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ENGINE REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))]

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Warning

•  A hot engine can cause severe burns. Turn off the engine and wait until it is cool before servicing.

•  Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

•  Highly pressurized fuel may spray out if the fuel line is cut. Due to the following dangers occurring with a fuel spray, always complete the “Fuel Line Safety Procedure” to prevent the fuel from spraying.

―  Fuel may cause irritation if it comes in contact with skin and eyes.

―  If fuel ignites and causes a fire, it may lead to serious injury or death, and damage to property and facilities.

Caution

•  If the intake-air system, exhaust system, or the engine is damaged, fragments of the damaged part may be remaining in the intake-air system or exhaust system. If the engine is replaced without removing fragments of the damaged part, it could cause engine damage or malfunction. Before replacing the engine, verify that no fragments remain in the parts to be reused.

•  Secure the steering wheel using tape or a cable to prevent the steering shaft from rotating after disconnecting the steering shaft. If the steering wheel rotates after the steering shaft and the steering gear and linkage are disconnected, the internal parts of the clock spring could be damaged.

•  Applying excessive force (force of 100 N {10.2 kgf, 22.5 lbf} or more) to the electric variable valve timing motor/driver may cause a malfunction. When servicing, be careful not to apply excessive force to the electric variable valve timing motor/driver using other parts or tools.

Note

•  Perform the engine and transaxle component removal/installation from below the vehicle.

Engine Removal

1.  Disconnect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION [(E)].)

2.  Remove the front under cover No.1 and No.2. (See FRONT UNDER COVER No.1 REMOVAL/INSTALLATION.) (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

3.  Remove the front splash shield. (See SPLASH SHIELD REMOVAL/INSTALLATION.)

4.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

5.  Drain the transaxle oil (MTX) or ATF (ATX). (See MANUAL TRANSAXLE OIL REPLACEMENT [C66M-R, C66MX-R].(MTX)) (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [EV6A-EL, EV6AX-EL (E)].(ATX))

6.  Drain the transfer oil. (AWD) (See TRANSFER OIL REPLACEMENT [C66MX-R].)

7.  Remove the front wheels and tires. (See WHEEL AND TIRE REMOVAL/INSTALLATION.)

8.  Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

9.  Remove the following parts as a single unit: (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

•  Air hose

•  Air cleaner cover

•  Air cleaner element

•  Air cleaner case

•  Fresh-air duct

•  Resonance chamber

10.  Remove the bolts and nut shown in the figure, and set the wiring harness aside.

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11.  Disconnect the connector.

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12.  Remove the battery tray and PCM component. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

13.  Disconnect the selector cable. (ATX) (See SELECTOR CABLE REMOVAL/INSTALLATION [(E)].)

14.  Disconnect the control cable. (MTX) (See CONTROL CABLE REMOVAL/INSTALLATION [C66M-R, C66MX-R].)

15.  Remove the clutch release cylinder with the pipe still connected. (MTX) (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION [C66M-R, C66MX-R].)

16.  Disconnect the vacuum hose. (SKYACTIV-G 2.5) (See VACUUM HOSE REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

17.  Disconnect the evaporative hose No.3. (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

18.  Disconnect the fuel hose. (See QUICK RELEASE CONNECTOR (EMISSION SYSTEM) REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

19.  Disconnect the heater hoses. (See A/C UNIT REMOVAL/INSTALLATION [(E)].)

20.  Disconnect the upper radiator hose from the engine side.

21.  Disconnect the lower radiator hose from the radiator.

22.  Disconnect the lower radiator hose clip.

23.  Remove the generator drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

24.  Remove the TWC installation nuts (exhaust manifold side) and secure the TWC using wire or rope so that it is out of the way. (2WD) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

25.  Remove the propeller shaft. (AWD) (See PROPELLER SHAFT REMOVAL/INSTALLATION [(E)].)

26.  Disconnect the front drive shaft (RH) from the transaxle side and set the drive shaft (RH) out of the way. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION [(E)].) (2WD)

27.   Remove the front drive shaft (RH). (AWD) (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION [(E)].)

28.  Remove the No.1 engine mount rubber and the front crossmember component as a single unit. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [(E)].)

29.  Remove the ground cable shown in the figure.

RH

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LH

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30.  Set the cooler hose (LO) aside. (See REFRIGERANT LINE REMOVAL/INSTALLATION [SKYACTIV-G].)

31.  Remove the A/C compressor with the cooler hose still connected and secure it using wire or rope so that it is out of the way. (See A/C COMPRESSOR REMOVAL/INSTALLATION [SKYACTIV-G].)

32.  Remove in the order indicated in the table.

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1	No.4 engine mount component (See ENGINE MOUNT DISASSEMBLY/ASSEMBLY [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].) (See Engine Removal.) (See Engine Installation.)
2	No.3 engine mount (See ENGINE MOUNT DISASSEMBLY/ASSEMBLY [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].) (See Engine Removal.) (See Engine Installation.)
3	Engine, transaxle

Engine Installation

Warning

•  When removing/installing the engine, verify that the engine and transaxle are securely supported. Otherwise, the engine may fall off and cause serious injury or death, and damage to the vehicle.

Caution

•  Slots have been adopted for the No.3 engine mount and No.4 engine mount bracket installation holes. Tighten the installation bolts and nuts so that they are centered on the slots. Otherwise, engine noise or vibration could increase.

Note

•  Retighten the engine front cover and transaxle stud bolts when the nuts of No.3 engine mount and No.4 engine mount bracket are loosened.

1.  Tighten the engine front cover stud bolts.

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2.  Measure the projection of the transaxle stud bolts. (MTX)

•  If the projection amount is not within the range, adjust the projection amount of the stud bolt.

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3.  Tighten the transaxle stud bolts. (ATX)

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Caution

•  When supporting the engine and transaxle, insert rubber of appropriate size (approx. 20 mm {0.79 in} thickness) between the engine lifter and the oil pan, transaxle to prevent the deformation of the oil pan and damage of the transaxle.

4.  Secure the engine and transaxle using a commercially available engine lifter.

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5.  Return the engine and transaxle to their original positions.

6.  Temporarily tighten the No.3 engine mount installation bolts and nuts using the following procedure:

(1)  Temporarily tighten the bolts so that the bolt holes of the body are centered on the No.3 engine mount slots.

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(2)  Temporarily tighten the nuts so that the stud bolts of the engine front cover are centered on the No.3 engine mount slots.

•  If the stud bolts are deviated from the center of the slots, align the stud bolts with the center of the slots while slightly moving the engine, and temporarily tighten the installation nuts.

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7.  Temporarily tighten the No.4 engine mount rubber installation bolts and nuts using the following procedure:

(1)  Temporarily tighten the bolts and nuts shown in the figure so that they are centered on the No.4 engine mount rubber slots.

•  If the stud bolts are deviated from the center of the slots, align the stud bolts with the center of the slots while slightly moving the transaxle, and temporarily tighten the installation nuts.

MTX

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ATX

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8.  Temporarily tighten the No.4 engine mount bracket installation bolts.

9.  Install the No.1 engine mount rubber and the front crossmember component as a single unit. (See FRONT CROSSMEMBER REMOVAL/INSTALLATION [(E)].)

Note

•  At this stage, only temporarily tighten the No.1 engine mount rubber, do not tighten it completely.

10.  Tighten the No.3 engine mount installation bolts and nuts in the order shown in the figure.

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11.  Tighten the No.4 engine mount bracket and rubber installation bolts and nuts in the order shown in the figure.

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12.  Tighten the No.1 engine mount rubber installation bolts.

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13.  Install the cooler hose (LO).

14.  Connect the ground cable shown in the figure.

RH

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LH

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15.  Install the A/C compressor. (See A/C COMPRESSOR REMOVAL/INSTALLATION [SKYACTIV-G].)

16.  Install the cooler hose (LO) aside. (See REFRIGERANT LINE REMOVAL/INSTALLATION [SKYACTIV-G].)

17.  Install the front drive shaft. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION [(E)].)

18.  Install the propeller shaft. (AWD) (See PROPELLER SHAFT REMOVAL/INSTALLATION [(E)].)

19.  Install the TWC. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

20.  Install the generator drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

21.  Connect the lower radiator hose to the radiator.

22.  Connect the lower radiator hose clip.

23.  Install the front wheels and tires. (See WHEEL AND TIRE REMOVAL/INSTALLATION.)

24.  Connect the upper radiator hose to the coolant control valve.

25.  Connect the heater hoses. (See A/C UNIT REMOVAL/INSTALLATION [(E)].)

26.  Connect the fuel hose. (See QUICK RELEASE CONNECTOR (FUEL SYSTEM) REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

27.  Connect the evaporative hose No.3. (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

28.  Connect the vacuum hose. (SKYACTIV-G 2.5) (See VACUUM HOSE REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

29.  Install the clutch release cylinder. (MTX) (See CLUTCH RELEASE CYLINDER REMOVAL/INSTALLATION [C66M-R, C66MX-R].)

30.  Connect the control cable. (MTX) (See CONTROL CABLE REMOVAL/INSTALLATION [C66M-R, C66MX-R].)

31.  Connect the selector cable. (ATX) (See SELECTOR CABLE REMOVAL/INSTALLATION [(E)].)

32.  Install the battery tray and PCM component and battery. (See BATTERY REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

33.  Connect the connector.

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34.  Install the bolts and nut.

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35.  Install the PCM component. (See PCM REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

36.  Install the air cleaner, air hose and fresh air duct as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

37.  Connect the negative battery terminal. (See NEGATIVE BATTERY TERMINAL DISCONNECTION/CONNECTION [(E)].)

38.  Refill the transfer oil. (AWD) (See TRANSFER OIL REPLACEMENT [C66MX-R].)

39.  Refill the transaxle oil (MTX) or ATF (ATX). (See MANUAL TRANSAXLE OIL REPLACEMENT [C66M-R, C66MX-R],(MTX))(See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [EV6A-EL, EV6AX-EL (E)].)

40.  Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

41.  Start the engine, and inspect and adjust the following:

•  Front wheel alignment (See FRONT WHEEL ALIGNMENT [(E)].)

•  Leakage of engine oil, engine coolant, ATF and fuel.

•  Runout and contact of pulley and belt.

•  Ignition timing, idle speed and idle mixture. (See ENGINE TUNE-UP [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)

•  Engine-driven accessories operation.

Note

•  If the engine is overhauled and assembled to the vehicle, perform a road test to verify that there is no abnormal vibration and noise.

42.  Install the front splash shield. (See SPLASH SHIELD REMOVAL/INSTALLATION.)

43.  Install the front under cover No.1 and No.2. (See FRONT UNDER COVER No.1 REMOVAL/INSTALLATION.) (See FRONT UNDER COVER No.2 REMOVAL/INSTALLATION.)

44.  Install the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION [SKYACTIV-G (WITH CYLINDER DEACTIVATION (E))].)