Toyota RAV4 2000-05

Engine

Print


NOTE
Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer system. The computer may undergo a relearning process once the negative battery cable is reconnected.


NOTE
Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer system. The computer may undergo a relearning process once the negative battery cable is reconnected.

Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Battery
     
    Hood
     
    Engine undercover
     

  6.  
  7. Drain the engine coolant and oil.
  8.  
  9. Drain the transaxle assembly.
  10.  
  11. Remove or disconnect the following:

    Air cleaner and case
     
    Accelerator cable from the throttle body, bracket and clamps
     

  12.  
  13. Disconnect and remove the engine wire from the No. 2 relay block, as follows:

    No. 2 relay block from the body by removing the 2 bolts
     
    Upper cover to the relay block
     
    Electrical connectors
     
    Engine wire, by removing the 2 nuts
     
    Charcoal canister
     
    Alternator
     
    Upper and lower radiator hoses
     
    Water inlet from the engine by removing the 2 nuts
     
    Heater hoses
     
    Fuel hose, by placing a rag under the fuel inlet hose
     
    Starter by disconnecting the electrical connectors and 2 bolts, if equipped with manual transmission
     
    Ground cable from the transaxle by removing the bolt
     
    Clutch release cylinder from the transaxle, if equipped with manual transmission
     
    Transaxle control cables (2 cable for manual transmission or 1 for automatic transmission) from the transaxle.
     
    Transaxle cable from the front suspension crossmember and engine mounting centermember by removing the 2 bolts, if equipped with an automatic transmission
     
    Transaxle oil cooler hoses, if equipped with an automatic transmission or 4WD with manual transmission
     

  14.  
  15. Detach the following:

    Vapor pressure sensor connector
     
    Igniter connector
     
    Ignition coil connector
     
    Noise filter connector
     
    Ignition coil wire
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    MAP sensor vacuum hose from the gas filter on the intake manifold
     
    Brake booster hose from the intake manifold
     
    Differential lock control solenoid connector, if equipped with a 4WD manual transmission
     
    Ground strap from cowl
     

  16.  
  17. Detach the engine wire from the passenger compartment, as follows:

    Right-hand scuff plate
     
    Right-hand side trim
     
    Right-hand carpet center cover
     
    2 ECM connectors
     
    2 connectors from the bracket connectors
     
    No. 4 junction block connector
     
    Wire clamp from the bracket
     
    Engine wire from the passenger compartment
     

  18.  
  19. Remove the front exhaust pipe, as follows:

    3 nuts and the front exhaust pipe from the exhaust manifold, using a 14mm deep socket wrench; discard the gasket
     
    2 bolts and 2 nuts holding the front exhaust pipe to the catalytic converter
     
    Front exhaust pipe and 2 gaskets
     

  20.  
  21. Remove the compressor from the engine and suspend the compressor securely.
  22.  


NOTE
It is not necessary to remove the air conditioning compressor lines in order to remove the engine.

  1. Remove or disconnect the following:

    Driveshaft, if equipped with 4WD
     
    Halfshaft
     
    Sway bar
     

  2.  
  3. Remove the front suspension crossmember assembly, as follows:

    2 centermember set nuts holding the centermember to the middle of the crossmember.
     
    2 rack and pinion assembly set bolts/nuts from the crossmember. Securely suspend the steering gear assembly.
     
    Catalytic converter with pipe from the ring
     
    Support the suspension crossmember with a jack
     
    6 bolts from the suspension crossmember
     
    Suspension crossmember with the lower suspension arms
     

  4.  
  5. Remove the engine mounting centermember, as follows:

    2 bolts holding the centermember to the front engine mounting insulator
     
    2 bolts holding the centermember to the body
     
    Centermember
     

  6.  
  7. Disconnect the power steering pump from the engine, as follows:

    2 vacuum hoses from the steering pump
     
    Adjusting bolt for the power steering unit. Loosen the pivot bolt to the power steering pump and remove the drive belt. Use Torque Wrench Adapter tool 09249-63010 and a deep socket to loosen the pivot bolt.
     
    Power steering pump from the engine by removing the 3 bracket bolts
     

  8.  
  9. Install a engine hanger to the engine.
  10.  
  11. Attach the engine sling device to the engine hangers.
  12.  
  13. Remove or disconnect the following:

    Left-hand engine mounting bracket from the mounting insulator by removing the 2 nuts and 2 bolts
     
    Ground connector next to the right-hand engine mount
     
    Right-hand engine mounting bracket from the mounting insulator by removing the bolt and 2 nuts
     

  14.  
  15. Lower the engine and transaxle and at the same time, raise the vehicle to gain clearance to the remove the engine.
  16.  
  17. Place the assembly on a stand and separate the engine from the transaxle.
  18.  

To install:



Click image to see an enlarged view

Fig. Exploded view of the engine accessory removal components-2.0L



Click image to see an enlarged view

Fig. Exploded view of the engine removal-2.0L

  1. Install or connect the following:

    Engine and transaxle assembly
     
    Left-hand engine mounting bracket to the mounting insulator. Tighten both nuts/bolts to 47 ft. lbs. (64 Nm).
     
    Bolt and 2 nuts to hold the right-hand engine mounting bracket to the mounting insulator. Tighten the bolt to 27 ft. lbs. (37 Nm) and both nuts to 38 ft. lbs. (52 Nm).
     
    Ground connector next to the right-hand engine mount
     
    Engine sling and hanger
     

  2.  
  3. Install the power steering pump, as follows:

    Pump with the bracket. Tighten the 3 bolts to 32 ft. lbs. (43 Nm).
     
    Pivot and adjusting bolts. Tighten the pivot bolt to 32 ft. lbs. (43 Nm) and the adjusting bolt to 29 ft. lbs. (39 Nm).
     
    Drive belt. Adjust the tension.
     
    Both air hoses to the power steering pump
     

  4.  
  5. Install or connect the following:

    Engine mounting centermember to the body; install the 4 bolts but do not tighten the bolts at this time
     

  6.  
  7. Install or connect the front crossmember, as follows:

    Suspension crossmember with the lower control arms. Torque both bolts crossmember-to-chassis bolts to 152 ft. lbs. (206 Nm).
     
    Rack and pinion. Tighten both nuts/bolts to 83 ft. lbs. (113 Nm).
     
    Centermember to the crossmember. Tighten both nuts to 82 ft. lbs. (112 Nm).
     
    Tighten the lower control arm rear brackets to 101 ft. lbs. (137 Nm).
     
    Tighten both engine mounting centermember-to-front engine mounting insulator bolts to 59 ft. lbs. (80 Nm).
     
    Tighten both engine mounting centermember-to-body bolts to 26 ft. lbs. (35 Nm).
     

  8.  
  9. Install or connect the following:

    Sway bar
     
    Halfshafts
     
    Driveshaft, if equipped with 4WD
     

  10.  
  11. Install the air conditioning compressor. Tighten nut/bolts, as follows:

    Stud bolt to 34 ft. lbs. (47 Nm)
     
    Bolt to 27 ft. lbs. (37 Nm)
     
    Nut to 20 ft. lbs. (27 Nm)
     

  12.  
  13. Install or connect the following:

    Air conditioning compressor connector
     
    Front exhaust pipe with new gaskets. Tighten the 3 nuts to 46 ft. lbs. (62 Nm) and 2 bolts to 35 ft. lbs. (48 Nm).
     

  14.  
  15. Attach the engine wire to the passenger compartment, as follows:

    Engine wire through the cowl panel
     
    Wire clamp to the bracket
     
    Both ECM connectors
     
    Both connectors on the bracket
     
    No. 4 junction block
     
    Right-hand floor carpet center cover
     
    Right-hand cowl side trim
     
    Right-hand scuff plate
     

  16.  
  17. Connect the following:

    Vapor pressure sensor connector
     
    Igniter connector
     
    Ignition coil connector
     
    Noise filter connector
     
    Ignition coil wire
     
    MAP sensor connector
     
    MAP sensor vacuum hose to the gas filter on the intake manifold
     
    Brake booster hose to the intake manifold
     
    Differential lock control solenoid connector, if equipped with 4WD manual transmission
     
    Ground strap to cowl
     

  18.  
  19. Install or connect the following:

    Transaxle oil cooler hoses, if equipped with an automatic transmission or 4WD with manual transmission
     
    Transaxle control cable(s) to the transaxle
     
    Transaxle control cable to the front crossmember and engine mounting centermember, for an automatic transmission
     
    Clutch release cylinder, for manual transmission Tighten both bolts to 108 inch lbs. (12 Nm).
     
    Ground cable to the transaxle
     
    Starter, for a manual transmission
     
    Fuel inlet hose to the fuel filter, using new gaskets. Tighten the union bolt to 22 ft. lbs. (29 Nm).
     
    Heater hoses
     
    Water inlet to the engine. Tighten both nuts to 78 inch lbs. (8.8 Nm).
     
    Upper and lower radiator hoses
     
    Alternator
     
    Charcoal canister
     

  20.  
  21. Connect the engine wire to the No. 2 relay box, as follows:

    Engine wire to the No. 2 relay block with the 2 nuts
     
    Connector
     
    Upper cover
     
    No. 2 relay block to the body with the 2 bolts
     

  22.  
  23. Install or connect the following:

    Accelerator cable to the throttle body, cable bracket and clamps
     
    Air cleaner case and cap
     
    Battery
     
    Negative battery cables
     

  24.  
  25. Fill the transaxle with oil.
  26.  
  27. Fill the engine with oil.
  28.  
  29. Fill the engine coolant.
  30.  
  31. Start the engine and check for leaks.
  32.  
  33. Install or connect the following:

    Engine undercovers
     
    Hood
     

  34.  
  35. Recheck all fluid levels.
  36.  
  37. Check and/or adjust the front wheel alignment.
  38.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Battery
     
    Hood
     
    Engine undercover
     

  6.  
  7. Drain the engine coolant and oil.
  8.  
  9. Drain the transaxle assembly.
  10.  
  11. Remove or disconnect the following:

    Air cleaner and case
     
    Accelerator cable from the throttle body, bracket and clamps
     

  12.  
  13. Disconnect and remove the engine wire from the No. 2 relay block, as follows:

    No. 2 relay block from the body by removing the 2 bolts
     
    Upper cover to the relay block
     
    Electrical connectors
     
    Engine wire, by removing the 2 nuts
     
    Charcoal canister
     
    Alternator
     
    Upper and lower radiator hoses
     
    Water inlet from the engine by removing the 2 nuts
     
    Heater hoses
     
    Fuel hose, by placing a rag under the fuel inlet hose
     
    Starter by disconnecting the electrical connectors and 2 bolts, if equipped with manual transmission
     
    Ground cable from the transaxle by removing the bolt
     
    Clutch release cylinder from the transaxle, if equipped with manual transmission
     
    Transaxle control cables (2 cable for manual transmission or 1 for automatic transmission) from the transaxle.
     
    Transaxle cable from the front suspension crossmember and engine mounting centermember by removing the 2 bolts, if equipped with an automatic transmission
     
    Transaxle oil cooler hoses, if equipped with an automatic transmission or 4WD with manual transmission
     

  14.  
  15. Detach the following:

    Vapor pressure sensor connector
     
    Igniter connector
     
    Ignition coil connector
     
    Noise filter connector
     
    Ignition coil wire
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    MAP sensor vacuum hose from the gas filter on the intake manifold
     
    Brake booster hose from the intake manifold
     
    Differential lock control solenoid connector, if equipped with a 4WD manual transmission
     
    Ground strap from cowl
     

  16.  
  17. Detach the engine wire from the passenger compartment, as follows:

    Right-hand scuff plate
     
    Right-hand side trim
     
    Right-hand carpet center cover
     
    2 ECM connectors
     
    2 connectors from the bracket connectors
     
    No. 4 junction block connector
     
    Wire clamp from the bracket
     
    Engine wire from the passenger compartment
     

  18.  
  19. Remove the front exhaust pipe, as follows:

    3 nuts and the front exhaust pipe from the exhaust manifold, using a 14mm deep socket wrench; discard the gasket
     
    2 bolts and 2 nuts holding the front exhaust pipe to the catalytic converter
     
    Front exhaust pipe and 2 gaskets
     

  20.  
  21. Remove the compressor from the engine and suspend the compressor securely.
    NOTE
    It is not necessary to remove the air conditioning compressor lines in order to remove the engine.

  22.  
  23. Remove or disconnect the following:

    Driveshaft, if equipped with 4WD
     
    Halfshaft
     
    Sway bar
     

  24.  
  25. Remove the front suspension crossmember assembly, as follows:

    2 centermember set nuts holding the centermember to the middle of the crossmember.
     
    2 rack and pinion assembly set bolts/nuts from the crossmember. Securely suspend the steering gear assembly.
     
    Catalytic converter with pipe from the ring
     
    Support the suspension crossmember with a jack
     
    6 bolts from the suspension crossmember
     
    Suspension crossmember with the lower suspension arms
     

  26.  
  27. Remove the engine mounting centermember, as follows:

    2 bolts holding the centermember to the front engine mounting insulator
     
    2 bolts holding the centermember to the body
     
    Centermember
     

  28.  
  29. Disconnect the power steering pump from the engine, as follows:

    2 vacuum hoses from the steering pump
     
    Adjusting bolt for the power steering unit. Loosen the pivot bolt to the power steering pump and remove the drive belt. Use Torque Wrench Adapter tool 09249-63010 and a deep socket to loosen the pivot bolt.
     
    Power steering pump from the engine by removing the 3 bracket bolts
     

  30.  
  31. Install a engine hanger to the engine.
  32.  
  33. Attach the engine sling device to the engine hangers.
  34.  
  35. Remove or disconnect the following:

    Left-hand engine mounting bracket from the mounting insulator by removing the 2 nuts and 2 bolts
     
    Ground connector next to the right-hand engine mount
     
    Right-hand engine mounting bracket from the mounting insulator by removing the bolt and 2 nuts
     

  36.  
  37. Lower the engine and transaxle and at the same time, raise the vehicle to gain clearance to the remove the engine.
  38.  
  39. Place the assembly on a stand and separate the engine from the transaxle.
  40.  

To install:

Click image to see an enlarged view

Fig. Exploded view of the engine accessory removal components-RAV4 model



Click image to see an enlarged view

Fig. Exploded view of the engine removal-RAV4 model

  1. Install or connect the following:

    Engine and transaxle assembly
     
    Left-hand engine mounting bracket to the mounting insulator. Tighten both nuts/bolts to 47 ft. lbs. (64 Nm).
     
    Bolt and 2 nuts to hold the right-hand engine mounting bracket to the mounting insulator. Tighten the bolt to 27 ft. lbs. (37 Nm) and both nuts to 38 ft. lbs. (52 Nm).
     
    Ground connector next to the right-hand engine mount
     
    Engine sling and hanger
     

  2.  
  3. Install the power steering pump, as follows:

    Pump with the bracket. Tighten the 3 bolts to 32 ft. lbs. (43 Nm).
     
    Pivot and adjusting bolts. Tighten the pivot bolt to 32 ft. lbs. (43 Nm) and the adjusting bolt to 29 ft. lbs. (39 Nm).
     
    Drive belt. Adjust the tension.
     
    Both air hoses to the power steering pump
     

  4.  
  5. Install or connect the following:

    Engine mounting centermember to the body; install the 4 bolts but do not tighten the bolts at this time
     

  6.  
  7. Install or connect the front crossmember, as follows:

    Suspension crossmember with the lower control arms. Torque both bolts crossmember-to-chassis bolts to 152 ft. lbs. (206 Nm).
     
    Rack and pinion. Tighten both nuts/bolts to 83 ft. lbs. (113 Nm).
     
    Centermember to the crossmember. Tighten both nuts to 82 ft. lbs. (112 Nm).
     
    Tighten the lower control arm rear brackets to 101 ft. lbs. (137 Nm).
     
    Tighten both engine mounting centermember-to-front engine mounting insulator bolts to 59 ft. lbs. (80 Nm).
     
    Tighten both engine mounting centermember-to-body bolts to 26 ft. lbs. (35 Nm).
     

  8.  
  9. Install or connect the following:

    Sway bar
     
    Halfshafts
     
    Driveshaft, if equipped with 4WD
     

  10.  
  11. Install the air conditioning compressor. Tighten nut/bolts, as follows:

    Stud bolt to 34 ft. lbs. (47 Nm)
     
    Bolt to 27 ft. lbs. (37 Nm)
     
    Nut to 20 ft. lbs. (27 Nm)
     

  12.  
  13. Install or connect the following:

    Air conditioning compressor connector
     
    Front exhaust pipe with new gaskets. Tighten the 3 nuts to 46 ft. lbs. (62 Nm) and 2 bolts to 35 ft. lbs. (48 Nm).
     

  14.  
  15. Attach the engine wire to the passenger compartment, as follows:

    Engine wire through the cowl panel
     
    Wire clamp to the bracket
     
    Both ECM connectors
     
    Both connectors on the bracket
     
    No. 4 junction block
     
    Right-hand floor carpet center cover
     
    Right-hand cowl side trim
     
    Right-hand scuff plate
     

  16.  
  17. Connect the following:

    Vapor pressure sensor connector
     
    Igniter connector
     
    Ignition coil connector
     
    Noise filter connector
     
    Ignition coil wire
     
    MAP sensor connector
     
    MAP sensor vacuum hose to the gas filter on the intake manifold
     
    Brake booster hose to the intake manifold
     
    Differential lock control solenoid connector, if equipped with 4WD manual transmission
     
    Ground strap to cowl
     

  18.  
  19. Install or connect the following:

    Transaxle oil cooler hoses, if equipped with an automatic transmission or 4WD with manual transmission
     
    Transaxle control cable(s) to the transaxle
     
    Transaxle control cable to the front crossmember and engine mounting centermember, for an automatic transmission
     
    Clutch release cylinder, for manual transmission Tighten both bolts to 108 inch lbs. (12 Nm).
     
    Ground cable to the transaxle
     
    Starter, for a manual transmission
     
    Fuel inlet hose to the fuel filter, using new gaskets. Tighten the union bolt to 22 ft. lbs. (29 Nm).
     
    Heater hoses
     
    Water inlet to the engine. Tighten both nuts to 78 inch lbs. (8.8 Nm).
     
    Upper and lower radiator hoses
     
    Alternator
     
    Charcoal canister
     

  20.  
  21. Connect the engine wire to the No. 2 relay box, as follows:

    Engine wire to the No. 2 relay block with the 2 nuts
     
    Connector
     
    Upper cover
     
    No. 2 relay block to the body with the 2 bolts
     

  22.  
  23. Install or connect the following:

    Accelerator cable to the throttle body, cable bracket and clamps
     
    Air cleaner case and cap
     
    Battery
     
    Negative battery cables
     

  24.  
  25. Fill the transaxle with oil.
  26.  
  27. Fill the engine with oil.
  28.  
  29. Fill the engine coolant.
  30.  
  31. Start the engine and check for leaks.
  32.  
  33. Install or connect the following:

    Engine undercovers
     
    Hood
     

  34.  
  35. Recheck all fluid levels.
  36.  
  37. Check and/or adjust the front wheel alignment.
  38.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Battery
     
    Hood
     
    Engine undercover
     

  6.  
  7. Drain the engine coolant and oil.
  8.  
  9. Drain the transaxle assembly.
  10.  
  11. Remove or disconnect the following:

    Air cleaner and case
     
    Accelerator cable from the throttle body, bracket and clamps
     

  12.  
  13. Disconnect and remove the engine wire from the No. 2 relay block, as follows:

    No. 2 relay block from the body by removing the 2 bolts
     
    Upper cover to the relay block
     
    Electrical connectors
     
    Engine wire, by removing the 2 nuts
     
    Charcoal canister
     
    Alternator
     
    Upper and lower radiator hoses
     
    Water inlet from the engine by removing the 2 nuts
     
    Heater hoses
     
    Fuel hose, by placing a rag under the fuel inlet hose
     
    Starter by disconnecting the electrical connectors and 2 bolts, if equipped with manual transaxle
     
    Ground cable from the transaxle by removing the bolt
     
    Clutch release cylinder from the transaxle, if equipped with manual transaxle
     
    Transaxle control cables (2 cables for manual transaxle or 1 for automatic transaxle) from the transaxle.
     
    Transaxle cable from the front suspension crossmember and engine mounting centermember by removing the 2 bolts, if equipped with an automatic transaxle
     
    Transaxle oil cooler hoses, if equipped with an automatic transaxle or 4WD with manual transaxle
     

  14.  
  15. Detach the following:

    Vapor pressure sensor connector
     
    Igniter connector
     
    Ignition coil connector
     
    Noise filter connector
     
    Ignition coil wire
     
    Manifold Absolute Pressure (MAP) sensor connector
     
    MAP sensor vacuum hose from the gas filter on the intake manifold
     
    Brake booster hose from the intake manifold
     
    Differential lock control solenoid connector, if equipped with a 4WD manual transaxle
     
    Ground strap from cowl
     

  16.  
  17. Detach the engine wire from the passenger compartment, as follows:

    Right side scuff plate
     
    Right side trim
     
    Right side carpet center cover
     
    2 ECM connectors
     
    2 connectors from the bracket connectors
     
    No. 4 junction block connector
     
    Wire clamp from the bracket
     
    Engine wire from the passenger compartment
     

  18.  
  19. Remove the front exhaust pipe, as follows:

    3 nuts and the front exhaust pipe from the exhaust manifold, using a 14mm deep socket wrench; discard the gasket
     
    2 bolts and 2 nuts holding the front exhaust pipe to the catalytic converter
     
    Front exhaust pipe and 2 gaskets
     

  20.  
  21. Remove the compressor from the engine and suspend the compressor securely.
    NOTE
    It is not necessary to remove the air conditioning compressor lines in order to remove the engine.

  22.  
  23. Remove or disconnect the following:

    Halfshaft, if equipped with 4WD
     
    Halfshaft
     
    Sway bar
     

  24.  
  25. Remove the front suspension crossmember assembly, as follows:

    2 centermember set nuts holding the centermember to the middle of the crossmember.
     
    2 rack and pinion assembly set bolts/nuts from the crossmember. Securely suspend the steering gear assembly.
     
    Catalytic converter with pipe from the ring
     
    Support the suspension crossmember with a jack
     
    6 bolts from the suspension crossmember
     
    Suspension crossmember with the lower suspension arms
     

  26.  
  27. Remove the engine mounting centermember, as follows:

    2 bolts holding the centermember to the front engine mounting insulator
     
    2 bolts holding the centermember to the body
     
    Centermember
     

  28.  
  29. Disconnect the power steering pump from the engine, as follows:

    2 vacuum hoses from the steering pump
     
    Adjusting bolt for the power steering unit. Loosen the pivot bolt to the power steering pump and remove the drive belt. Use Torque Wrench Adapter tool 09249-63010 and a deep socket to loosen the pivot bolt.
     
    Power steering pump from the engine by removing the 3 bracket bolts
     

  30.  
  31. Install a engine hanger to the engine.
  32.  
  33. Attach the engine sling device to the engine hangers.
  34.  
  35. Remove or disconnect the following:

    Left side engine mounting bracket from the mounting insulator by removing the 2 nuts and 2 bolts
     
    Ground connector next to the right side engine mount
     
    Right side engine mounting bracket from the mounting insulator by removing the bolt and 2 nuts
     

  36.  
  37. Lower the engine and transaxle and at the same time, raise the vehicle to gain clearance to the remove the engine.
  38.  
  39. Place the assembly on a stand and separate the engine from the transaxle.
  40.  

To install:

Click image to see an enlarged view

Fig. Engine accessory removal components-2.0L



Click image to see an enlarged view

Fig. Engine assembly and related components-2.0L

  1. Install or connect the following:

    Engine and transaxle assembly
     
    Left side engine mounting bracket to the mounting insulator. Tighten both nuts/bolts to 47 ft. lbs. (64 Nm).
     
    Bolt and 2 nuts to hold the right side engine mounting bracket to the mounting insulator. Tighten the bolt to 27 ft. lbs. (37 Nm) and both nuts to 38 ft. lbs. (52 Nm).
     
    Ground connector next to the right side engine mount
     
    Engine sling and hanger
     

  2.  
  3. Install the power steering pump, as follows:

    Pump with the bracket. Tighten the 3 bolts to 32 ft. lbs. (43 Nm).
     
    Pivot and adjusting bolts. Tighten the pivot bolt to 32 ft. lbs. (43 Nm) and the adjusting bolt to 29 ft. lbs. (39 Nm).
     
    Drive belt. Adjust the tension.
     
    Both air hoses to the power steering pump
     

  4.  
  5. Install or connect the following:

    Engine mounting centermember to the body; install the 4 bolts but do not tighten the bolts at this time
     

  6.  
  7. Install or connect the front crossmember, as follows:

    Suspension crossmember with the lower control arms. Torque both bolts crossmember-to-chassis bolts to 152 ft. lbs. (206 Nm).
     
    Rack and pinion. Tighten both nuts/bolts to 83 ft. lbs. (113 Nm).
     
    Centermember to the crossmember. Tighten both nuts to 82 ft. lbs. (112 Nm).
     
    Tighten the lower control arm rear brackets to 101 ft. lbs. (137 Nm).
     
    Tighten both engine mounting centermember-to-front engine mounting insulator bolts to 59 ft. lbs. (80 Nm).
     
    Tighten both engine mounting centermember-to-body bolts to 26 ft. lbs. (35 Nm).
     

  8.  
  9. Install or connect the following:

    Sway bar
     
    Halfshafts
     
    Driveshaft, if equipped with 4WD
     

  10.  
  11. Install the air conditioning compressor. Tighten nut/bolts, as follows:

    Stud bolt to 34 ft. lbs. (47 Nm)
     
    Bolt to 27 ft. lbs. (37 Nm)
     
    Nut to 20 ft. lbs. (27 Nm)
     

  12.  
  13. Install or connect the following:

    Air conditioning compressor connector
     
    Front exhaust pipe with new gaskets. Tighten the 3 nuts to 46 ft. lbs. (62 Nm) and 2 bolts to 35 ft. lbs. (48 Nm).
     

  14.  
  15. Attach the engine wire to the passenger compartment, as follows:

    Engine wire through the cowl panel
     
    Wire clamp to the bracket
     
    Both ECM connectors
     
    Both connectors on the bracket
     
    No. 4 junction block
     
    Right side floor carpet center cover
     
    Right side cowl side trim
     
    Right side scuff plate
     

  16.  
  17. Connect the following:

    Vapor pressure sensor connector
     
    Igniter connector
     
    Ignition coil connector
     
    Noise filter connector
     
    Ignition coil wire
     
    MAP sensor connector
     
    MAP sensor vacuum hose to the gas filter on the intake manifold
     
    Brake booster hose to the intake manifold
     
    Differential lock control solenoid connector, if equipped with 4WD manual transaxle
     
    Ground strap to cowl
     

  18.  
  19. Install or connect the following:

    Transaxle oil cooler hoses, if equipped with an automatic transaxle or 4WD with manual transaxle
     
    Transaxle control cable(s) to the transaxle
     
    Transaxle control cable to the front crossmember and engine mounting centermember, for an automatic transaxle
     
    Clutch release cylinder, for manual transaxle Tighten both bolts to 108 inch lbs. (12 Nm).
     
    Ground cable to the transaxle
     
    Starter, for a manual transaxle
     
    Fuel inlet hose to the fuel filter, using new gaskets. Tighten the union bolt to 22 ft. lbs. (29 Nm).
     
    Heater hoses
     
    Water inlet to the engine. Tighten both nuts to 78 inch lbs. (8.8 Nm).
     
    Upper and lower radiator hoses
     
    Alternator
     
    Charcoal canister
     

  20.  
  21. Connect the engine wire to the No. 2 relay box, as follows:

    Engine wire to the No. 2 relay block with the 2 nuts
     
    Connector
     
    Upper cover
     
    No. 2 relay block to the body with the 2 bolts
     

  22.  
  23. Install or connect the following:

    Accelerator cable to the throttle body, cable bracket and clamps
     
    Air cleaner case and cap
     
    Battery
     
    Negative battery cables
     

  24.  
  25. Fill the transaxle with oil.
  26.  
  27. Fill the engine with oil.
  28.  
  29. Fill the engine coolant.
  30.  
  31. Start the engine and check for leaks.
  32.  
  33. Install or connect the following:

    Engine undercovers
     
    Hood
     

  34.  
  35. Recheck all fluid levels.
  36.  
  37. Check and/or adjust the front wheel alignment.
  38.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Properly discharge the fuel system. Discharge the air conditioning system.
  4.  
  5. Disconnect the negative battery cable.
    NOTE
    Wait at least 90 seconds after disconnecting the negative battery cable before starting any repair work to prevent air bag and seat belt pretensioner activation.

  6.  
  7. Remove the engine undercovers.
  8.  
  9. Drain the transaxle fluid. Drain the transfer case fluid, if equipped. Drain the engine oil. Drain the engine coolant.
  10.  
  11. Matchmark and remove the hood.
  12.  
  13. Remove the radiator reservoir. Remove the cowl top ventilation louver.
  14.  
  15. Disconnect the positive battery cable. Remove the battery. Remove the battery tray. Remove the five bolts and the battery bracket.
  16.  
  17. Remove the air cleaner assembly.
  18.  
  19. Remove the J/B cover, located inside the engine compartment. Loosen the bolt. Remove the assembly. Pull out the wire connector. Disconnect the connector. Disconnect the wire clamp.
  20.  
  21. Remove the two screws and the glove box door. Disconnect the six engine wire connectors from the ECM and the instrument panel wire. Pull out the engine wire from the cabin.
  22.  
  23. Disconnect the accelerator cable. Disconnect the ground wire from the cylinder head.
  24.  
  25. Remove the air conditioning hoses from the compressor. Disconnect the air conditioning hoses from the power steering pump.
  26.  
  27. Remove the radiator hoses. Disconnect the heater hoses.
  28.  
  29. Drain the power steering fluid. Disconnect and plug the power steering pump hoses.
  30.  
  31. Remove the fuel tube connector. Disconnect the connector from the fusible link block.
  32.  
  33. If equipped with manual transaxle, remove the two clips and washers and disconnect the two control cables.
  34.  
  35. Remove the starter.
  36.  
  37. If equipped with manual transaxle, remove the heat insulator and disconnect the clutch release cylinder and line from the transaxle.
  38.  
  39. If equipped with automatic transaxle, remove the nut holding the control shift lever to the control cable. Remove the clip and disconnect the control cable. Disconnect the control cable from the cable clamp.
  40.  
  41. Disconnect the ground cable from the transaxle.
  42.  
  43. If equipped with automatic transaxle, disconnect and plug the transaxle cooler lines.
  44.  
  45. If equipped with 4WD, remove the driveshaft.
  46.  
  47. Remove the front halfshafts.
  48.  
  49. Remove the four bolts, two compression rings, two gaskets and the front exhaust pipe.
  50.  
  51. Disconnect the front stabilizer bar links.
  52.  
  53. Remove the two bolts and disconnect the power steering gear assembly.
  54.  
  55. Attach a suitable engine removal fixture to the engine using engine hanger tools 12281-28010 and 12281-28020 or equivalent.
    NOTE
    Do not attempt to hang the engine by hooking the chain to any other part.

  56.  
  57. Remove the two nuts and bolt holding the right side engine mounting insulator to the timing chain cover.
  58.  
  59. Remove the bolt holding the left side engine mounting insulator to the mounting bracket.
  60.  
  61. Support the suspension crossmember with a jack. Remove the six bolts holding the suspension crossmember engine mounting member to the body.
  62.  
  63. Carefully lower the engine assembly out of the vehicle.
    NOTE
    Be sure the assembly is clear of all wiring, hoses and cables before removing it.

  64.  
  65. Separate the engine, transaxle, front suspension crossmember and center engine mounting member, as required.
  66.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Tighten the six upper engine to transaxle bolts to 34 ft. lbs. for bolt -A- and 47 ft. lbs. for bolt -B-.
  4.  
  5. Tighten the four lower engine to transaxle bolts to 32 ft. lbs.

    Click image to see an enlarged view

    Fig. Engine to transaxle bolt locations-2005 2.4L engine



    Click image to see an enlarged view

    Fig. Suspension crossmember bolt locations-2005 2.4L engine

  6.  
  7. If equipped with automatic transaxle, tighten the torque converter retaining bolts to 30 ft. lbs.
    NOTE
    Install the green colored bolt first.

  8.  
  9. Tighten the six suspension crossmember engine mounting bolts to 29 ft. lbs for bolt -A-, 83 ft. lbs. for bolt -B- and 116 ft. lbs. for bolt -C-.
  10.  
  11. Be sure to fill the engine with the proper grade and type engine oil.
  12.  
  13. Be sure to fill the transaxle with the proper grade and type transaxle fluid.
  14.  
  15. Be sure to fill the cooling system with the proper grade and type engine coolant.
  16.  
  17. Recharge the air conditioning system.
  18.  
  19. Start the engine and check for leaks, correct as required.
  20.  

 
label.common.footer.alt.autozoneLogo