Removal and Installation

Engine Assembly

REMOVAL
1. Set the vehicle on a lift.
2. Open the front hood fully and support with the front food stay.
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 flap lid and remove the fuel filler cap.
7. Remove the air intake duct, air cleaner case and air intake chamber.
8. Remove the under cover.
9. Remove the radiator from vehicle.
10. Disconnect the A/C pressure hoses from A/C compressor.
11. Remove the air intake chamber stay.





12. Disconnect the following connectors and cables.
a. Front oxygen (A/F) sensor connector
b. Rear oxygen sensor connector





c. Engine ground cable





d. Engine harness connectors





e. Generator connector and terminal





f. A/C compressor connectors





g. Power steering switch connector





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





b. Heater inlet and outlet hoses
14. Remove the power steering pump from bracket.
a. Loosen the lock bolt and slider bolt, and then remove the front side V-belt.
b. Remove the pipe with bracket.





c. Remove the bolts which install the power steering pump to bracket.





d. Remove the power steering tank from bracket by pulling it upward.





e. Move the power steering pump to the right side wheel apron to prevent it from falling.

NOTE: Use a shop cloth not to scratch.





15. Remove the front and center exhaust pipe.
16. Remove the nuts which hold lower side of transmission to engine.





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





18. Remove the housing cover mounting bolts.
19. 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 torque converter clutch to drive plate.
d. Remove all the bolts by rotating them in the direction of engine rotation little by little using a socket wrench.





20. Remove the pitching stopper.





21. Disconnect the fuel delivery hose (A) and evaporation hose (B).

CAUTION:
^ Catch fuel from the hose into container.
^ Disconnect the hose with its end wrapped with cloth to prevent fuel from splashing.

ST 42099AEOOO CONNECTOR REMOVER





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





23. Support the transmission with a garage jack.

CAUTION: Doing this is very important because the transmission lowers for its own weight. This work is also of great importance for facilitating reinstallation.





CAUTION: Before removing the engine away from transmission, check to be sure no work has been overlooked.

24. Separation of engine and transmission.
a. Remove the starter.
b. Remove the bolts which hold upper side of transmission to engine.





25. Set the ST to converter case. (AT model)
ST 498277200 STOPPER SET





26. Remove the engine from vehicle.
a. Slightly raise the engine.
b. Raise the transmission with garage jack.
c. Move the engine horizontally until main shaft 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 level gauge, etc.

27. Remove the front cushion rubbers.

INSTALLATION
a. Install the front cushion rubbers.
Tightening torque: 35 Nm (3.6 kgf-m, 25.8 ft. lbs.)
b. 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.





c. Apply a small amount of grease to splines of main shaft. (MT model)
d. Tighten the bolts which hold upper side of transmission to engine.
Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft. lbs.)





e. Remove the lifting device and wire ropes.
f. Remove the garage jack.
g. Install the pitching stopper.
Tightening torque:
T1: 50 Nm (5.1 kgf-m, 36.9 ft. lbs.)
T2: 58 Nm (5.9 kgf-m, 42.8 ft. lbs.)
h. Remove the ST from converter case. (AT model)





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

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

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. Clog the service hole plug and prevent foreign matters from being mixed.
11. Install the power steering pump on bracket.
a. Install the power steering tank to bracket.





b. Install the power steering pump on bracket, and tighten the bolts.
Tightening torque: 22 Nm (2.2 kgf-m, 16 ft. lbs.)





c. Install the pipe with their bracket.





d. Connect the power steering switch connector.





e. Install the front side belt and adjust it.
12. Lift-up the vehicle.
13. Tighten the nuts which hold lower side of transmission to engine.
Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft. lbs.)





14. Tighten the nuts which install the front cushion rubber onto crossmember.
Tightening torque: 85 Nm (8.7 kgf-m, 63 ft. lbs.)

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





15. Install the front and center exhaust pipe.
16. Lower the vehicle.
17. Connect the following hoses:
a. Fuel delivery hose and evaporation hose
b. Heater inlet and outlet hoses
c. Brake booster vacuum hose
18. Connect the following connectors:
a. Front oxygen (A/F) sensor connector
b. Rear oxygen sensor connector
c. Engine ground cable
Tightening torque: 14 Nm (1.4 kgf-m, 10. 1 ft. lbs.)
d. Engine harness connectors
e. Generator connector and terminal
f. A/C compressor connector
19. Install the air intake chamber stay.
Tightening torque: 16 Nm (1.6 kgf-m, 11.6 ft. lbs.)
20. Tighten the engine ground cable.
Tightening torque: 14 Nm (1.4 kgf-m, 10. 1 ft. lbs.)
21. Install the A/C pressure hoses.
22. Install the radiator to vehicle.
23. Install the air intake duct, air cleaner case and air intake chamber.
24. Install the under cover.
25. Install the battery in the vehicle, and connect cables.
26. Fill engine coolant.
27. Check the ATF level and replenish it if necessary.
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 a lift.

INSPECTION
1. Check pipes, hoses, connectors and clamps are installed firmly.
2. Check that the engine coolant and ATF are at specified levels.
3. Start the engine, and make sure that no leaks of exhaust gas, engine coolant and fuel, noise and vibrations.