Removal and Replacement

Engine Assembly

Removal
1. Set the vehicle on a lift.
2. Open the front hood fully, and then support with the hood stay.
3. Collect the refrigerant from A/C system.
4. Release the fuel pressure.
a. Disconnect the fuel pump relay connector.





b. Start the engine, and run until stalls.
c. After the engine stalls, crank it for 5 seconds more.
d. Turn the ignition switch to OFF.
5. Remove the fuel filler cap.
6. Disconnect the ground cable from battery.
7. Remove the radiator from vehicle.
8. Remove the coolant filler tank.
9. Remove the secondary air pump.
10. Disconnect the A/C pressure hoses from A/C compressor.





11. Remove the intercooler.
12. Disconnect the following connectors and cable.
a. Engine harness connector





b. Engine ground terminal





c. Engine harness connector





d. Generator connector, terminal and A/C compressor connectors





e. Power steering switch connector





13. Disconnect the following hoses.
a. Brake booster vacuum hose





b. Heater inlet and outlet hose
14. Remove the power steering pump.
a. Remove the front side V-belt.
b. Remove the power steering pipe with bracket from fuel pipe protector RH.





c. Remove the power steering pump.





d. Remove the reservoir tank from bracket by pulling it upward.





e. Place the power steering pump on right side wheel apron.





15. Lift-up the vehicle.
16. Remove the ATF cooler pipe from frame. (AT model)
17. Remove the center exhaust pipe.
18. Remove the nuts which hold the lower side of transmission to engine.





19. Remove the nuts which install the front cushion rubber onto front crossmember.





20. Separate the clutch release fork from release bearing. (MT model)
21. Separate the torque converter clutch from drive plate. (AT model)
a. Lower the vehicle.
b. Remove the service hole plug.
c. Remove the bolts which hold the torque converter clutch to drive plate.
d. While rotating the crank pulley in the direction of engine rotation little by little using a socket wrench, remove all the bolts.





22. Remove the pitching stopper.





23. Using ST, disconnect fuel hoses from fuel pipes.

CAUTION:
^ Be careful not to spill fuel.
^ Catch fuel from hoses using a container or cloth.

ST 42099AE000 CONNECTOR REMOVER





24. Support the engine with a lifting device and wire ropes.





25. Support the transmission with a garage jack.

CAUTION: Before moving the engine away from transmission, check to be sure no work has been overlooked. Doing this is very important in order to facilitate re-installation and because transmission lowers under its own weight.





26. Separation of the engine and transmission
a. Remove the starter.
b. Install the ST to torque converter clutch case. (AT model)
ST 498277200 STOPPER SET





c. Remove the bolts which hold the right upper side of transmission to engine.





27. Remove the engine from vehicle.
a. Slightly raise the engine.
b. Raise the transmission with garage jack.
c. Move the engine horizontally until the mainshaft is withdrawn from clutch cover.
d. Slowly move the engine away from engine compartment.

NOTE: Be careful not to damage adjacent parts or body panels with crank pulley, oil pressure gauge, etc.

28. Remove the front cushion rubbers.

Installation
1. Install the clutch release fork and bearing to transmission. (MT model)
2. Install the front cushion rubbers to engine.
Tightening torque: 35 Nm (3.6 kgf-m, 25.8 ft. lbs.)
3. Install the engine onto transmission.
a. Position the engine in engine compartment, and then align it with the transmission.

NOTE: Be careful not to damage the adjacent parts or body panels with crank pulley, oil pressure gauge, etc.

b. Apply a small amount of grease to the splines of mainshaft. (MT model)
4. Tighten the bolts which hold the right upper side of transmission to engine.
Tightening torque: 50 Nm (5.1 kgf-m, 37 ft. lbs.)





5. Remove the lifting device and wire ropes.





6. Remove the garage jack.
7. Install the pitching stopper.
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 37 ft. lbs.)
T2: 58 Nm (5.9 kgf-m, 43 ft. lbs.)





8. Remove the ST from torque converter clutch case. (AT model)

NOTE: Be careful not to drop the ST into torque converter clutch case when removing ST.

ST 498277200 STOPPER SET
9. Install the starter.
10. Install the torque converter clutch onto drive plate. (AT model)
a. Tighten the bolts which hold the torque converter clutch to drive plate.
b. While rotating the crank pulley in the direction of engine rotation little by little using a socket wrench, remove all the bolts.

CAUTION: Be careful not to drop bolts into the torque converter clutch housing.

Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft. lbs.)





c. Install the service hole plug.
11. Install the power steering pump on bracket.
a. Install the power steering tank on bracket.





b. Install the power steering pump.
Tightening torque: 20.1 Nm (2.05 kgf-m, 14.8 ft. lbs.)





c. Install the power steering pipe bracket on intake manifold RH.





d. Install the front side V-belt, and adjust it.
12. Lift-up the vehicle.
13. Tighten the nuts which hold the lower side of transmission to engine.
Tightening torque: 50 Nm (5.1 kgf-m, 37 ft. lbs.)





14. Tighten the nuts which install the front cushion rubber onto crossmember.
Tightening torque: 85 Nm (8.7 kgf-m, 62.7 ft. lbs.)

NOTE: Make sure the front cushion rubber mounting bolts (A) and locator (B) are securely installed.





15. Install the ATF cooler pipe to frame. (AT model)
16. Install the center exhaust pipe.
17. Lower the vehicle.
18. Connect the following hoses:
a. Fuel delivery hose, return hose and evaporation hose
b. Heater inlet and outlet hoses
c. Brake booster vacuum hose
19. Connect the following connectors and terminals:
a. Engine ground terminal
b. Engine harness connectors
c. Generator connector and terminal
d. A/C compressor connectors
e. Power steering switch connector
20. After connecting each cable, adjust them.
21. Install the air intake system.
a. Install the intercooler.
b. Install the air cleaner element and air cleaner upper cover.
c. Install the engine harness connector bracket.
d. Install the filler hose to air cleaner case.
22. Install the A/C pressure hoses.

NOTE: Use new O-rings.

Tightening torque: 15 Nm (1.5 kgf-m, 10.8 ft. lbs.)





23. Install the radiator.
24. Install the coolant filler tank.
25. Install the secondary air pump.
26. Install the battery in the vehicle, and then connect the cables.
27. Fill engine coolant.
28. Charge the A/C system with refrigerant.
29. Remove the front hood stay, and close the front hood.
30. Take off the vehicle from lift arms.