Removal and Replacement

Engine Assembly

REMOVAL

1) Change the bolt installation position from (A) to (B), then open the front hood completely.

Tightening torque:
7.5 Nm (0.8 kgf-m, 5.5 ft-lb)





2) Remove the V-belt covers.





3) Collect the refrigerant from A/C system.
4) Release the fuel pressure.
5) Remove the battery.
6) Remove the air intake duct (Rear).
7) Remove the air intake boot.
8) Disconnect the connector (A) from the mass air flow and intake air temperature sensor, and remove the clip (B) which holds the mass air flow and intake air temperature sensor harness.
9) Remove the suction hose (C) from the air cleaner case (rear).





10) Remove the air cleaner case (rear).





11) Remove the radiator.
12) Disconnect the engine harness connector.
(1) Remove the bolt securing the bulkhead harness connector bracket.





(2) Disconnect the bulkhead harness connector from the engine harness connector (black) and engine harness connector (brown).





13) Remove the bolts which secure the generator cord stay to the chain cover.





14) Disconnect connector (A) and terminal (B) from the generator, and disconnect connector (C) from A/C compressor.
15) Remove the generator cord from the clip (D) and move the generator cord to the left side wheel apron.





16) Disconnect the following hoses.
(1) A/C pressure hose
(2) Brake booster vacuum hose





(3) Heater inlet hose and heater outlet hose





17) Remove the power steering pump.
(1) Remove the V-belts.
(2) Remove the generator.
(3) Disconnect the connector from power steering pump switch.





(4) Remove the power steering pump from the engine.





(5) Place the power steering pump on the right side wheel apron.
18) Lift up the vehicle.
19) Remove the front exhaust pipe.
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.
^ AT model





^ MT model





22) Remove the nuts which secure the engine mounting to the front crossmember.





23) Separate the torque converter clutch from the drive plate. (AT model)
(1) Lower the vehicle.
(2) Remove the service hole plug.
(3) Insert the wrench into the crank pulley bolt and rotate the crank pulley to remove the bolts which hold torque converter clutch to drive plate.





24) Remove the pitching stopper.





25) Disconnect the fuel delivery hose and evaporation hose.

CAUTION:
^ Be careful not to spill fuel.
^ Catch the fuel from hoses using a container or cloth.

(1) Attach ST to the fuel delivery pipe and push ST in the direction of arrow mark to disconnect the quick connector of the fuel delivery hose.
ST 42099AE000 QUICK CONNECTOR RELEASE





(2) Remove the clip and disconnect the evaporation hose from the evaporation pipe.





26) Support the engine with a lifting device and wire ropes.





27) Support the transmission with a garage jack.

CAUTION:
Be sure to perform this procedure to prevent the transmission from lowering by its own weight.





28) Separate the 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) Attach the ST to the torque converter clutch case. (AT model)
ST 498277200 STOPPER SET





(3) Remove the bolts which hold the upper side of the transmission to the engine.
^ AT model





^ MT model





29) Remove the engine from vehicle.

NOTE:
Be careful not to damage adjacent parts or body panels with crank pulley, oil level gauge, etc.

(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. (MT model)
(4) Slowly move the engine away from engine compartment.
30) Remove the engine mounting from the engine.

INSTALLATION

1) Install the engine mounting onto the engine.

Tightening torque:
35 Nm (3.6 kgf-m, 25.8 ft-lb)

2) Apply a small amount of grease to splines of main shaft. (MT model)

Grease:
NICHIMOLY N-130 or equivalent

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) Tighten the bolts which hold upper side of transmission to engine.

Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)

^ AT model





^ MT model





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-lb)
T2: 58 Nm (5.9 kgf-m, 42.8 ft-lb)





8) Remove the ST from torque converter clutch case. (AT model)

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

ST 498277200 STOPPER SET





9) Install the starter.
10) Install the torque converter clutch to drive plate. (AT model)
(1) Insert the wrench into the crank pulley bolt and rotate the crank pulley to install the bolts which hold torque converter clutch to drive plate.

NOTE:
Be careful not to drop bolts into the torque converter clutch case.

Tightening torque:
25 Nm (2.5 kgf-m, 18.4 ft-lb)





(2) Fit the plug to service hole.
11) Install the power steering pump.
(1) Install the power steering pump onto the engine.

Tightening torque:
Refer to "COMPONENT" of "Power Steering" for the tightening torque.





(2) Connect the connector to the power steering pump switch.





(3) Install the generator.
(4) Install the V-belts.
12) Lift up the vehicle.
13) Install the bolts and nuts which hold lower side of the transmission to engine.

Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)

^ AT model





^ MT model





14) Install the nuts which hold the engine mounting to the crossmember.

Tightening torque:
85 Nm (8.7 kgf-m, 62.7 ft-lb)





15) Connect the ground cable.

Tightening torque:
7.5 Nm (0.8 kgf-m, 5.5 ft-lb)





16) Install the front exhaust pipe.
17) Lower the vehicle.
18) Connect the following hoses.
(1) Fuel delivery hose and evaporation hose
(2) Heater inlet hose and heater outlet hose
(3) Brake booster vacuum hose
(4) A/C pressure hose
19) Place the generator code and install the generator cord to the clip (D).
20) Connect connector (A) and terminal (B) to the generator, and connect connector (C) to A/C compressor.

Tightening torque:
15 Nm (1.5 kgf-m, 11.1 ft-lb)





21) Install the generator cord stay to the chain cover.

NOTE:
Install the generator cord stay so that the folded end (A) touches at the chain cover boss.

Tightening torque:
6.4 Nm (0.7 kgf-m, 4.7 ft-lb)





22) Connect the engine harness connector.
(1) Connect the bulkhead harness connector to the engine harness connector (black) and engine harness connector (brown).





(2) Install the bolt which secures the bulkhead harness connector bracket.

Tightening torque:
6.4 Nm (0.7 kgf-m, 4.7 ft-lb)





23) Install the radiator.
24) Install the air intake case (rear).





25) Install the clip (B) which secures the mass air flow and intake air temperature sensor harness, and connect the connector (A) to the mass air flow and intake air temperature sensor.
26) Install the suction hose (C) to the air cleaner case (rear).





27) Install the air intake boot.
28) Install the air intake duct (rear).
29) Install the battery.
30) Fill engine coolant.
31) Check the ATF level and replenish it if necessary. (AT model)
32) Charge the A/C system with refrigerant.
33) Install the V-belt cover.

Tightening torque:
13 Nm (1.3 kgf-m, 9.6 ft-lb)





34) Change the bolt installation position from (B) to (A), then close the front hood.

Tightening torque:
7.5 Nm (0.8 kgf-m, 5.5 ft-lb)





INSPECTION

1) Check that pipes, hoses, connectors and clamps are installed firmly.
2) Check the engine coolant is at specified level.
3) Check that the ATF is at specified level. (AT model)
4) Start the engine and check for exhaust gas, engine coolant, leaks of fuel, etc. Also check for noise and vibrations