Removal and Replacement
Engine AssemblyREMOVAL
1) Change the front hood damper mounting position from (A) to (B), and completely open the front hood.
2) Remove the collector cover.
3) Collect the refrigerant from A/C system.
4) Release the fuel pressure.
5) Disconnect the ground cable from battery.
6) Open the fuel filler lid and remove the fuel filler cap.
7) Remove the air intake duct.
8) Remove the intercooler.
9) Remove the air by-pass valve.
10) Remove the radiator.
11) Remove the front exhaust pipe.
12) Lower the vehicle.
13) Disconnect the bulkhead harness connector from the engine harness connector (brown).
14) Remove the bolt securing the bulkhead harness connector bracket, and disconnect the bulkhead harness connector from the engine harness connector (black).
15) Disconnect the connector (A) and connector (B) from A/C compressor, and remove the clip (C) securing the generator cord to the intake manifold protector LH.
16) Disconnect the following hoses.
1) A/C pressure hose
2) Brake booster vacuum hose
3) Heater inlet hose and heater outlet hose
17) Lift up the vehicle.
18) Remove the intake duct from the air intake boot.
19) Disconnect the ground cable on the engine side, and remove the engine harness cover.
20) Lower the vehicle.
21) Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the fuel delivery hose.
ST 42099AE000 QUICK CONNECTOR RELEASE
CAUTION:
^ Be careful not to spill fuel.
^ Catch the fuel from hoses using a container or cloth.
22) Disconnect the fuel return hose using the ST.
ST 18371AA000 CONNECTOR REMOVER
CAUTION:
^ Be careful not to spill fuel.
^ Catch the fuel from hoses using a container or cloth.
1) Attach ST to the fuel return pipe as shown in the figure.
2) Insert the front side of ST into the quick connector.
3) Insert the back side of ST into the quick connector and push ST in the direction of arrow mark to disconnect the fuel return hose.
23) Remove the clip and disconnect the evaporation hose from the fuel pipe.
24) Support the engine with a lifting device and wire ropes.
25) Remove the stopper rod.
26) Remove the bolt and nut which secure engine mounting to the cradle.
27) Lift up the vehicle.
CAUTION:
When lifting up the vehicle, raise up wire ropes at the same time.
28) Remove the bolts which secure the engine mounting onto the engine, and remove the engine mounting.
29) Remove the bolts and nuts which hold the lower side of transmission to the engine.
30) Lower the vehicle.
CAUTION:
When lifting down the vehicle, lower wire ropes at the same time.
31) Support the transmission with a garage jack.
NOTE:
Fine adjustment of the transmission height can be performed with this operation.
32) Separation of engine and transmission
CAUTION:
Before removing the engine away from transmission, check to be sure no work has been overlooked.
1) Remove the starter.
2) Remove the bolts which hold the upper side of the transmission to the engine.
33) Remove the engine from vehicle.
1) Slightly raise the engine.
2) Adjust the height of the transmission with garage jack.
3) Move the engine horizontally until main shaft is withdrawn from clutch cover.
4) Move the engine from engine compartment slowly.
NOTE:
Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.
INSTALLATION
1) Apply a small amount of grease to splines of main shaft.
Grease:
NICHIMOLY(R) N-130 or equivalent
2) Position the engine in engine compartment and align it with transmission.
NOTE:
Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.
3) Tighten the bolts which hold upper side of transmission to engine.
4) Remove the garage jack.
5) Install the starter.
6) Lift up the vehicle.
CAUTION:
When lifting up the vehicle, raise up wire ropes at the same time.
7) Attach the bolts and nuts which hold lower side of the transmission to engine.
8) Set the engine mounting, and tighten the bolts which hold engine mounting to the engine.
9) Lower the vehicle.
CAUTION:
When lifting down the vehicle, lower wire ropes at the same time.
10) Attach the bolts and nuts which secure engine mounting to the cradle.
11) Install the stopper rod.
12) Remove the lifting device and wire ropes.
13) Lift up the vehicle.
14) Install the intake duct to the air intake boot.
15) Install the engine harness cover, and connect the ground cable.
16) Lower the vehicle.
17) Connect the following hoses.
1) Fuel delivery hose, fuel return hose and evaporation hose
2) Heater inlet hose and heater outlet hose
3) Brake booster vacuum hose
4) A/C pressure hose
18) Install the clip (C) securing the generator cord to the intake manifold protector LH, and connect the connector (A) and connector (B) to the A/C compressor.
19) Connect the bulkhead harness connector to the engine harness connector (black), and install the bolt securing the bulkhead harness connector bracket.
20) Connect the bulkhead harness connector to the engine harness connector (brown).
21) Install the front exhaust pipe.
22) Install the radiator.
23) Install the air by-pass valve.
24) Install the intercooler.
25) Install the air intake duct.
26) Connect the ground cable to battery.
27) Fill engine coolant.
28) Charge the A/C system with refrigerant.
29) Install the collector cover.
30) Change the front hood damper mounting position from (B) to (A), and close the front hood.
INSPECTION
1) Check that the pipes, hoses, connectors and clamps are securely connected.
2) Check that the engine coolant is up to specified level.
3) Start the engine and check for exhaust gas leakage, engine coolant leakage, fuel leakage, noise or vibration.