Removal and Installation
Engine AssemblyREMOVAL
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 it 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. Disconnect the A/C pressure hoses from A/C compressor.
10. Remove the intercooler.
11. 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. Clutch release spring
12. Disconnect the following hoses.
a. Brake booster vacuum hose
b. Heater inlet outlet hose
13. Remove the power steering pump from bracket.
a. Loosen the lock bolt and slider bolt, and then remove the front side V-belt.
b. Disconnect the power steering switch connector.
c. Remove the Pipe with bracket from intake manifold.
d. Remove the power steering pump from engine.
e. Remove the power steering tank from bracket by pulling it upward.
f. Place the power steering pump on right side wheel apron.
14. Lift-up the vehicle.
15. Remove the center exhaust pipe.
16. Remove the nuts which hold the lower side of transmission to engine.
17. Remove the nuts which install the front cushion rubber onto front crossmember.
18. Lower the vehicle.
19. Separate the clutch release fork from release bearing.
a. Remove the clutch operating cylinder from transmission.
b. Remove the plug using a 10 mm hexagon wrench.
c. Screw the 6 mm dia. bolt into release fork shaft, and remove it.
d. Raise the release fork, and then unfasten the release bearing tabs to free release fork.
NOTE: Step (4) is required to prevent interference with engine when removing the engine from transmission.
20. Remove the pitching stopper.
21. Disconnect the fuel delivery hose (A), return hose (B) and evaporation hose (C).
NOTE:
^ Catch fuel from the hose into container.
^ Disconnect the hose with its end wrapped with cloth to prevent fuel from splashing.
ST 42099AE000 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 in order to facilitate re-installation and because transmission lowers under its own weight.
CAUTION: Before removing the engine away from transmission, check to be sure no work has been overlooked.
24. Separation of the engine and transmission
a. Remove the starter.
b. Remove the bolts which hold the right upper side of transmission to engine.
25. 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.
26. Remove the front cushion rubbers.
INSTALLATION
1. Install the clutch release fork and bearing onto transmission.
a. Remove the release bearing from clutch cover with flat-tip screwdriver.
b. Install the release bearing on transmission.
c. Install the release fork into release bearing tab.
d. Apply grease to the specified points.
^ Spline NICHIMOLY 130
e. Insert the release fork shaft into release fork.
CAUTION: Make sure the cutout portion of release fork shaft contacts spring pin.
f. Tighten the plug.
Tightening torque: 44 Nm (4.5 kgf-m, 33.5 ft. lbs.)
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.
4. Tighten the bolts which hold the upper side of transmission to engine.
Tightening torque: 50 Nm (5.1 kgf-m, 36.9 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, 36.9 ft. lbs.)
T2: 58 Nm (5.9 kgf-m, 42.8 ft. lbs.)
8. Install the power steering pump on bracket.
a. Install the power steering tank on bracket.
b. Install the power steering pump.
Tightening torque: 20 Nm (2.0 kgf-m, 14.5 ft. lbs.)
c. Install the power steering pipe bracket on intake manifold RH.
d. Connect the power steering switch connector.
e. Install the front side V-belt, and adjust it.
9. Lift-up the vehicle.
10. Tighten the nuts which hold the lower side of transmission to engine.
Tightening torque: 50 Nm (5.1 kgf-m, 36.9 ft. lbs.)
11. 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.
12. Install the center exhaust pipe.
13. Lower the vehicle.
14. Connect the following hoses:
a. Fuel delivery hose, return hose and evaporation hose
b. Heater inlet and outlet hoses
c. Brake booster vacuum hose
15. Connect the following connectors and terminals:
a. Engine ground terminal
b. Engine harness connectors
c. Generator connector and terminal
d. A/C compressor connectors
16. 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.
17. Install the A/C pressure hoses.
NOTE: Use new O-rings.
Tightening torque: 25 Nm (2.5 kgf-m, 18.4 ft. lbs.)
18. Install the radiator.
19. Install the coolant filler tank.
20. Install the window washer tank.
21. Install the battery in the vehicle, and then connect the cables.
22. Fill coolant.
23. Charge the A/C system with refrigerant.
24. Remove the front hood stay, and close the front hood.
25. Take off the vehicle from lift arms.
INSPECTION
1. Check that the pipes and hoses are installed firmly.
2. Check that the engine coolant is at specified level.