Removal and Replacement
Engine AssemblyREMOVAL
1) Set the vehicle on a lift.
2) Change the bolt installation position from (A) to (B), then open the front hood completely.
3) Remove the V-belt covers.
4) Collect the refrigerant from A/C system.
5) Release the fuel pressure.
6) Remove the battery.
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.
11) Remove the coolant filler tank.
12) Disconnect the A/C pressure hoses from A/C compressor.
13) Disconnect the bulkhead harness connectors from the engine harness connectors.
14) Remove the engine harness connector from the engine harness bracket.
15) Disconnect the following connectors and terminals.
1) Generator connector and terminal
2) A/C compressor connector
3) Secondary air pump connector
16) Disconnect the following hoses.
1) Brake booster vacuum hose (A) and pressure regulator vacuum hose (B)
2) Heater inlet hose and heater outlet hose
17) Remove the power steering pump.
1) Remove the front side belts.
2) Disconnect the power steering pump switch connector.
3) Remove the power steering pump from the engine.
4) Place the power steering pump on the right side wheel apron.
18) Remove the center exhaust pipe.
19) Remove the turbocharger.
20) Remove the joint pipe and front exhaust pipe.
21) Disconnect the ground cable on the engine side.
22) Remove the bolts and nuts which hold the lower side of transmission to the engine.
23) Remove the nuts which secure the engine mounting to the front crossmember.
24) Lower the vehicle.
25) Separate the clutch release fork from the release bearing.
1) Remove the clutch operating cylinder from the transmission.
2) Remove the plug using a hexagon wrench (10 mm).
3) Screw-in the 6 mm dia. bolt into the release fork shaft to remove.
4) Raise the release fork, unlock the release bearing tab, then remove the release fork.
NOTE:
Step (4) is required to avoid interference with the engine when removing the engine from the transmission.
26) Remove the pitching stopper.
27) Disconnect the fuel delivery hose, fuel return hose and evaporation hose.
1) Disconnect the quick connector of the fuel delivery hose and fuel return hose by pushing the ST in the direction of the arrow.
ST 42099AE000 QUICK CONNECTOR RELEASE
2) 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.
28) Support the engine with a lifting device and wire ropes.
29) Support the transmission with a garage jack.
CAUTION:
Be sure to perform this procedure to prevent the transmission from lowering by its own weight.
30) 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.
31) Remove the engine from vehicle.
1) Slightly raise the engine.
2) Raise the transmission with garage jack.
3) Move the engine horizontally until main shaft is withdrawn from clutch cover.
4) 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.
32) Remove the turbocharger and joint pipe from the engine.
33) Remove the engine mounting from the engine.
INSTALLATION
1) Install the clutch release fork and bearing to the transmission.
1) Using a flat tip screwdriver, remove the release bearing from the clutch cover.
2) Attach the release bearing to the transmission.
3) Install the release fork into the release bearing tab.
4) Apply grease to the specified areas.
5) Insert the release shaft to release fork.
NOTE:
Allow the cutout portion of release shaft to come into contact with the spring pin.
6) Tighten the plugs.
2) Install the engine mounting onto the engine.
Tightening torque:
35 N.m (3.6 kgf-m, 25.8 ft-lb)
3) Apply a small amount of grease to splines of main shaft.
Grease:
NICHIMOLY N-130 or equivalent
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.
9) Install the starter.
10) Install the power steering pump onto the engine.
1) Install the power steering pump.
2) Connect the power steering pump switch connector.
3) Install and adjust the front side belt.
11) Lift up the vehicle.
12) Install the bolts and nuts which hold lower side of the transmission to engine.
13) Install the nuts which hold the engine mounting to the crossmember.
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) 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 and pressure regulator vacuum hose
19) Connect the following connectors and terminals.
1) Generator connector and terminal
Tightening torque:
15 N.m (1.5 kgf-m, 11.1 ft-lb)
2) A/C compressor connector
3) Secondary air pump connector
20) Install the engine harness connector to engine harness bracket, then connect the bulkhead harness connector to the engine harness connector.
21) Install the intercooler.
22) Install the A/C pressure hoses to A/C compressor.
23) Install the radiator.
24) Install the coolant filler tank.
25) Install the air cleaner case and air intake duct.
26) Install the battery.
27) Fill engine coolant.
28) Charge the A/C system with refrigerant.
29) Install the V-belt cover.
30) Change the bolt installation position from (B) to (A), then close the front hood.
INSPECTION
1) Check that pipes, hoses, connectors and clamps are installed firmly.
2) Check 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.