ENGINE REMOVAL — Cautions / Removal Steps 1-28
EM-40prose procedureWARNING
Do not remove engine until exhaust system has completely cooled off.
CAUTION
When lifting engine, take care not to foul other components, cables and wires. Pay special attention to brake lines, brake master cylinder, and radiator (fan) assembly.
When hoisting the engine, always use engine slingers in a safe and secure manner.
When removing drive shaft, be careful not to damage the transmission oil seal.
IMPORTANT
Engine cannot be removed separately from vehicle. Remove engine with transaxle.
Removal
Engine removal (steps 1-28)
- 1Drive vehicle on to a two post lift. If a two post lift is not available, place the vehicle on axle stands on a flat and solid surface.
- 2Drain transmission oil.
- 3Disconnect gear selector rods from transaxle (M/T).
- 4Disconnect NCVT selector cable (NCVT).
- 5Remove stabiliser bar.
- 6Remove lower suspension arm bolts.
- 7Disconnect drive shafts from transaxle.
- 8Remove exhaust by disconnecting at front (below first catalytic converter) and at rear (at rear axle). Make sure to disconnect the earth strap at the second catalytic converter.
- 9Remove hood.
- 10Release fuel pressure. Refer to section MA.
- 11Disconnect battery harness and remove battery.
- 12Remove front splash guards.
- 13Drain cooling system by removing lower radiator hose.
- 14Remove radiator expansion tank for access.
- 15Remove air filter assembly.
- 16Disconnect gearbox earth strap.
- 17Disconnect exhaust gas harness.
- 18Disconnect distributor harness and distributor sensor harness.
- 19Disconnect connectors for access for battery tray removal.
- 20Remove battery tray.
- 21Disconnect gear position switch harness (M/T).
- 22Disconnect clutch cable (M/T).
- 23Disconnect radiator top hose. On NCVT models, also disconnect two lower hoses from radiator.
- 24Disconnect earth wires on engine bracket.
- 25Disconnect injector harness.
- 26Disconnect 3 connectors on throttle chamber.
- 27Disconnect 2 connectors on main relay box.
- 28Disconnect earth strap on inner wing.
See also
MA — Fuel pressure release