Engine mechanism - Engine assembly

22.

Remove drive belt.

Drive belt tensioner could turn belt tensioner clockwise to

loosen it.

23.

Remove alternator mounting components [4G18-

3701100].

24.

Remove compressor assembly.

25.

Remove front chassis bracket.

26.

Remove front exhaust pipe assembly.

27.

Remove steering middle shaft assembly.

(a) Remove steering column seal hole cover.

(b) Make alignment mark on steering middle shaft.

(c) Remove 2 bolts and steering middle shaft.

(d) Remove steering column cover.

28.

Remove the nuts on left side of front shaft hub.

(a) Completely knock out the concave part of fixed nuts with

special tool and hammer.

Notes:

Completely knock out the concave part of fixed

nuts before removing the fixed nuts.

Do not damage thread of drive shaft.

Do not sharpen the sharp end of special tool.

Place the special tool in groove with its plane facing

upward.

(b) Remove fixed nuts with socket wrench (30mm).

Hint:  perform the same steps at another side.

29.

Disassemble left side transversal lever  assembly.

Disassemble transversal lever assembly from steering

knuckle with special tool.

Hint:  perform the same steps at another side.

Alignment

mark

Special tool

Special tool

37

Sliding out

Lifting

Engine mechanism - Engine assembly

30.

Disassemble left end front stabilizer link

         assembly.

Fix bolts with hex socket wrench, and then remove nuts.

Hint:  perform the same steps at another side.

31.

Disassemble lower left control arm assembly.

(a) As shown in the diagram, remove bolt and 2 nuts.

(b) Disassemble drive shaft from shaft hub with plastic

hammer.

Hint:  perform the same steps at another side.

32.

Remove oil return pipe assembly.

After removing 3 retaining clips and 2 bolts of power steer-

ing oil reservoir, remove the oil return pipe from vehicle.

33.

Remover engine assembly [4G18-1000000] and

         transmission assembly.

(a) Erect engine hanger.

(b) Remove 4 bolts, 2 nuts and right engine mounting

assembly.

(c) Remove through bolt and nut, and then remove left

engine mounting assembly from vehicle.

(d) As shown in the diagram, remove 6 bolts.

(e) Carefully remove engine assembly and transmission

assembly from vehicle.

 38

34.

Remove power steering pump assembly.

35.

Remove sub frame together with side member.

(a) Remove front engine mounting assembly and rear en-

gine mounting assembly from engine assembly.

(b) Remove sub frame assembly.

36.

Remove starter mounting components

     [4G18-3708100].

37.

Remove transmission assembly.

(a) Fix crankshaft with special tool, ant then remove 6 bolts.

(b) Remove transmission assembly.

38.

Remove clutch assembly [4G18-1601000]

     and flywheel components [4G18-1005120J].

(a) Fix crankshaft with special tool, ant remove clutch

assembly at first.

(b) Then remove flywheel components.

39.

Remove throttlesupporting plate [4G18-1008202].

40.

Remove intake manifold assembly  [4G18-

1008200].

(f) As shown in the diagram, install front and rear hooks of

engine.
Torque:  
Hint:  install engine hooks to front and rear sides of

engine.

(g) Lift engine assembly with chain pulley block and en-

gine lifting device.

Engine mechanism - Engine assembly

Special tool

39

41.

Remove exhaust manifold upper heat shield components [4G18-1008120].

42.

Remove exhaust manifold assembly [4G18-1008100].

43.

Remove fuel rail injector assembly [4G18-1112100].

44.

Remove ignition coil installation components.

45.

Remove oil level gauge tube components [4G18-1002140].

46.

Remove temperature regulator assembly [4G18-1306100].

47.

Disassemble warm air water outlet pipe components [4G18-1300100].

48.

Remove oil pressure alerter [4G18-3757100].

Remove oil pressure alerter with SST.

49.

Remove the hoses on all hose joint of engine.

Remove clips and hose.

50.

Remove drive belt tensioner device.

51.

Remove phase sensor [4G18-3600030].

Engine hook

Front

Rear

52.

Remove speed sensor [4G18-3600010].

53.

Remove knock sensor.

Remove knock sensor with special tool.

54.

Remove water temperature sensor.

Remove water temperature sensor with special tool.

55.

Replace engine assembly.

56.

Install water temperature sensor.

(a) Install new gasket to water temperature sensor.

(b) Install water temperature sensor with special tool.

Torque:  

57.

Install knock sensor.

Install knock sensor with special tool.

Torque:  

m

58.

Install speed sensor.

Install speed sensor and harness clips.

Torque: 

59.

Install phase sensor.

Torque: 

60.

Install drive belt tensioner device.

Torque:  nut:   

m

             Bolt:  

m

61.

Install the hoses on all hose joint of engine.

Install clips and hose.

62.

Install oil pressure alerter.

(a) Clean thread of oil pressure alerter and coat adhesive.

Adhesive:  anaerobic pipe thread sealing adhesive 1545

(Kesaixin 1545)

(b) Install oil pressure alerter with special tool.

Torque:  

63.

Install warm air water outlet pipe components.

Install new gasket and warm air water outlet pipe

components.

Torque:  nut:  

m

                  Bolt:  

Engine mechanism - Engine assembly

 40