Engine Assembly

Removal & Installation

2.0L DOHC Engine and 2.5L DOHC Engine

To Remove:

1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
2. Open and support the front hood.
3. Raise the rear seat, and turn the floor mat up.
4. Release the fuel pressure.
5. Disconnect the fuel pump relay connector.
6. Start the engine, and run until stalls. After the engine stalls, crank it for five seconds more and turn the ignition switch to "OFF".
7. Remove or disconnect the following
   • Filler cap
   • Ground terminal from battery
   • Radiator from vehicle
   • Coolant filler tank
8. Collect refrigerant, and remove the pressure hoses.
9. Remove or disconnect the following:
   • A/C pressure hoses from A/C compressor
   • Intercooler
   • Engine harness connector
   • Engine ground terminal

   • Engine harness connector

   • Alternator connector, terminal and A/C compressor connectors
   • Accelerator cable (2.0L Engine)
   • Clutch release spring
   • Brake booster vacuum hose
   • Heater inlet outlet hose
   • Power steering pump from bracket
   • Front side V-belt

   • Power steering switch connector

   • Pipe with bracket from intake manifold
   • Power steering pump from engine
   • Power steering tank from the bracket and place aside
10. Safely raise and support the vehicle.
11. Remove or disconnect the following:
    • ATF cooler pipe from frame (A/T vehicles)
    • Center exhaust pipe

    • Nuts connecting lower side of transmission to engine
    • Nuts connecting the front cushion rubber onto front crossmember
12. Lower the vehicle.
13. Remove or disconnect the following:
    • Clutch operating cylinder from transmission (M/T Vehicles)
    • Plug using a 10 mm hexagon wrench (M/T Vehicles)

    • Release fork shaft, by screwing the 6 mm diameter bolt into the release fork shaft (M/T Vehicles)
    • Clutch release fork from release bearing (M/T Vehicles)
    • Torque converter clutch from drive plate after removing the service hole plug and bolts (A/T vehicles)

      Note: You can remove the other bolts while rotating the engine using ST. (ST 499977400 Crank Pulley Wrench), or equivalent.

    • Pitching stopper
    • Fuel delivery hose, return hose and evaporation hose

      CAUTION
      Wrap hose end with cloth to prevent fuel from leaking. Catch fuel from hose into container.

    • Fuel filter and bracket (2.0L Engine)
14. Support the engine with a lifting device and wire and the transmission with a garage jack.

    CAUTION
    Before moving the engine away from transmission, check to be sure no work has been overlooked.

15. Remove the starter.

16. Install the ST to torque converter clutch case. (AT vehicles) (ST 498277200 Stopper Set, or equivalent.
17. Remove or disconnect the following:
    • Bolts connecting right upper side of transmission to engine
    • Engine from vehicle
    • Front cushion rubbers

To Install:

1. Remove the release bearing from clutch cover. (M/T Vehicles)
2. Install or connect the following:
   • Release bearing on transmission (M/T Vehicles)
   • Release fork into release bearing tab (M/T Vehicles)

3. Apply grease to the points above as shown (M/T Vehicles).
   • Spline FX2200
   • Shaft SUNLIGHT 2
4. Insert the release fork shaft into release fork, ensuring that the cutout portion of release fork shaft contacts spring pin and tighten the plug (M/T Vehicles)
   • Torque to: 32.5 ft. lbs. (44 Nm)
5. Install or connect the following:
   • Cushion rubbers to engine
     1. Torque to: 25 ft. lbs. (34 Nm)
   • Engine to transmission

     Note: Apply a small amount of grease to splines of mainshaft. (M/T vehicles)

   • Bolts connecting right upper side of transmission to engine
     1. Torque to: 37 ft. lbs. (50 Nm)
6. Remove the lifting device and transmission jack.
7. Install the pitching stopper.
   • T1 - Torque to: 37 ft. lbs. (50 Nm)
   • T2 - Torque to: 43 ft. lbs. (58 Nm)
8. Remove the ST from torque converter clutch case. (A/T vehicles)
9. Install or connect the following:
   • Starter
   • Torque converter clutch onto drive plate and tighten the bolts connecting the torque converter to drive plate. (A/T vehicles)
     1. Torque to: 18 ft. lbs. (25 Nm)

     Note: You can tighten other bolts while rotating the engine by using ST.

   • Service hole plug
   • Fuel filter and bracket
   • Power steering tank on bracket
   • Power steering pump
     1. Torque to: 15 ft. lbs. (20 Nm)
   • Power steering pipe bracket on right side intake manifold, and install the spark plug codes
   • Power steering switch connector
   • Front side V-belt (adjust)
10. Safely raise and support the vehicle.
11. Install or connect the following:
    • Nuts connecting lower side of transmission to engine
      1. Torque to: 37 ft. lbs. (50 Nm)
    • Nuts connecting the front cushion rubber onto crossmember
      1. Torque to: 61 ft. lbs. (83 Nm)
    • ATF cooler pipe to frame (A/T vehicles)
    • Center exhaust pipe
12. Lower the vehicle.
13. Install or connect the following:
    • Fuel delivery hose, return hose and evaporation hose
    • Heater inlet and outlet hoses
    • Brake booster vacuum hose
    • Engine ground terminal
    • Engine harness connectors
    • Alternator connector
    • Alternator terminal
      1. Torque to: 4.34 ft. lbs. (5.88 Nm)
    • A/C compressor connectors
    • Accelerator cable
    • Clutch release spring
    • Intercooler
    • Air cleaner element and air cleaner upper cover
    • Engine harness connector bracket
    • Filler hose to air cleaner case
    • A/C pressure hoses using new O-rings
      1. Torque to: 18 ft. lbs. (25 Nm)
    • Radiator
    • Coolant filler tank
    • Window washer tank
    • Battery in the vehicle, and connect cables
14. Fill coolant.
15. Charge the A/C system with refrigerant.
16. Close the front hood.

2.5L SOHC Engine

To Remove:

1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
2. Open and support front hood.
3. Collect and re-cycle the following:
   • Engine coolant
   • Engine oil
   • Refrigerant
4. Release fuel pressure.

   Fuel Hose Pressure Relief

5. Remove or disconnect the following:
   • Battery ground cable
   • Fuel filler cap
   • Pressure hoses (with A/C)

     Air Cleaner Assembly

   • Air intake duct
   • Air cleaner case
   • Resonator chamber

     Air Cleaner Stay

   • Air cleaner case stay
   • Front and rear oxygen sensor connectors

     Engine Ground

   • Engine ground

     Engine Harness Connectors

   • Engine harness connectors

     A/C and Alternator Connectors

   • Alternator connector terminal
   • A/C compressor connector (with A/C)

     Accelerator and Cruise Control Cables (if equipped w/cruise)

   • Accelerator cable
   • Cruise control cable
   • Pressure switch

     Brake Booster Vacuum Hose

   • Brake booster vacuum hose

     Heater Hoses

   • Heater inlet/outlet hose’s

     Power Steering Pump Bracket Bolts

   • Power steering pump from bracket
   • Front side V-belt, by loosening lock bolt and slider bolt

     Pipe with Bracket

   • Pipe with bracket
   • Power steering tank from the bracket by pulling it upward

     Note: Using a fender cover on the right fender area, place the power steering pump on the right side wheel apron.

   • Front and center exhaust pipe
   • Nuts connecting lower side of transmission to engine

     Rubber Cushion Mounting Bolts

   • Front cushion rubber to crossmember
   • Torque converter clutch to drive plate bolts. (AT model)

     Note: Additional bolts can be removed by manually rotating the crank shaft pulley. It may be nec. To install a flex plate holding device to insure engine does not turn over while removing bolts.

   • Service hole plug
   • Fuel delivery hose, return hose, and evaporation hose

   CAUTION
   Disconnect the hose with its end wrapped in cloth to prevent fuel from splashing. Catch fuel in an approved container.

   Lifting Device

6. Support engine with a lifting device and wire ropes.

   Floor Jack

7. Support transmission with a floor jack.

   CAUTION
   Before lifting engine away from transmission, check to be sure additional wires, hoses, cables or connections are not still connected to engine. Doing this is very important for reinstallation and because transmission lowers under its own weight.

8. Remove or disconnect the following:
   • Starter
   • Bolts connecting upper side of transmission to engine
9. Install ST to torque converter clutch case (A/T).
10. Slightly raise engine.
11. Raise transmission with floor jack.
12. Move engine horizontally until main shaft is withdrawn from clutch cover (M/T).

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

13. Remove engine from vehicle
14. Remove front cushion rubbers

To Install:

1. Install front cushion rubbers.
   • Torque to: 26 ft. lbs. (35 Nm)

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

2. Apply a small amount of grease to spline of main shaft. (M/T Vehicles).
3. Lower engine into engine bay and align it with transmission.
4. Install and tighten upper and lower transmission bell housing bolts.
   • Torque to: 37 ft. lbs. (50 Nm)

   WARNING
   Be sure not to pinch bodily appendages as engine may shift until mounts are re-connected!

5. Remove lifting device and wire ropes.
6. Remove floor jack.
7. Install or connect the following:
   • Upper Engine torque strut
     1. T1 - Torque to: 37 ft. lbs. (50 Nm)
     2. T2 - Torque to: 43 ft. lbs. (58 Nm)
   • Starter
   • Torque converter clutch onto drive plate. (A/T Vehicles)

     Note: Additional bolts can be installed by manually rotating the crank shaft pulley. Remember to remove the flex plate holding device.

   • Torque converter to flex plate mating bolts
     1. Torque to: 18 ft. lbs. (25 Nm)
   • Clog plug onto service hole
   • Power steering tank on bracket
   • Power steering pump on bracket
     1. Torque to: 15 ft. lbs. (20 Nm)
   • Power steering pump bracket bolts
   • Spark plug wires
   • Power steering switch connector
   • Front side V-belt (adjust it)
   • Resonator chamber
     1. Torque to: 24.6 ft. lbs. (33 Nm)
   • Upper and lower bell housing bolts
     1. Torque to: 37 ft. lbs. (50 Nm)
   • Front cushion rubber to crossmember nuts
     1. Torque to: 63 ft. lbs. (85 Nm)

        CAUTION
        Be sure the front cushion rubber mounting bolts (A) and locator (B) are securely installed.

     2. Front and center exhaust pipe
     3. Fuel delivery hose, return hose and evaporation hose
     4. Heater inlet and outlet hoses
     5. Brake booster vacuum hose
     6. Engine ground terminals
        1. Torque to: 124 inch lbs. (14 Nm)
     7. Engine harness connectors
     8. Alternator connector and terminal
     9. A/C compressor connectors
     10. Power steering pressure switch
     11. Accelerator cable (be sure to adjust)
     12. Cruise control cables (be sure to adjust (with cruise control))
     13. Air cleaner case stay
         1. Torque to: 12 ft. lbs. (16 Nm)
     14. A/C pressure hoses
         1. Torque to: 18 ft. lbs. (25 Nm)
     15. Radiator to vehicle
     16. ATF cooler pipe to body
     17. Air intake duct and cleaner case
     18. Compartment under cover
     19. Fuel filler cap
     20. Battery and cables
8. Check and fill fluids.
9. Charge A/C system with refrigerant.
10. After starting vehicle, check for leaks and correct if present.
11. Remove front hood stay, and close front hood.