Removal and Replacement

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. Release the fuel pressure.
4. Remove the fuel filler cap.
5. Disconnect the ground cable from battery.





6. Remove the air intake duct, air cleaner case and air intake chamber.
7. Remove the under cover.
8. Remove the radiator from vehicle.
9. Disconnect the A/C pressure hoses from A/C compressor.
10. Remove the air intake chamber stay.





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





Rear oxygen sensor connector





Engine ground cable





Engine harness connectors





Generator connector and terminal





(A) Terminal
(B) Generator connector

A/C compressor connectors





Power steering switch connector





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





15. Heater inlet and outlet hoses

16. Remove the power steering pump from bracket.
17. Loosen the lock bolt and slider bolt, and then remove the front side V-belt.
18. Remove the pipe with bracket.





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





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





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





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





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





25. Separate the torque converter clutch from drive plate. (AT model)
26. Lower the vehicle.
27. Remove the service hole plug.

28. Remove the bolts which hold torque converter clutch to drive plate.
29. Remove other bolts while rotating the engine using a socket wrench.





30. Remove the pitching stopper.





31. Disconnect the fuel delivery hose (A), return hose (B) and evaporation hose (C).

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

ST 32005086 CONNECTOR REMOVER





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





32. Support the transmission with a garage jack.

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





(A) Transmission
(B) Garage jack

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

33. Separation of engine and transmission.
34. Remove the starter.
35. Remove the bolts which hold upper side of transmission to engine.





36. Set the ST to converter case. (AT model)
ST 32005099 STOPPER SET





37. Remove the engine from vehicle.
38. Slightly raise the engine.
39. Raise the transmission with garage jack.
40. Move the engine horizontally until main shaft is withdrawn from clutch cover.
41. 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.

42. Remove the front cushion rubbers.

Installation
1. Install the front cushion rubbers.
2. Tightening torque: 35 Nm (3.6 kgf-m, 25.8 ft. lbs.)
3. 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.





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





6. Remove the lifting device and wire ropes.
7. Remove the garage jack.
8. 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.)





9. 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 32005099 STOPPER SET
10. Install the starter.
11. Install the torque converter clutch to drive plate. (AT model)
12. Tighten the bolts which hold torque converter clutch to drive plate.
13. Tighten other bolts while rotating the engine using a socket wrench.

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

Tightening torque: 25 Nm (2.5 kgf-m, 18.1 ft. lbs.)





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





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





18. Install the pipe with their bracket.





19. Connect the power steering switch connector.





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





23. 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.

24. Install the front and center exhaust pipe.
25. Lower the vehicle.
26. Connect the following hoses:
27. Fuel delivery hose, return hose and evaporation hose
28. Heater inlet and outlet hoses
29. Brake booster vacuum hose
30. Connect the following connectors:
31. Front oxygen (A/F) sensor connector
32. Rear oxygen sensor connector
33. Engine ground cable
Tightening torque: 14 Nm (1.4 kgf-m, 10.1 ft. lbs.)
34. Engine harness connectors
35. Generator connector and terminal
36. A/C compressor connector
37. Install the air intake chamber stay.
Tightening torque: 16 Nm (1.6 kgf-m, 11.6 ft. lbs.)
38. Install the A/C pressure hoses.
39. Install the radiator to vehicle.
40. Install the air intake duct, air cleaner case and air intake chamber.
41. Install the under cover.
42. Install the battery in the vehicle, and connect cables.
43. Fill engine coolant.
44. Check the ATF level and replenish it if necessary.
45. Charge the A/C system with refrigerant.
46. Remove the front hood stay, and close the front hood.
47. 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.