Table of contents: General description of the job ↓ Preparatory work ↓ Left side of the engine compartment ↓ Right side of the engine compartment ↓ Under the car ↓ In the passenger compartment, on the…↓ The process of removal ↓ Engine separation work ↓
Attention:
Raise the engine with safety precautions and do not perform unnecessary operations.
Do not begin work until the exhaust system and engine coolant have cooled sufficiently.
When performing work not related to the engine, refer to the chapters corresponding to the work being performed.
Lift the engine by the indicated places.
Use a 2-arm lift. If a jack is used for emergency reasons, support the rear axle at the support point with a transmission lift or other suitable tool before starting work to prevent the center of gravity from shifting rearward.
2WD models
4WD models
General description of the job
Remove the engine with the transmission and suspension beam through the bottom of the car, and then separate the engine. 2WD models: Only the engine with the transmission assembly is removed.
Preparatory work
1. Relieve excess fuel pressure.
2. If possible, remove the engine hood cover.
3. Drain the coolant from the radiator drain hole.
4. Remove the following parts:
- Battery, engine underbody protection, radiator.
- Radiator fan, left and right mudguards.
- Left and right front wheels, drive belts and generator.
- Air duct and air cleaner housing.
5. Disconnect the accelerator cable from the throttle drum and move it to the side.
Left side of the engine compartment
6. Disconnect all hoses (vacuum, etc.) on the left side, disconnect the ground wiring.
7. Disconnect the 2 electrical wiring connectors from the top of the left pillar and secure the ends of the wires.
8. Disconnect the fuel supply and return hoses.
Caution: Immediately plug the fuel hose to prevent fuel from leaking.
9. Disconnect the heater hose and insert a plug to prevent coolant from leaking.
10. Disconnect the automatic transmission control cable from the gearbox and move it to the side.
Right side of the engine compartment
11. Disconnect the air conditioning and generator wiring and move it towards the body.
12. Remove the air conditioning compressor from the bracket and move it to the side, securing it with a rope from the side of the car body.
Under the car
13. Remove the front exhaust pipe.
14. Remove the driveshaft (4WD models).
15. Remove the ABS sensors, brake calipers and tie them to the car body with rope.
16. Remove the steering knuckles from the struts.
17. Disconnect the steering shaft and rack.
Before disconnecting, apply alignment marks to facilitate subsequent assembly.
In the passenger compartment, on the front passenger side
18. Disconnect all engine compartment wiring connectors located at the rear of the glove box, starting with the ECCS unit wiring. Pull the wiring into the engine compartment.
Caution: Cover the connectors with electrical tape to prevent dirt, water, etc. from getting into them. Be careful not to damage the wiring when removing the engine.
The process of removal
Choose one of three engine removal methods, depending on the equipment available and safety considerations. Method A is described below.
- Method A: While supporting the engine with a winch, support the suspension beam with a jack and lower it.
- Method B: Support the engine and gearbox oil pans and suspension beam with a jack, lift and separate from the body.
- Method C: Prop in 3 places (see method B) with three jacks and lower.
19. Attach the engine lifting eyes to the cylinder head.
: 29.4-37.3 Nm (3.0-3.8 kg·m)
20. Remove the right insulator (on the front of the engine).
Remove the load with a winch or jack and loosen the bolts.
21. Unscrew the bolt of the left insulator (on the back of the gearbox).
Remove the load with a winch or jack and loosen the bolt.
22. Raise the vehicle to the height required for work and securely support the suspension beam with a jack.
Using suitable tools, support the beam to stabilize its position.
23. Attach the winch chain hooks to the engine lifting eyes.
24. Remove the 2 mounting bolts from the front of the center beam.
25. Unscrew the 4 suspension beam mounting nuts.
26. Secure the winch ropes, carefully lower the jack and remove the engine, gearbox and suspension beam assembly from the vehicle.
27. Remove the steering pump with the tubes connected to it from the bracket and secure it with a rope where it will not interfere with the work.
Attention:
Make sure that there is no contact between engine and gearbox parts and the body.
Make sure you haven't forgotten to disconnect anything.
Make sure that the car's center of gravity does not shift and that it does not fall off the lift.
Engine separation work
Carry out work on a level surface.
Caution: Support the engine from below with a wooden block and securely attach the winch hooks to the lifting eyes.
28. Remove the suspension beam from the engine and gearbox assembly.
29. Separate the gearbox from the engine.