To remove the air inlet hose from the air-to-air cooler (F4R engine), disconnect the hose using the tool (Car1363)
Do not use brake cleaner or other cleaning agents.
Wipe the air-to-air cooler mounting surface and hose with a lint-free cloth.
If the hose is not being replaced, reinstall the clamp.
If the hose or air-to-air cooler is damaged, be sure to replace them.
Failure to follow this procedure may result in air leaks or hose disconnection.
Removal
Place the vehicle on a two-post lift.
Remove the upper engine covers.
Remove the front Wheels.
Remove the left and right fender liners.
Remove the engine oil sump guard.
Drain the transmission oil.
Drain the engine oil.
Disconnect the battery.
Drain the refrigerant from the refrigeration circuit using a filling station.
Remove the side subframe reinforcements and the front bumper.
Disconnect the hood release cable.
Disconnect the windshield washer pipes.
Drain the engine cooling system.
Loosen the mounting bolts and remove the front body panel.
Disconnect the fuel supply line from the fuel rail (Fig. 1).
Fig. Disconnecting the fuel supply line: 1 - fuel line
Disconnect the supply hose from the engine cooling system radiator using a tool
Disconnect the wiring connectors from the electric cooling fan.
Disconnect the wiring harness from the electric cooling fan.
Fig. Disconnecting the Air Duct from the Air-to-Air Cooler: 1 - Air Duct
Disconnect the air duct from the air-to-air cooler (Fig. 2).
Disconnect:
- — Boost pressure sensor wiring harness;
- — Air temperature sensor wiring harness;
- — Engine cooling fan resistor wiring harness.
Fig. Disconnecting the boost pressure and air temperature sensor wiring connectors, and the engine cooling fan resistor: 1 - boost pressure sensor, 2 - air temperature sensor, 3 - engine cooling fan resistor, 4 - air duct.
Move the air duct aside (Fig. 3).
Remove the air filter outlet duct.
Disconnect the expansion tank hoses from the engine cooling radiator.
Fig. Removing the electric water pump: 1 - bolt, 2 - bracket, 3 - electric water pump
Disconnect the pressure sensor connector on the lower air conditioning line of the condenser.
Remove the refrigeration circuit lines from the condenser and the refrigeration circuit line between the compressor and the receiver-dryer.
Be sure to plug the openings of the lines and the reducer to prevent water from entering the system.
Remove the engine cooling system radiator assembly with the condenser.
Disconnect the ECU connectors.
Loosen the mounting bolts and remove the battery tray.
Move the canister purge solenoid valve to the side.
Loosen the bolt, pull the water pump mounting post and, moving the water Electric pump, remove the water electric pump bracket (Fig. 4).
Fig. 5 Removing the ECU: 1 - Electronic Control Unit
Remove the ECU assembly with the bracket (Fig. 5).
Remove the air filter housing.
Disconnect the relay box wiring harness connectors.
Disconnect the ground bus.
Fig. 6. Removing the brake booster vacuum hose: 1 - hose
Remove the brake booster vacuum hose (Fig. 6).
Disconnect the downstream oxygen sensor connector.
Disconnect the gear selector and shift cables from the gearbox.
Fig. Disconnecting the Gearbox Lever Cable
Disconnect the cables from the levers on the gearbox by squeezing the cable end at points A, pull the lock in direction B, and lift the cables at point C, as shown in Figure 7.
Fig. Removing the ball end of the multifunction switch cable: 1 - ball end
Remove the ball end of the multifunction switch cable (Fig. 8).
Remove the multifunction switch drive cable by releasing the cable sheath stopper.
Place a rag under the master cylinder.
Remove the retainer from the fitting on the intermediate pipe of the master cylinder.
Disconnect the pipe from the slave cylinder. Insert plugs into the holes.
Remove the supply line to the slave cylinder cylinder.
Remove the right front drive shaft.
Remove the left front drive shaft.
Remove the exhaust downpipe fasteners.
Remove the upper and lower torque rods.
Remove the subframe.
Install a hydraulic crane with a hoist or chain.
Mark the position of the engine pendulum mount relative to the body.
Remove the engine mount.
Remove the gearbox pendulum mount.
Turn the engine and gearbox assembly over and remove it.
Installation
Install the engine and gearbox assembly on car.
Install:
- – engine pendulum mount;
- – gearbox pendulum mount;
- – lower torque rod;
- – upper torque rod;
- – left front wheel drive shaft;
- – right front wheel drive shaft.
Install the remaining components in the reverse order of removal.
Tighten to the specified torque:
- – upper front panel mounting bolts (21 Nm);
- – lower front panel mounting bolts (44 Nm);
- – front subframe mounting bolt (105 Nm);
- – rear subframe mounting bolt (21 Nm);
- – wheel mounting bolts (110 Nm).
Add brake fluid to the reservoir.
Bleed the clutch hydraulic system.
Fill the transmission with fluid.
Fill the engine with oil.
Fill the cooling system with fluid.
Fill the refrigeration circuit with refrigerant using a filling station.
Properly secure the brake hose and ABS speed sensor wires. Do not twist the brake hose.
Connect the battery.
Bleed the cooling system.
Tighten the battery cover bolts to the specified torque (4 Nm).