Contents: Removal ↧ Installation ↧
Removal
Note: On vehicles with a manual transmission, it must be removed before removing the engine.
1. Remove the fuel pump fuse.
2. Perform the fuel rail pressure reduction procedure.
3. Remove the hood.
4. Drain the engine oil.
5. Disconnect and insulate the negative battery cable.
6. Disconnect the negative battery cable from the engine frame.
7. Drain the air conditioning (A/C) system if your vehicle has one.
8. Disconnect the supply air temperature sensor connector.
9. Remove the air duct from the throttle body and the air filter housing.
10. Disconnect the vent tube from the valve cover.
11. Remove the right front wheel.
12. Remove the right front wheel mudguard.
13. Remove the accessory drive belt.
14. Drain the coolant.
15. Remove the cooling system radiator and engine cooling fans.
16. Disconnect the upper radiator hose from the coolant distributor.
17. Disconnect the coolant expansion tank hose from the radiator.
18. Disconnect the power steering return hose and drain the fluid from the system if the vehicle is equipped with power steering.
19. Disconnect the power steering high pressure hose from the power steering pump.
20. Disconnect the electrical connector at the ignition coil and the ECM ground terminal at the intake manifold and at the starter.
21. Disconnect the oxygen sensor connector installed in front of the catalytic converter.
22. Disconnect the electrical connectors on the fuel injectors.
23. Disconnect the idle air control valve connector.
24. Disconnect the throttle position sensor connector.
25. Disconnect the coolant temperature sensor (CTS) connector and the knock sensor, if equipped on the vehicle.
26. Disconnect the generator voltage regulator connector.
27. Disconnect all necessary vacuum lines, including the brake booster vacuum hose.
28. Disconnect the fuel supply line from the fuel rail.
29. Disconnect the throttle cable from the throttle body and the intake manifold bracket.
30. Disconnect the camshaft position (CMP) sensor connector.
31. Disconnect the coolant expansion tank hose at the throttle body.
32. Disconnect the heater supply hose from the coolant distributor.
33. Disconnect the heater outlet hose.
34. Disconnect the coolant expansion tank hose from the coolant line.
35. Disconnect the lower radiator hose at the coolant line.
36. Disconnect the wire from the "S" terminal of the starter solenoid.
37. Remove the air conditioning compressor hose retaining bolt.
38. Disconnect the compressor hose from the compressor.
39. Disconnect the air conditioning compressor coil connector.
40. Loosen the air conditioning compressor mounting bolts.
41. Remove the air conditioning compressor.
42. Remove the A/C compressor mounting bracket bolts.
43. Remove the air conditioning compressor mounting bracket from the engine block.
44. Remove the catalytic converter nuts from the exhaust manifold.
45. Remove the nuts from the front muffler pipe and connecting pipe.
46. Remove the crankshaft pulley bolt.
47. Remove the crankshaft pulley.
48. Disconnect the pipes from the Fuel vapor capture system (EVAP) tank.
49. Disconnect the electrical connector at the evaporator solenoid and runout sensor.
50. Disconnect the electrical connector on the oil pressure valve.
51. Disconnect the CMP sensor connector.
52. Remove the mounting screw of the crank position sensor SKR.
53. Remove the crank shaft position sensor SCR.
54. Remove the battery.
55. Remove the battery shelf.
56. Remove the right strut gearbox bolts from the gearbox.
57. Disconnect the auxiliary switch connector.
58. Remove the hydraulic clutch pipe.
59. Remove the gearbox housing bolts.
60. Place a floor jack under the gearbox.
61. Install a hoist to lift the engine.
62. Disconnect the right engine mount bracket from the rubber mount by removing the two mounting bolts.
63. Remove the right engine mounting bracket.
64. Disconnect the gearbox from the engine block.
65. Remove the engine.
Installation
1. Install the engine into the engine compartment.
2. Align the gearbox mounting bushings with the gearbox holes.
3. Tighten the gearbox housing bolts to 75 Nm.
4. Install the right engine mount bracket onto the engine block and tighten the right engine mount bracket mounting bolts to 60 Nm.
6. Tighten the bolts securing the cushion to the bracket to a torque of 60 Nm.
7. Remove the engine support jack.
8. Remove the engine lifting hoist.
9. Install the right gearbox strut bolts to the gearbox and tighten to 60 Nm.
10. Connect the auxiliary switch electrical connector.
11. Install the hydraulic clutch pipe.
12. Install the battery shelf.
13. Install the battery.
14. Connect the pipelines from the Fuel Vapor Capture System (EVAP) tank.
15. Connect the electrical connectors of the fuel vapor recovery system canister filter cleaner solenoid.
16. Connect the oil pressure sensor connector.
17. Install the crankshaft pulley and tighten the crankshaft pulley mounting bolt to a torque of 95 Nm.
18. Tighten the crankshaft pulley mounting screw by 30°+15°.
19. Install the crankshaft position sensor CKP and tighten the mounting bolt to a torque of 10 Nm.
20. Connect the connector of the crank shaft position sensor SCR.
21. Tighten the nuts securing the exhaust pipe to the catalytic converter to a torque of 30 Nm.
22. Tighten the nuts securing the catalytic converter to the exhaust manifold to a torque of 40 Nm.
23. Connect the power steering hose to the power steering pump.
24. Install the air conditioning compressor mounting bracket, if equipped on the vehicle, and tighten the bolts to 50 Nm.
25. Install the air conditioning compressor, if equipped on the vehicle, and tighten the air conditioning compressor mounting bolts to 27 Nm.
26. Connect the air conditioning compressor coil connector.
27. Install the alternator drive belt.
28. Install the air conditioning compressor drive belt, if equipped on the vehicle.
29. Install the air conditioning compressor hose and tighten the hose mounting bolt to 33 Nm.
30. Install the right front wheel mudguard.
31. Install the right front wheel.
32. Connect the fuel supply line to the fuel rail.
33. Connect all necessary vacuum lines, including the brake booster vacuum hose.
34. Connect the oxygen sensor installed in front of the catalytic converter.
35. Connect the starter solenoid terminal "S" cable.
36. Connect the generator voltage regulator connector.
37. Connect the CTS sensor connector.
38. Connect the TP sensor connector.
39. Connect the IAC valve connector.
40. Connect the CMP sensor connector.
41. Connect the electrical connectors to the fuel injectors.
42. Connect the ignition coil electrical connectors and the PCM/ECM ignition terminal on the intake manifold.
43 Install the air duct between the throttle body and the air cleaner housing.
44. Connect the ventilation tube to the timing cover.
45. Connect the IAT sensor connector.
46. Install the radiator and cooling fans.
47. Connect the lower radiator hose to the coolant line.
48. Connect the upper hose to the thermostat housing.
49. Connect the coolant expansion tank to the radiator.
50. Connect the radiator outlet hose to the coolant pipe.
51. Connect the heater supply hose to the coolant distributor.
52. Connect the coolant expansion tank hose to the coolant line.
53. Connect the coolant expansion tank hose to the throttle body.
54. Connect the throttle cable to the throttle body and intake manifold bracket. Install the fuel pump fuse.
55. Connect the negative battery cable to the vehicle frame.
56. Connect the negative battery cable to the battery.
57. Pour engine oil into the crankcase.
58. Fill the engine cooling system.
59. Fill the cooling system.
60. If necessary, drain the power steering system.
61. Refill the air conditioning system with refrigerant if necessary.
62. Install the hood.
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