Removal and Replacement
The content of this article/image reflects the changes identified in
TSB - MU 18-131-08.
Engine Assembly
REMOVAL
1) Set the vehicle on a lift.
2) Change the bolt mounting position from (A) to (B), and completely open the front hood.
Tightening torque: 7.5 Nm (0.76 kgf-m, 5.5 ft. lbs.)
3) Remove the V-belt covers.
4) Collect the refrigerant from the A/C system.
5) Release the fuel pressure.
6) Disconnect the battery cable, and remove the battery from the vehicle.
7) Open the fuel filler lid and remove the fuel filler cap.
8) Remove the air intake duct and air cleaner case.
9) Remove the intercooler.
10) Remove the radiator from the vehicle.
11) Remove the coolant filler tank.
12) Disconnect the A/C pressure hoses from A/C compressor.
13) Disconnect the following connectors and cables.
a) Engine harness connectors
b) Generator connector and terminal
c) A/C compressor connector
d) Secondary air pump connector
14) Disconnect the following hoses.
a) Brake booster vacuum hose (A) and pressure regulator vacuum hose (B)
b) Heater inlet and outlet hoses
15) Remove the power steering pump.
a) Remove the front side belts.
b) Disconnect the power steering pump switch connector.
c) Remove the power steering pump from the engine.
d) Place the power steering pump on the right side wheel apron.
16) Remove the center exhaust pipe.
17) Remove the turbocharger.
18) Remove the joint pipe and front exhaust pipe.
19) Lift up the vehicle.
20) Disconnect the ground cable on the engine side.
21) Remove the bolts and nuts which hold the lower side of transmission to the engine.
22) Remove the nuts which hold the engine mount to the front cross member.
23) Remove the pitching stopper.
24) Disconnect the fuel delivery hose, fuel return hose, and evaporation hose.
a) Disconnect the quick connector on the fuel delivery hose and fuel return hose by pushing the ST in the direction of the arrow.
ST 42099AEOOO QUICK CONNECTOR RELEASE
b) Remove the clip and disconnect the evaporation hose from the fuel pipe.
CAUTION:
^ Be careful not to spill fuel.
^ Catch the fuel from hoses using a container or cloth.
25) Support the engine with a lifting device and wire ropes.
26) Support the transmission with a garage jack.
CAUTION: Doing this is very important to prevent the transmission from lowering due to its own weight.
27) Separation of engine and transmission.
CAUTION: Before removing the engine away from transmission, check to be sure no work has been overlooked.
a) Remove the starter.
b) Remove the bolts which hold the upper side of the transmission to the engine.
28) 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.
29) Remove the turbocharger and joint pipe from the engine.
30) Remove the engine mount from the engine.
INSTALLATION
1) Install the engine mount onto the engine.
Tightening torque: 35 Nm (3.6 kgf-m, 25.8 ft. lbs.)
2) Install the turbocharger and joint pipe to the engine.
3) Apply a small amount of grease to splines of main shaft.
4) 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.
5) Tighten the bolts which hold upper side of transmission to engine.
6) Remove the lifting device and wire ropes.
7) Remove the garage jack.
8) Install the pitching stopper.
Tightening torque:
9) Install the starter.
10) Install the power steering pump.
a) Install the power steering pump.
b) Connect the power steering pump switch connector.
c) Install and adjust the front side belt.
11) Lift up the vehicle.
12) Tighten the bolts and nuts which hold lower side of the transmission to engine.
13) Tighten the nuts which hold the engine mount to the cross member.
14) Connect the ground cable.
15) Install the joint pipe and front exhaust pipe.
16) Install the turbocharger.
17) Install the center exhaust pipe.
18) Lower the vehicle.
19) Connect the following hoses.
a) Fuel delivery hose, fuel return hose and evaporation hose
b) Heater inlet and outlet hoses
c) Brake booster vacuum hose and pressure regulator vacuum hose
20) Connect the following connectors and terminals.
a) Engine harness connectors
b) Generator connector and terminal
Tightening torque: 15 Nm (1.5 kgf-m, 11.1 ft. lbs.)
c) A/C compressor connector
d) Secondary air pump connector
21) Install the intercooler.
22) Install the A/C pressure hoses.
23) Install the radiator.
24) Install the coolant filler tank.
25) Install the air cleaner case and air intake duct.
26) Install the battery to the vehicle, and connect the battery cables.
27) Fill engine coolant.
28) Charge the A/C system with refrigerant.
29) Install the V-belt cover.
30) Change the bolt mounting position from (B) to (A), and close the front hood.
31) Lower the vehicle from the lift.
INSPECTION
1) Check that pipes, hoses, connectors and clamps are installed firmly.
2) Check that the engine coolant is at specified level.
3) Start the engine and check for exhaust gas, engine coolant, leaks of fuel, etc. Also check for noise and vibrations.