Engine Removal/Installation
ENGINE REMOVAL/INSTALLATION [SKYACTIV-G 2.0]
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.
- 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". Before Service Precaution
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.
- Applying excessive force (force of 100 N {10.2 kgf, 22.5 lbf} or more) to the electric variable valve timing motor/driver may cause a malfunction. When servicing, be careful not to apply excessive force to the electric variable valve timing motor/driver using other parts or tools.
NOTE:
- Perform the engine and transaxle component removal/installation from below the vehicle.
1. Remove the battery cover. Removal and Replacement
2. Disconnect the negative battery cable. Removal and Replacement
3. Remove the plug hole plate. Plug Hole Plate Removal/Installation
4. Remove the air cleaner and air hose as a single unit. Service and Repair
5. Set the wiring harness aside using the following procedure:
a. Remove the bolt, nut and connector shown in the figure.
b. Remove the wiring harness clip shown in the figure.
6. Remove the battery tray and PCM component. Removal and Replacement
7. Remove the aerodynamic under cover No.2 and splash shield as a single unit. Aerodynamic Under Cover No. 2 Removal/Installation Splash Shield Removal/Installation
8. Drain the engine coolant. Service and Repair
9. Drain the transaxle oil (MTX) or ATF (ATX). Manual Transaxle Oil Replacement [C66M-R] Automatic Transaxle Fluid (ATF) Replacement [FW6A-EL]
10. Remove the front wheels and tires. Service and Repair
11. Disconnect the selector cable. (ATX) Automatic Transaxle Removal/Installation [FW6A-EL]
12. Disconnect the shift cable. (MTX) Manual Transaxle Removal/Installation
13. Remove the clutch release cylinder with the pipe still connected. (MTX) Manual Transaxle Removal/Installation
14. Disconnect the brake vacuum hose. Service and Repair
15. Disconnect the evaporative hose. Service and Repair
16. Disconnect the fuel hose. Quick Release Connector Removal/Installation
17. Disconnect the upper radiator hose. Service and Repair
18. Disconnect the heater hose. Removal and Replacement
19. Disconnect the lower radiator hose. Service and Repair
20. Remove the coolant reserve tank. Service and Repair
21. Remove the generator drive belt. Service and Repair
22. Remove the A/C compressor with the cooler hose still connected and secure it using wire or rope so that it is out of the way. Service and Repair
23. Remove the TWC. Service and Repair
24. Disconnect the drive shafts from the engine side, set the drive shafts out of the way. Drive Shaft Removal/Installation
25. Disconnect the power steering pipe component and then drain the power steering fluid. Service and Repair Service and Repair
26. Disconnect the ground cable from the wiring harness bracket.
27. Remove in the order indicated in the table.
28. Install in the reverse order of removal.
29. Refill the transaxle oil (MTX) or ATF (ATX). Manual Transaxle Oil Replacement [C66M-R] Automatic Transaxle Fluid (ATF) Replacement [FW6A-EL]
30. Refill the engine coolant. Service and Repair
31. Start the engine, and inspect and adjust the following:
- Front wheel alignment Front Wheel Alignment
- Power steering fluid air bleeding Service and Repair
- Leakage of engine oil, engine coolant, ATF (ATX), transaxle oil (MTX), and fuel.
- Runout and contact of pulley and belt.
- Ignition timing, idle speed and idle mixture. Service and Repair
- 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.
No.1 Engine Mount Rubber, Front Crossmember Component Removal Note
1. Loosen the No.1 engine mount rubber installation bolt (front crossmember side) shown in the figure.
2. Remove the No.1 engine mount rubber installation bolt (No.1 engine mount bracket side) shown in the figure.
3. Remove the No.1 engine mount rubber and the front crossmember component as a single unit. Service and Repair
No.3 Engine Mount, No.4 Engine Mount Rubber Removal Note
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 the deformation of the oil pan and damage of the transaxle.
1. Secure the engine and transaxle using a commercially available engine lifter.
2. Remove the No.4 engine mount rubber.
3. Remove the No.3 engine mount.
Engine Mount Installation Note
NOTE:
- Retighten the No.3 engine mount stud bolts when the No.3 engine mount nuts are loosened
1. Tighten the No.3 engine mount stud bolts.
Tightening torque
- 7-13 Nm {72-132 kgf-cm, 62-115 in-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 the deformation of the oil pan and damage of the transaxle.
2. Secure the engine and transaxle using a commercially available engine lifter.
3. Temporarily tighten the No.3 engine mount installation bolts and nuts.
4. Temporarily tighten the No.4 engine mount rubber installation bolt as shown in the figure.
5. Install the No.1 engine mount rubber and the front crossmember component as a single unit. Service and Repair
6. Temporarily tighten the No.1 engine mount rubber installation bolts in the order shown in the figure.
CAUTION:
- Install the bolts while being careful of their length to prevent interference between the steering gear housing and bolt.
Bolt stem length
- Front crossmember side: 62 mm {2.4 in}
- No.1 engine mount bracket side: 65 mm {2.6 in}
7. Tighten the No.3 engine mount installation bolts and nuts in the order shown in the figure.
8. Tighten the No.4 engine mount rubber installation bolt.
Tightening torque
- 94-152 Nm {9.6-15 kgf-m, 70-112 ft-lbf}
9. Tighten the No.1 engine mount rubber installation bolts in the order shown in the figure.
CAUTION:
- Tighten the bolts in the order shown in the figure to prevent abnormal noise and vibration after assembly.
Tightening torque
- 73-90 Nm {7.5-9.1 kgf-m, 54-66 ft-lbf}