Necessary equipment
- EN-48243 Engine Removal/Installation Rack Assembly
- EN-48244 Rack bracket for engine removal/installation assembly
Removal procedure
1. Remove the fuel pump fuse.
2. Start the engine. After stopping the engine, crank the engine for 10 seconds to relieve pressure in the fuel system.
3. Drain the engine oil.
4. Drain the engine coolant. See Section 1D2, Engine Cooling System - FAM II 2.4D.
5. Drain the power steering fluid.
6. Drain transmission oil. See Section 5A, AISIN 55-51LE Automatic transaxle with final drive assembly or Section 5B, Five-speed final drive assembly (D33).
7. Discharge the air conditioning system, if equipped. Follow See Section 7B, Heating, Ventilation, and Air Conditioning Control.
8. Disconnect the intake air temperature sensor connector (IAT).
9. Remove the engine cover screw.
10. Disconnect the breather hose and the positive crankcase ventilation hose from the cylinder head cover.
11. Remove the air filter assembly. See «Air filter assembly» in this section.
12. Remove the resonator from the electronic throttle body.
13. Disconnect the upper radiator hose from the thermostat.
14. Disconnect the lower radiator hose from the coolant pipe.
15. Disconnect the coolant hoses from the electronic throttle body.
16. Disconnect expansion tank hose from cylinder block.
17. Disconnect the heater outlet hose from the coolant pipe.
18. Disconnect the heater inlet hose from the cylinder head.
19. Disconnect the fuel line from the fuel rail.
20. Disconnect the power steering return hose and pressure hose from the power steering pump. See Section 6A, Power Steering System.
21. Disconnect all required electrical connectors i.e. A/C Pressure Sensor, EGR Valve, Direct Ignition System, Coolant Temperature Sensor, Electronic Throttle Control System, Oxygen Sensor, Crankshaft Position Sensor, Camshaft Position Sensor, Manifold Absolute Pressure Sensor, fuel injector, ECM controller (ECM), knock sensor, alternator, starter terminal, etc.
22. Remove the ground terminals from the starter, intake manifold and cylinder block.
23. Remove all unnecessary parts and disconnect all connectors and cables from the transaxle assembly. See Section 5A, AISIN 55-51LE Automatic transaxle with final drive assembly or Section 5B, Five-speed final drive assembly (D33).
24. Disconnect all necessary vacuum lines, including the brake booster vacuum hose.
25. Remove the air conditioning compressor. Follow See Section 7B, Heating, Ventilation, and Air Conditioning Control.
26. Disconnect the engine wires from the engine.
27. Loosen the nuts securing the catalytic converter to the exhaust pipe of the muffler.
28. Remove the bolt and nut from the muffler exhaust pipe mounting bracket.
29. Remove the front silencer pipe from the catalytic converter. See Section 1G2, Exhaust System - FAM II 2.4D.
30. For vehicles with permanent all-wheel drive: Remove propshaft. See Section 3B, Rear Drive Axle.
31. Disconnect the stabilizer link. See Part 2D. Rear suspension.
32. Disconnect the rod end connection. See Part 2D. Rear suspension.
33. Disconnect the tie rod connection. See Part 2D. Rear suspension.
34. Dismantle the left and right axle shafts. See Section 3A, Automatic Transaxle Assembly, Drive Axle or Section 3B, Manual Transaxle Assembly, Drive Axle.
35. Remove the power steering intermediate shaft. See section 6C, "Steering gear with hydraulic booster".
36. Unscrew the fixing bolts of the support bracket. See section 2C, "Front suspension".
37. Unscrew the fixing bolts of the support.
Attention! Verify that all components of the EN-48243 Engine Assembly Remove/Install Rack are aligned exactly with the EN-48244 Bracket as shown.
- 1~4: Support bracket
- A: Diesel engine oil pan bracket
- b: FAM II 2.4D Engine oil pan bracket
- c&d: HFV6 3.2L Engine Oil Pan Bracket
- E: Bracket for manual transmission with final drive assembly
- F: Bracket for automatic transmission with final drive assembly
- G: Transfer case bracket (M/T and A/T)
- H: Gearbox suspension bracket assembly (M/T and A/T)
Attention! Lower the vehicle enough to take the load off the engine mount and transaxle assembly, otherwise damage to the suspension and rack/rack bracket failure may occur.
38. Lower the vehicle and place the engine assembly on the EN-48243 engine install/remove rack assembly with the EN-48244 rack bracket to support.
39. Remove the engine mount. See «Engine mount» in this section.
40. Remove the transmission mount assembly with final drive. See «Gearbox suspension with final drive, assy» in this section.
Attention! Make sure all wires, connectors and hoses are disconnected from the engine and transaxle assembly.
41. Raise the vehicle for free removal of the engine and transaxle assembly.
42. Place a lifting device on the engine support bracket and raise the engine assembly so that the front and rear transaxle mounts are unloaded.
43. Remove the front transmission suspension with final drive assembly from the support. See «Gearbox Front Suspension with Final Drive Assembly» in this section.
44. Remove the rear suspension of the gearbox with final drive assembly from the support. See «Rear Suspension Gearbox with Final Drive Assembly» in this section.
45. Raise the engine assembly and remove the support from the engine and transaxle assembly.
46. Separate the cylinder block from the transaxle assembly as follows.
- Remove torque converter bolts.
- Unscrew the fixing bolts connecting the gearbox with final drive assembly to the engine block.
- Loosen the mounting bolts connecting the oil flange to the transaxle assembly.
- Loosen the starter mounting bolts.
Installation procedure
1. Install the torque converter mounting bolts.
Tighten
Tighten torque converter bolts to 45 Nm (33 lb-ft).
2. Install the transaxle assembly to the engine block.
Tighten
Tighten the transaxle housing screws to 75 Nm (55 lb-ft).
Tighten the oil sump flange-to-transaxle bolts to 50 Nm (37 lb-ft).
3. Install starter mounting screws.
Tighten
Tighten the fixing bolt connecting the starter to the engine block to a torque of 75 Nm (55 lb-ft).
Tighten the fixing bolt connecting the gearbox to the final drive assembly with the starter, to a torque of 75 Nm (55 lb-ft).
Attention! Verify that all components of the EN-48243 Motor Assembly Removal/Installation Rack are aligned exactly with the EN-48244 Rack Bracket.
4. Install the engine and gearbox with final drive assembly on the support.
Attention! Before tightening the transaxle front mount pinch bolt, move the engine assembly back and forth or side to side for proper installation.
5. Install the transaxle front suspension assembly.
Tighten
Tighten the transaxle front mount retaining bolts to 50 Nm (37 lb-ft).
Tighten the pinch bolt of the front suspension of the gearbox with final drive assembly to the support to a torque of 90 Nm (66 lb-ft).
Attention! Before tightening the transaxle rear mount pinch bolt, move the engine assembly back and forth or side to side for proper installation.
6. Install the transaxle rear mount assembly to the engine block.
Tighten
Tighten the bolts of the rear suspension of the gearbox with final drive assembly to 90 Nm (66 lb-ft).
Tighten the pinch bolt of the rear suspension of the gearbox with final drive assembly to the bracket to 90 Nm (66 lb-ft).
7. Raise the car.
8. Lower the vehicle and place the engine and transaxle assembly connected to the support on the EN-48243 engine install/remove rack assembly with EN-48244 rack bracket in the vehicle.
9. Establish a suspension bracket of the check point with the main transfer in gathering. See «Gearbox suspension with final drive, assy» in this section.
Tighten
Tighten the transaxle mount retainer bolts to 37 Nm (27 lb-ft).
Tighten the locking bolts of the gearbox suspension bracket with final drive assembly to 50 Nm (37 lb-ft).
10. Install the engine mount. See «Engine mount» in this section.
Tighten
Tighten the retaining bolt of the engine mount frame side bracket to 100 Nm (74 lb-ft), and nuts with a torque of 90 Nm (66 lb-ft).
Tighten the engine mount adapter retaining bolts to 50 Nm (37 lb-ft).
11. Remove the EN-48243 engine removal/installation rack assembly from the vehicle with the EN-48244 rack bracket.
12. Screw the fixing bolts connecting the support to the body. See section 2C, "Front suspension". Section 2C, Front Suspension.
Tighten
Tighten the support mounting bolts to 155 Nm (114 lb-ft).
13. Install the support bracket retaining bolts. See section 2C, "Front suspension". Section 2C, Front Suspension.
Tighten
Tighten the support bracket bolts to 50 Nm (37 lb-ft).
14. Install the power steering intermediate shaft. See section 6C, "Steering gear with hydraulic booster".
15. Install the left and right axle shafts. See Section 3A, Automatic Transaxle Assembly, Drive Axle or Section 3B, Manual Transaxle Assembly, Drive Axle.
16. Install the tie rod connection. See Part 2D. Rear suspension.
17. Install the rod end connection. See Part 2D. Rear suspension.
18. Install the stabilizer link. See Part 2D. Rear suspension.
19. Install the exhaust pipe to the catalytic converter. See Section 1G2, Exhaust System - FAM II 2.4D.
Tighten
Tighten the nuts securing the catalytic converter to the exhaust pipe of the muffler to a torque of 40 Nm (30 lb-ft).
Tighten the bolt and nut of the muffler exhaust pipe mounting bracket to 40 Nm (30 lb-ft).
20. For vehicles with permanent all-wheel drive: install propeller shaft. See Section 3B, Rear Drive Axle.
21. Install the engine wires to the engine.
22. Connect all necessary vacuum lines, including the brake booster vacuum hose.
23. Connect earth clamps.
24. Connect all necessary electrical connectors.
25. Connect the power steering hoses to the power steering pump. See section 6C, "Steering gear with hydraulic booster".
26. Connect the fuel supply line to the fuel rail.
27. Connect the heater inlet and outlet hoses to the cylinder head.
28. Connect all necessary cooling system hoses to the electronic throttle body, thermostat, coolant pipe and engine block.
29. Install the resonator to the electronic throttle body.
30. Install the air cleaner assembly. See «Air filter assembly» in this section.
31. Install the breather hose and the positive crankcase ventilation hose to the cylinder head cover.
32. Connect the intake air temperature sensor connector (IAT).
33. Install the decorative engine cover.
34. Install the fuel pump fuse.
35. Fill the crankcase with engine oil.
36. Refill the engine cooling system. See Section 1D2, Engine Cooling System - FAM II 2.4D.
37. Refill the power steering system and bleed the system. See Section 6A, Power Steering System
38. Charge the air conditioning refrigeration system, if equipped. Follow See Section 7B, Heating, Ventilation, and Air Conditioning Control.
