ENGINE REMOVAL/INSTALLATION [SKYACTIV-G 2.5T]

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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

•  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.

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

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 FRONT SPLASH SHIELD REMOVAL/INSTALLATION.)

4.  Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.5T].)

5.  Drain the ATF. (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [GW6A-EL, GW6AX-EL].)

6.  Drain the transfer oil. (4WD) (See TRANSFER OIL REPLACEMENT [GW6AX-EL].)

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 2.5T].)

9.  Remove the air cleaner, air hose and fresh air duct as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

10.  Remove the bolt, nut, clip and connector shown in the figure, and set the wiring harness aside.

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11.  Set the DC-DC converter (i-ELOOP) aside in the direction of the arrow shown in the figure with the wiring harness connected. (with i-ELOOP) (See DC-DC CONVERTER (i-ELOOP) REMOVAL/INSTALLATION [i-ELOOP].)

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12.  Remove the battery and battery tray. (See BATTERY REMOVAL/INSTALLATION.)

13.  Remove the air inlet pipe. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

14.  Remove the turbocharger air outlet pipe and charge air cooler inlet hose. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

15.  Remove the charge air cooler outlet pipe and charge air cooler outlet hose as a single unit. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

16.  Disconnect the selector cable. (See AUTOMATIC TRANSAXLE SHIFT MECHANISM REMOVAL/INSTALLATION.)

17.  Disconnect the brake vacuum hose. (See VACUUM HOSE REMOVAL/INSTALLATION [L.H.D.].) (See VACUUM HOSE REMOVAL/INSTALLATION [R.H.D.].)

18.  Disconnect the clip shown in the figure from the protector.

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19.  Disconnect the evaporative hose. (See PURGE SOLENOID VALVE REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

20.  Disconnect the fuel hose. (See QUICK RELEASE CONNECTOR REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

21.  Disconnect the upper radiator hose.

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22.  Remove the lower radiator hose and pipe component using the following procedure:

(1)  Disconnect the lower radiator hose shown in the figure.

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(2)  Disconnect the connector and clip shown in the figure. (taiwan)

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(3)  Disconnect the clip shown in the figure. (except taiwan)

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(4)  Remove the lower radiator hose and pipe component.

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23.  Disconnect the heater hoses.

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24.  Remove the generator drive belt. (See DRIVE BELT REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

25.  Disconnect the water hose from water-cooled oil cooler.

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26.  Disconnect the oil hoses from radiator. (if equipped) (See OIL COOLER REMOVAL/INSTALLATION [GW6A-EL, GW6AX-EL].)

27.  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.)

28.  Remove the TWC installation nuts (WU-TWC 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 2.5T].)

29.  Remove the TWC. (4WD) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

30.  Remove the propeller shaft. (4WD) (See PROPELLER SHAFT REMOVAL/INSTALLATION.)

31.  Disconnect the front drive shaft (LH) from the transaxle side and set the drive shaft (LH) out of the way. (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)

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

33.  Remove the front drive shaft (RH). (4WD) (See FRONT DRIVE SHAFT REMOVAL/INSTALLATION.)

34.  Remove the bolt and set the ground cable aside.

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35.  Remove in the order indicated in the table.

2WD

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4WD

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36.  Install in the reverse order of removal.

37.  Refill the transfer oil. (4WD) (See TRANSFER OIL REPLACEMENT [GW6AX-EL].)

38.  Refill the ATF. (See AUTOMATIC TRANSAXLE FLUID (ATF) REPLACEMENT [GW6A-EL, GW6AX-EL].)

39.  Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT [SKYACTIV-G 2.5T].)

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

•  Front wheel alignment (See FRONT WHEEL ALIGNMENT.)

•  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 2.5T].)

•  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.

No.1 Engine Mount Rubber, Front Crossmember Component Removal Note

1.  Disconnect the service plug. (with i-ELOOP) (See SERVICE PLUG DISCONNECTION/CONNECTION [i-ELOOP].)

2.  Disconnect the generator terminal B cable. (with i-ELOOP) (See GENERATOR REMOVAL/INSTALLATION [WITH i-ELOOP (SKYACTIV-G 2.5T)].)

3.  Remove the bolts shown in the figure and remove the wiring harness bracket. (with i-ELOOP)

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4.  Remove the clips shown in the figure and set the wiring harness aside. (with i-ELOOP)

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5.  Loosen the No.1 engine mount rubber installation bolt (front crossmember side) shown in the figure.

2WD

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4WD

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

No.3 Engine Mount, No.4 Engine Mount Bracket Removal Note

1.  Remove the clip and bolt shown in the figure and set the ground cable aside.

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2.  Set the PCM wiring harness and PCM component aside using the following procedure:

(1)  Disconnect the PCM connector (140 pin side) from the PCM. (See PCM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

(2)  Remove the bolt, clip and connector shown in the figure and set aside the PCM wiring harness to the engine upper side.

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(3)  Remove the bolts shown in the figure.

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(4)  Move the PCM component in the direction of the arrow shown in the figure and set it aside with the connector (60-pin side) connected.

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3.  Remove the nut shown in the figure and set the cooler hose aside.

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4.  Disconnect the ground cable shown in the figure.

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5.  Disconnect the clip shown in the figure.

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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.

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

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7.  Remove the No.4 engine mount bracket.

8.  Remove the No.3 engine mount.

Engine Mount Installation Note

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

•  When loosening the nuts of the No.3 engine mount and the No.4 engine mount bracket, the engine front cover and the transaxle stud bolt may loosen.

1.  Tighten the engine front cover stud bolts.

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2.  Tighten the transaxle stud bolts.

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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.

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

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

(1)  Temporarily tighten the bolts shown in the figure so that they are centered on the No.3 engine mount slots.

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

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Note

•  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.

5.  Temporarily tighten the No.4 engine mount bracket installation bolt and nuts using the following procedure:

(1)  Temporarily tighten the bolt shown in the figure.

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(2)  Temporarily tighten the nuts shown in the figure so that they are centered on the No.4 engine mount bracket slots.

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Note

•  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.

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

7.  Temporarily tighten the following parts:

2WD

?  No.1 engine mount bracket, No.1 engine mount rubber and bracket plate

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4WD

?  No.1 engine mount rubber, bracket plate and deadweight

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8.  Tighten the No.1 engine mount bracket and bracket plate installation bolts in the order shown in the figure. (2WD)

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

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10.  Tighten the No.4 engine mount bracket installation bolt and nuts in the order shown in the figure.

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

2WD

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4WD

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12.  Install the clips shown in the figure. (with i-ELOOP)

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13.  Install the wiring harness bracket shown in the figure. (with i-ELOOP)

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14.  Connect the generator terminal B cable. (with i-ELOOP) (See GENERATOR REMOVAL/INSTALLATION [WITH i-ELOOP (SKYACTIV-G 2.5T)].)

15.  Install the service plug. (with i-ELOOP) (See SERVICE PLUG DISCONNECTION/CONNECTION [i-ELOOP].)

16.  Connect the clip shown in the figure.

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17.  Install the ground cable shown in the figure.

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18.  Return the cooler hose that was set aside to its original position and tighten the nut.

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19.  Install the PCM component using the following procedure:

(1)  Return the PCM component that was set aside to its original position.

(2)  Temporarily tighten the bolt shown in the figure.

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(3)  Tighten the PCM component installation bolts in the order shown in the figure.

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Tightening torque

9—10 N·m {92—101 kgf·cm, 80—88 in·lbf}

(4)  Install the wiring harness protector and connector.

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(5)  Connect the PCM connector (140-pin side) to the PCM. (See PCM REMOVAL/INSTALLATION [SKYACTIV-G 2.5T].)

20.  Install the ground cable shown in the figure.

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