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.
Remove the engine room under cover and side covers.
(Refer to Engine And Transaxle Assembly - "Engine Room Under Cover")
Drain the coolant.
(Refer to Cooling System - "Coolant")
Remove the air duct.
(Refer to Intake and Exhaust System - "Air Cleaner")
Remove the battery.
(Refer to Engine Electrical System - "Battery")
Remove the air cleaner assembly.
(Refer to Intake and Exhaust System - "Air Cleaner")
Remove the battery tray.
(Refer to Engine Electrical System - "Battery")
Remove the intercooler inlet pipe & hose (A).
Tightening torque
Clamps :
4.9 ~ 6.9 N.m (0.5 ~ 0.7 kgf.m, 3.6 ~ 5.1 lb-ft)
(If equipped with a cap, tighten it until the cap is removed.)
Bolt :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
Align the marks of the intercooler pipes/hoses and assembling parts.
Remove the intercooler outlet pipe & hose (A).
Tightening torque :
4.9 ~ 6.9 N.m (0.5 ~ 0.7 kgf.m, 3.6 ~ 5.1 lb-ft)
(If equipped with a cap, tighten it until the cap is removed.)
Align the marks of the intercooler pipes/hoses and assembling parts.
Disconnect the radiator lower hose (A).
Disconnect the radiator upper hose (A).
Remove the engine control module (ECM).
(Refer to Engine Control/Fuel System - "Engine Control Module (ECM)")
Disconnect the main wiring harness connectors (A).
Detach the main wiring harness protector (A).
Disconnect the diesel wiring cable (A) from the battery "+" cable.
Disconnect the front connector (A).
Disconnect the wiring cable (A) from the fuse box.
Detach the battery wiring harness protector (A).
Disconnect the wire harness connectors, control cables and hoses from the transaxle.
Manual Transaxle : (Refer to Manual Transaxle System - "Manual Transaxle")
Automatic Transaxle : (Refer to Automatic Transaxle System - "Automatic Transaxle")
Disconnect the engine ground line (A).
Disconnect the transaxle ground line (A).
Disconnect the fuel hose quick connectors (A).
Disconnect the brake vacuum hose (A).
Disconnect the heater hoses (A).
After recovering refrigerant, detach the air compressor high and low pressure pipes.
(Refer to Heating, Ventilation, Air Conditioning - "Compressor")
Remove the propeller shaft. (If equipped with 4WD system)
(Refer to Driveshaft And Axle - "Propeller Shaft Assembly")
Remove the front muffler.
(Refer to Intake and Exhaust System - "Muffler")
Remove the roll rod bracket (A).
Tightening torque
Bolts (B) :
49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)
Bolt (C) :
107.9 ~ 127.5 N.m (11.0 ~ 13.0 kgf.m, 79.6 ~ 94.0 lb-ft)
Remove the roll rod mounting support bracket (A).
Tightening torque :
49.0 ~ 68.6 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 50.6 lb-ft)
Remove the sub frame.
(Refer to Suspension System - "Sub Frame")
Support the engine assembly with a floor jack.
Remove the engine mounting support bracket (A).
Tightening torque :
88.3 ~ 107.9 N.m (9.0 ~ 11.0 kgf.m, 65.1 ~ 79.6 lb-ft)
Remove the service cover (A).
Remove the transaxle mounting bolt (A).
Tightening torque :
88.3 ~ 107.9N.m (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)
Remove the engine and transaxle assembly (A) by lifting vehicle.
Before removing the engine and transaxle assembly, make sure hoses and wire connectors are disconnected.
When removing the engine and transaxle assembly, be careful not to damage any surrounding parts or body components.
When assembling the engine assembly and the transaxle assembly, make sure the dust hole cover is assembled together. Otherwise the encoder can be damaged by foreign substances.
Install in the reverse order of removal.
Perform the following :
Adjust shift cable.
Refill engine with engine oil.
Refill transaxle with transaxle fluid.
Refill radiator and reservoir tank with engine coolant.
Inspect for fuel leakage.
After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes.
Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.
Place the heater control knob on "HOT" position.
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. |
Clean battery posts and cable terminals with sandpaper and assemble them, then apply grease to prevent corrosion.
