ENGINE REMOVAL/INSTALLATION

BHE011002000W04

Warning
• Fuel vapour 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 from the pressurized fuel system are dangerous. Fuel can ignite and cause serious injury or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure" when servicing the fuel system. (See BEFORE REPAIR PROCEDURE.)
• After disconnecting the steering shaft joint, always set the EPS system to the neutral position to prevent system malfunction. (See EPS SYSTEM NEUTRAL POSITION SETTING.)
Caution
• To allow the PCM to identify that the engine has been replaced, pump the brake pedal 20 times within 8 s after the ignition switch is turn to the ON position (engine off).
Note
• Remove the engine, transmission, and crossmember component as a single unit downward of the vehicle.

1. Remove the following parts:

(1) The front wheel and tires (SeeGENERAL PROCEDURES (SUSPENSION)
(2) The engine cover (SeeENGINE COVER REMOVAL/INSTALLATION.)
(3) The front suspension tower bar (SeeFRONT SUSPENSION TOWER BAR REMOVAL/INSTALLATION.)
(4) The battery cover, battery, battery box and battery tray (SeeBATTERY REMOVAL/INSTALLATION.)
(5) The air cleaner, intake-air duct and air cleaner insulator (SeeINTAKE-AIR SYSTEM REMOVAL/INSTALLATION.)
(6) The PCM (See PCM REMOVAL/INSTALLATION.)
(7) The secondary air injection pump. (See SECONDARY AIR INJECTION (AIR) PUMP REMOVAL/INSTALLATION.)

2. Drain the engine coolant. (SeeENGINE COOLANT REPLACEMENT.)

3. Disconnect the brake vacuum hose.

4. Disconnect the quick release connector going to the charcoal canister from the engine room side. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION.)

5. Disconnect the plastic fuel hose. (See BEFORE REPAIR PROCEDURE.) (See FUEL INJECTOR REMOVAL/INSTALLATION.)

6. Remove the ignition coil. (See IGNITION COIL REMOVAL/INSTALLATION.)

7. Remove the A/C belt. (See DRIVE BELT REPLACEMENT.)

8. 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.

9. Disconnect the engine wiring harness from the main fuse block side.

10. Remove the engine under cover.

11. Disconnect front ABS wheel speed sensor connector. (See FRONT ABS WHEEL-SPEED SENSOR REMOVAL/INSTALLATION.)

12. Disconnect the radiator hose, the heater hose and coolant reserve tank hose.

13. Remove the clutch release cylinder with the pipes connected and secure the clutch release cylinder using wire or rope so that it is out of the way. (MT) (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION.)

14. Remove the shift lever component . (MT) (See TRANSMISSION REMOVAL/INSTALLATION [R15M-D].) (See TRANSMISSION REMOVAL/INSTALLATION [Y16M-D].)

15. Disconnect the selector link. (AT) (See AUTOMATIC TRANSMISSION REMOVAL/INSTALLATION.)

16. Remove the engine, transmission, and crossmember component using an engine lifter in the order indicated in the table.

Warning
• Remove the engine, transmission and crossmember carefully, holding it steady. If the transmission falls it could be damaged or cause injury.

1
Universal joint
2
Oil hose
3
AT oil cooler hose (AT)
4
Calliper component
5
Front strut lower bolt
6
Front tunnel member
7
Rear tunnel member
8
Catalytic converter, middle pipe, main silencer
9
Heat insulator
10
Propeller shaft
11
Transverse member
12
Power plant frame
13
Engine, transmission, crossmember component

17. Remove the engine and transmission from the crossmember component lifter in the order indicated in the table by suspending them with a crane.

1
Engine mount rubber (RH)
2
Engine mount bracket (RH)
3
Engine mount rubber (LH)
4
Engine mount bracket (LH)
5
Engine, transaxle
6
AT oil cooler pipe

18. Install in the reverse order of removal.

19. Start the engine and inspect and adjust the following:

• Pulley and belt for runout, tension, and contact
• Leakage of engine oil, engine coolant, ATF, MT oil, and fuel
• Ignition timing, idle speed, and idle mixture (CO and HC) (See ENGINE TUNE-UP.)
• Front wheel alignment (See FRONT WHEEL ALIGNMENT.)
• Engine-driven accessories operation

20. Perform the on-road test and verify that there is no vibration or noise.

Oil Hose Removal Note

1. Remove the clip as shown in the figure and disconnect the oil pipe.

Caution
• Catch the remaining engine oil in the oil cooler using a plate pipe to prevent spillage.

Power Plant Frame, Crossmember Bolt Removal/Installation Note

1. Secure the engine, transmission, and crossmember component using an engine lifter.

Note
• When installing the power plant frame, tighten the tightening bolts and nuts temporarily at this time, and after installing all parts, adjust the transmission installation positions referring to 'Power Plant Frame Installation Note' and then tighten them completely. (SeePower Plant Frame Installation Note)

Oil Hose Installation Note

1. Connect a new clip as shown in the figure and connect the oil hose.

Caution
• Always install the oil hose with the three holes on the oil hose grooves and the three clip projections aligned.