1.
Remove the engine cover (A).
Use fender covers to avoid damaging painted surfaces.
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
Mark all wiring and hoses to avoid misconnection.
Remove the engine cover (A).
Remove the under cover (A).
Loosen the radiator drain plug (A) and drain the engine coolant. Remove the radiator cap to speed draining.
Remove the air cleaner assembly.
Remove the air duct (A).
Disconnect the air flow sensor (AFS) connector (B).
Disconnect the breather hose (C).
Remove the intake air hose (D) and air cleaner assembly (E).
Tightening torque :
Clamps: 2.9 ~ 4.9N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6lb-ft)
Bolts: 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
Disconnect the terminals (A) from the battery and remove the battery (B).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Remove the battery tray (A).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Disconnect the intake air temperature sensor connector (A) and remove the intercooler inlet pipe&hose (B) and outlet pipe&hose (C).
Tightening torque :
Clamps: 4.9 ~ 6.9N.m (0.5 ~ 0.7kgf.m, 3.6 ~ 5.1lb-ft)
Bolt: 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Disconnect the boost pressure sensor (BPS) connector (A) and remove the intercooler inlet pipe & hose (B) and outlet pipe & hose (C).
Remove the upper radiator hose (A) and lower radiator hose (B).
Disconnect the engine wire harness connectors and remove the wire harness clamps from the cylinder head cover and the intake manifold.
Disconnect the difference pressure sensor connector (A). (With DPF) [Euro - 5 only]
Disconnect the exhaust gas temperature sensor connector (B). (With DPF) [Euro - 5 only]
Disconnect the lambda sensor connector (C). [Euro - 4/5 only]
Disconnect the cam position sensor (CMPS) connector (A).
Disconnect the rail pressure sensor connector (B).
Disconnect the glow plug connector (C).
Disconnect the fuel pressure regulator valve connector (D).
Disconnect the boost pressure sensor (BPS) connector (E). [2.2L only]
Disconnect the oil pressure switch connector (F).
Disconnect the crankshaft position sensor (CKPS) connector (G).
Disconnect the EGR cooling valve connector (H). [Euro - 4/5 only]
Disconnect the fuel temperature sensor connector (I).
Disconnect the rail pressure regulator valve connector (J).
Disconnect the injector connectors (K).
Disconnect the air control valve connector (L).
Disconnect the variable swirl control actuator connector (A). [Euro - 4/5 only]
Disconnect the engine coolant temperature sensor (ECTS) connector (B).
Disconnect the E-VGT actuator connector (C).
Disconnect the EGR actuator connector (D).
Disconnect the alternator connector (A) and the cable (B).
Disconnect the starter connector (C) and the cable (D).
Disconnect the air compressor switch connector (E).
Disconnect the wire harness connectors, control cable and ground line. (Refer to MT or AT group)
Remove the wire harness protector (A).
Disconnect the engine ground line (A).
Disconnect the fuel hoses (A).
Disconnect the brake vacuum hose (A).
Disconnect the heater hoses (A).
Disconnect the power steering oil hoses (A). (Refer to ST group)
After recovering refrigerant, disconnect the air compressor high and low pressure pipes (A). (Refer to HA group)
Remove the propeller shaft (A). (Refer to DS group)
Remove the front muffler (A).
Tightening torque :
39.2 ~ 58.8N.m (4.0 ~ 6.0kgf.m, 28.9 ~ 43.4lb-ft)
Remove the steering u-joint mounting bolt (A) and connector (B). (Refer to ST group)
Remove the front wheels. (Refer to SS group)
Remove the shock absorber mounting, the stabilizer bar link mounting, the lower arm ball joint mounting, and the steering tie rod mounting. (Refer to SS, ST group)
Remove the drive shaft from the axle hub. (Refer to DS group)
Remove the engine mounting bracket (A).
Tightening torque :
Bolts(B), Nut(C) : 63.7 ~ 83.4N.m (6.5 ~ 8.5kgf.m, 47.0 ~ 61.5lb-ft)
Nut(D) : 78.5 ~ 107.9N.m (8.0 ~ 11.0kgf.m, 57.9 ~ 79.6lb-ft)
Remove the transaxle mounting bracket and support bracket fixing bolt (A).
Tightening torque :
78.5 ~ 107.9N.m (8.0 ~ 11.0kgf.m, 57.9 ~ 79.6lb-ft)
Support the sub frame (A) with a floor jack, and then remove the sub frame brackets (B, C) and mounting bolts.
Tightening torque :
137.3 ~ 156.9N.m (14.0 ~ 16.0kgf.m, 101.3 ~ 115.7lb-ft)
After removing the sub frame mounting bolt, the engine and transaxle assembly may fall downward, and so support them securely with floor jack.
Verify that the hoses and connectors are disconnected before removing the engine and transaxle assembly.
Remove the engine and transaxle assembly (A) by lifting vehicle.
When remove the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.
Installation is in the reverse order of removal.
Perform the following :
Adjust the shift cable.
Refill engine with engine oil.
Refill transaxle with fluid.
Clean the battery posts and cable terminals with sandpaper and assemble them, then apply grease to prevent corrosion.
Inspect for fuel leakage.
If the engine does not run immediately after assembling the fuel line, remove trapped air and be pressurized in the fuel line by operating the low pressure fuel pump using the GDS.
Check for fuel leakage at any point in the fuel lines.
Refill radiator with engine coolant.
Bleed air from the cooling system.
Start engine and let it run until it warms up. (Until the radiator fan operates 3 or 4 times.)
Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system.
Put radiator cap on tightly, then run the engine again and check for leaks.
