in the table.

27.  Install in the reverse order of removal.

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

•  Runout and contact of the pulley and belt.
•  Leakage of engine oil, engine coolant, ATF, and fuel
•  Ignition timing, idle speed, and idle mixture (CO and HC concentration) (See ENGINE TUNE-UP[L3])
•  Engine-driven accessories operation
Note
•  If there is any malfunction, loosen the engine mount installation bolts and nuts, and adjust the engine installation position.
•  If installing an overhauled engine, perform a road test and verify that there is no abnormal vibration ore noise.

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1
No.2 engine mount through bolt
2
Engine mount member, No.2 engine mount rubber
(See Engine Mount Member, No.2 Engine Mount Rubber Removal Note.)
(See Engine Mount Member, No.2 Engine Mount Rubber Removal Note.)
3
No.1 engine mount through bolt
4
No.1 engine mount rubber
5
No.3 engine mount bracket
(See Engine Mount Member, No.2 Engine Mount Rubber Removal Note.)
(See Engine Mount Member, No.2 Engine Mount Rubber Removal Note.)
6
No.4 engine mount through bolt
7
No.4 engine mount bracket
(See Engine Mount Member, No.2 Engine Mount Rubber Removal Note.)
8
Engine, transaxle


Engine Mount Member, No.2 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.
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(1)  Install the right rear shaft of the SST to the bolt of the right shock absorber as shown in the figure.
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(2)  Install the left rear shaft of the SST to the bolt of the left shock absorber. (Identical position to the right side)
(3)  Install the left/right front shaft of the SST with front foot No.2 to the bolt as shown in the figure.
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(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.

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Note
•  The SST (49 E017 5A0) can be used in place of the SST (49 C017 5A0).

3.  Remove the engine mount member and No.2 engine mount rubber.


No.3 Engine Mount Bracket Removal Note

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

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2.  Remove the SST.

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No.4 Engine Mount Rubber Installation Note

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

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2.  Install the No.4 engine mount bracket to the transaxle and temporarily tighten the bolts and nuts.

3.  Temporarily tighten the No.4 engine mount rubber and bracket through bolt.

Caution
•  Make sure that the through bolt is completely seated.

4.  Tighten the new No.4 engine mount bracket bolts, nuts, and through bolt in the order as shown in the figure.

Caution
•  After tightening nut (2), retighten nut (1).
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Tightening torque
Nut (1), (2): 66.6—93.1 N·m {6.80—9.49 kgf·m, 49.2—68.6 ft·lbf}
Bolt (3): 66.6—93.1 N·m {6.80—9.49 kgf·m, 49.2—68.6 ft·lbf}
Bolt (4): 85.3—116.6 N·m {8.70—11.8 kgf·m, 63.0—85.9 ft·lbf}


No.3 Engine Mount Bracket Installation Note

1.  Tighten the No.3 engine mount bracket installation stud bolts.

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Tightening torque
7.0—13.0 N·m {71.4—132 kgf·cm, 62.0—115 in·lbf}

2.  Install the No.3 engine mount bracket and temporarily tighten.

3.  Tighten the No.3 engine mount bracket bolt and nut in the order shown in the figure.

Tightening torque
74.5—104.9 N·m {7.60—10.6 kgf·m, 55.0—77.3 ft·lbf}
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4.  Install the SST using the following procedure.

Caution
•  Refer to the SST instruction manual for the basic handing procedure.
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(1)  Install the right rear shaft of the SST to the bolt of the right shock absorber as shown in the figure.
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(2)  Install the left rear shaft of the SST to the bolt of the left shock absorber. (Identical position to the right side)
(3)  Install the left/right front shaft of the SST with front foot No.2 to the bolt as shown in the figure.
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(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.

5.  Support the engine using the SST.

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Note
•  The SST (49 E017 5A0) can be used in place of the SST (49 C017 5A0).

6.  Remove the engine jack.


No.1 Engine Mount Rubber Installation Note

Caution
•  After removing the SST (49 E017 5A0), tighten the No.1 engine mount rubber properly.

1.  Install the No.1 engine mount rubber to the crossmember and temporarily tighten.

2.  Tighten the No.1 engine mount through bolt.

Tightening torque
85.3—116.3 N·m {8.70—11.8 kgf·m, 63.0—85.7 ft·lbf}


Engine Mount Member, No.2 Engine Mount Rubber Installation Note

Caution
•  Temporarily tighten the No.2 engine mount through bolt, install the engine mount member, and then properly tighten the through bolt.

1.  Tighten the engine mount member bolts and nut.

Tightening torque
66.6—93.1 N·m
{6.80—9.49 kgf·m, 49.2—68.6 ft·lbf}

2.  Remove the SST.

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3.  Properly tighten the No.1 engine mount rubber bolts and nut.

Tightening torque
66.6—93.1 N·m
{6.80—9.49 kgf·m, 49.2—68.6 ft·lbf}

4.  Tighten the No.2 engine mount through bolt.

Tightening torque
85.3—116.3 N·m {8.70—11.8 kgf·m, 63.0—85.7 ft·lbf}