ENGINE ASSEMBLY
Mechanical
9. Engine Assembly
S183079
(3) Disconnect A/C pressure hoses from A/C compressor.
A: REMOVAL
S183079A18
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1)  Set the vehicle on lift arms.
2)  Open front hood fully and support with stay.
3)   Raise rear seat, and turn floor mat up.
4)   Release fuel pressure.
(1) Disconnect fuel pump relay connector.
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10)   Remove intercooler. <Ref. to IN(DOHC TURBO)-10, REMOVAL, Intercooler.>
11)   Disconnect the following connectors and cable.
(1) Engine harness connector
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5)
(2)  Start the engine, and run until stalls.
(3)  After the engine stalls, crank it for five sec≠onds more.
(4)  Turn ignition switch to "OFF". Remove filler cap.
6) Disconnect battery ground terminal.
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(2) Engine ground terminal
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7)   Remove radiator from vehicle. <Ref. to CO-25, REMOVAL, Radiator.>
8)   Remove coolant filler tank. <Ref. to CO-37, REMOVAL, Coolant Filler Tank.>
9)  Collect refrigerant, and remove pressure hoses.
(1)   Place and connect the attachment hose to the refrigerant recycle system.
(2)  Collect refrigerant from A/C system.
(3) Engine harness connector
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ENGINE ASSEMBLY
Mechanical
(4) Generator connector, terminal and A/C compressor connectors
(2) Heater inlet outlet hose
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13) Remove power steering pump from bracket.
(1)   Loosen lock bolt and slider bolt, and remove front side V-belt. <Ref. to ME(DOHC TURBO)-44, FRONT SIDE BELT, REMOVAL, V-belt.>
(2)   Disconnect the power steering switch con≠nector.
(A)    A/C compressor connector
(B)    Generator connector and terminal
(5) Accelerator cable
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(6) Clutch release spring
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(3) Remove pipe with bracket from intake mani≠fold.
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12) Disconnect the following hoses (1) Brake booster vacuum hose
(4) Remove power steering pump from engine.
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ENGINE ASSEMBLY
Mechanical
(5) Remove power steering tank from the bracket by pulling it upward.
16) Remove nuts which install front cushion rub≠ber onto front crossmember.
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(6) Place power steering pump on the right side wheel apron.
17) Separate clutch release fork from release bearing. (MT vehicles)
(1)   Remove clutch operating cylinder from transmission.
(2)   Remove plug using 10 mm hexagon wrench.
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14)   Remove center exhaust pipe. <Ref. to EX(DOHC TURBO)-9, REMOVAL, Center Exhaust Pipe.>
15)   Remove nuts which hold lower side of trans≠mission to engine.
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ENGINE ASSEMBLY
Mechanical
(3) Screw 6 mm dia. bolt into release fork shaft, and remove it.
19) Remove pitching stopper.
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20) Disconnect fuel delivery hose, return hose and evaporation hose.
CAUTION:
ē  Catch fuel from hose into container.
ē  Disconnect hose with its end wrapped with cloth to prevent fuel from splashing.
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(A)    Shaft
(B)     Bolt
(4) Raise release fork and unfasten release bearing tabs to free release fork.
CAUTION:
Step (4) is required to prevent interference with engine when removing engine from transmis≠sion.
18) Select torque converter clutch from drive plate. (AT vehicles)
(1)   Lower the vehicle.
(2)   Remove service hole plug.
(3)   Remove bolts which hold torque converter clutch to drive plate.
(4)   Remove other bolts while rotating tha engine using ST.
ST 499977300 CRANK PULLEY WRENCH
21) Remove fuel filter and bracket.
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ENGINE ASSEMBLY
Mechanical
22) Support engine with a lifting device and wire ropes.
24) Separation of engine and transmission.
(1)   Remove starter. <Ref. to SC-5, REMOVAL, Starter. >
(2)   Install ST to torque converter clutch case. (AT vehicles)
ST 498277200 STOPPER SET
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23) Support transmission with a garage jack.
CAUTION:
Before moving engine away from transmission, check to be sure no work has been overlooked. Doing this is very important in order to facili≠tate re-installation and because transmission lowers under its own weight.
(3) Remove bolt which holds right upper side of transmission to engine.
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25)   Remove engine from vehicle.
(1)  Slightly raise engine.
(2)   Raise transmission with garage jack.
(3)   Move engine horizontally until mainshaft is withdrawn from clutch cover.
(4)  Slowly move engine away from engine compartment.
CAUTION:
Be careful not to damage adjacent parts or body panels with crank pulley, oil pressure gauge, etc.
26)   Remove front cushion rubbers.
B: INSTALLATION
S183079A11
1) Install clutch release fork and bearing onto transmission. (MT vehicles)
ME(DOHC TURBO)-37
ENGINE ASSEMBLY
Mechanical
(1) Remove release bearing from clutch cover with flat type screw driver.
ē
(4) Apply grease to specified points. Spline FX2200 Shaft SUNLIGHT 2
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ē
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(2)   Install release bearing on transmission.
(3)  Install release fork into release bearing tab.
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(A)    Spline (FX2200)
(B)    Shaft (SUNLIGHT 2)
(5) Insert release fork shaft into release fork.
CAUTION:
Make sure the cutout portion of release fork
shaft contacts spring pin.
(A)     Release fork
(B)     Release bearing
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(A)     Release fork
(B)     Release shaft
(C)    Spring pin
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ENGINE ASSEMBLY
Mechanical
(6) Tighten plug.
Tightening torque:
44 Nm (4.5 kgf-m, 32.5 ft-lb)
6) Remove garage jack.
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7) Install pitching stopper.
Tightening torque:
T1: 49 Nm (5.0 kgf-m, 36.2 ft-lb) T2: 57Nm (5.8 kgf-m, 42 ft-lb)
2)   Install front cushion rubbers to engine.
Tightening torque:
34 Nm (3.5 kgf-m, 25.3 ft-lb)
3)   Install engine onto transmission.
(1)   Position engine in engine compartment and align it with transmission.
CAUTION:
Be careful not to damage adjacent parts or body panels with crank pulley, oil pressure gauge, etc.
(2)  Apply a small amount of grease to splines of mainshaft. (MT vehicles)
4)  Tighten bolt which hold right upper side of transmission to engine.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
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8)   Remove ST from torque converter clutch case. (AT vehicles)
NOTE:
Be careful not to drop the ST into the torque con≠verter clutch case when removing ST.
ST 498277200 STOPPER SET
9)   Install starter. <Ref. to SC-6, INSTALLATION, Starter. >
10)   Install torque converter clutch onto drive plate. (AT vehicles)
(1) Tighten bolts which hold torque converter clutch to drive plate.
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5) Remove lifting device and wire ropes.
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ENGINE ASSEMBLY
Mechanical
(2) Tighten other bolts while rotating the engine by using ST.
CAUTION:
Be careful not to drop bolts into torque con≠verter clutch housing.
ST 499977300 CRANK PULLEY WRENCH
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
(1) Install the power steering tank on bracket.
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(2) Install power steering pump on bracket, and tighten bolts.
Tightening torque:
20.1 Nm (2.05 kgf-m, 14.8 ft-lb)
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(3) Clog plug onto service hole. 11) Push clutch release lever to fit bearing into clutch cover.
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(3) Install power steering pipe bracket on right side intake manifold, and install spark plug codes.
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12) Install fuel filter and bracket.
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(4) Connect power steering switch connector.
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13) Install power steering pump on bracket.
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ENGINE ASSEMBLY
Mechanical
(5) Install front side V-belt, and adjust it. <Ref.
to ME(SOHC)-42, FRONT SIDE BELT,
INSTALLATION, V-belt.>
14) Tighten nuts which hold lower side of trans≠mission to engine.
Tightening torque:
50 Nm (5.1 kgf-m, 36.9 ft-lb)
CAUTION:
After connecting each cable, adjust them.
20) Install air intake system.
(1)   Install intercooler. <Ref. to IN(DOHC TURBO)-10, INSTALLATION, Intercooler.>
(2)   Install air cleaner element and air cleaner upper cover.
(3)   Install engine harness connector bracket.
(4)   Install filler hose to air cleaner case.
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15) Tighten nuts which install front cushion rubber onto crossmember.
Tightening torque:
83 Nm (8.5 kgf-m, 61 ft-lb)
CAUTION:
Make sure the front cushion rubber mounting
bolts (A) and locator (B) are securely installed.
(A)     Filler hose
(B)    Connector bracket
21) Install A/C pressure hoses. (With A/C)
CAUTION:
Use new O-rings.
Tightening torque:
25 Nm (2.5 kgf-m, 18.1 ft-lb)
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16)   Install center exhaust pipe.
<Ref. to EX(DOHC TURBO)-7, INSTALLATION, Front Exhaust Pipe.>
17)  Connect the following hoses.
(1)   Fuel delivery hose, return hose and evapo≠ration hose
(2)   Heater inlet and outlet hoses
(3)   Brake booster vacuum hose
18)  Connect the following connectors and termi≠nals.
(1)   Engine ground terminal
(2)   Engine harness connectors
(3)  Generator connector and terminal
(4)  A/C compressor connectors (With A/C)
19)  Connect the following cables.
(1)  Accelerator cable
(2)  Clutch release spring
22)   Install radiator. <Ref. to CO-27, INSTALLATION, Radiator.>
23)   Install coolant filler tank. <Ref. to CO-27, INSTALLATION, Radiator.>
24)   Install window washer tank.
25)   Install battery in the vehicle, and connect cables.
26)   Fill coolant.
<Ref. to CO-27, INSTALLATION, Radiator.>
27)  Charge A/C system with refrigerant.
<Ref. to AC-20, OPERATION, Refrigerant Charg≠ing Procedure.>
28)   Remove front hood stay, and close front hood.
29)  Take off the vehicle from lift arms.
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