Engine Assembly

Repair Procedures

Removal

1. 1
   Remove the air cleaner assembly. (Refer to Air Intake and Exhaust System - "Air Cleaner").
2. 2
   Remove the engine undercover and side cover. (Refer to Engine and Transaxle Assembly - Engine Room Under Cover)
3. 3
   Drain the engine coolant. (Refer to Cooling System — Engine Coolant)
4. 4
   Recover the refrigerant, then remove the high-pressure line and the low-pressure line. (Refer to Heating, Ventilation and Air Conditioning - "Compressor")
5. 5
   Remove the battery and battery tray. (Refer to Engine Electrical System - "Battery")
6. 6
   Remove the intake hoses and intercooler pipe (A). Tightening torque: Hose clamp bolt: 4.9–6.9 N·m N·m (If equipped with a cap, tighten until the cap breaks off.) Pipe mounting bolt: 18.6–24 N·m N·m

   

7. 7
   Disconnect the outlet hose and intercooler pipe (A). Tightening torque: 4.9–6.9 N·m N·m (If equipped with a cap, tighten until the cap breaks off.)

   

8. 8
   Disconnect the water return hose (A) and the turbocharger water drain hose (B).

   

9. 9
   Disconnect the upper radiator hose (A).

   

10. 10
    Disconnect the radiator lower hose (A).

    

11. 11
    Disconnect the fuel hose (A) and the hose (B) of the purge control solenoid valve (PCSV).

    

12. 12
    Disconnect the brake booster vacuum hose (A).

    

13. 13
    Disconnect the recirculation valve (RCV) hose (A) and the vacuum hose (B).

    

14. 14
    Disconnect the heater hoses (A).

    

15. 15
    Disconnect the wiring connectors and harness clips, and remove the connector brackets around the engine and transaxle.

    

16. 16
    Disconnect the wire cable from the fuse block (A).

    

17. 17
    Disconnect the transaxle wiring harness connectors and the control cable from the transaxle. (Refer to Manual Transaxle System - Manual Transaxle)
18. 18
    Remove the front muffler. (Refer to Intake and Exhaust System - "Muffler")
19. 19
    Remove the roller rod bracket (A). Tightening torque: Bolt (B): 127.5–147 N·m N·m Bolt (C): 49.0–64 N·m N·m

    

20. 20
    Remove the roller rod bracket (A).

    Tightening Torque: 49.0–69 N·m

    

21. 21
    Remove the suspension member. (Refer to Suspension System - "Suspension Member")
22. 22
    Support the engine and transaxle assembly with a lift table.
23. 23
    Remove the engine mounting bracket (A).

    Tightening Torque: 49.0–64 N·m

    

24. 24
    Disconnect the transaxle ground cable (A).

    

25. 25
    Remove the transaxle side panel seal (A).

    

26. 26
    Remove the transmission mounting bolts (A).

    Tightening torque: 88.2 - 108 N·m

    

27. 27
    Remove the engine and transmission assembly (A) by raising the vehicle.

    

Installation

• Fill the engine with engine oil.
• Fill the transmission with fluid.
• Fill the radiator and the coolant reservoir with engine coolant.
• Clean the battery terminals and cable terminals with sandpaper. Then assemble them and apply grease to prevent corrosion.
• Inspect for fuel leaks.
• After assembling the fuel line, turn the ignition ON (do not crank the engine) so the fuel pump operates for about two seconds and pressurizes the fuel line.
• Repeat this procedure two or three times, then check all fuel line connections for leaks.
• Set the heater control knob to the "HOT" position.
• Bleed air from the cooling system.
• Start the engine and let it run until warm (until the radiator fan cycles 3 or 4 times).
• Turn the engine OFF. Check the coolant level in the radiator and add coolant if necessary. This allows trapped air to be bled from the cooling system.
• Tightly close the radiator cap, then restart the engine and check for leaks.