Engine Assembly

Removal & Installation

2.5L SOHC & 2.5L DOHC Turbo

To Remove:

1. Set the vehicle on lift arms
2. Open front hood fully and support with stay fixture
3. Collect and re-cycle the following
   • Engine coolant
   • Engine oil
   • Refrigerant
4. Release fuel pressure

   Fuel Hose Pressure Relief

   CAUTION
   Using approved container to catch fuel, disconnect hose with its end wrapped with cloth to prevent splashing.

5. Remove or disconnect the following
   • Battery ground cable
   • Fuel filler cap
   • Fuel delivery hose, return hose and evaporation hose
   • Pressure hoses (with A/C)

     Air Cleaner Assembly

   • Air intake duct
   • Air cleaner case
   • Resonator chamber

     Air Cleaner Stay

   • Air cleaner case stay
   • Coolant filler tank
   • Window washer solvent tank
   • Turbo intercooler (w/turbo)
   • Compartment under cover
   • Radiator
   • Automatic Transmission Fluid cooler pipe from body

     Engine Ground

   • Engine ground terminal

     Engine Harness Connectors

   • Engine harness connectors

     A/C and Alternator Connectors

   • Alternator connector terminal
   • A/C compressor connector (w/AC)

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

   • Accelerator cable
   • Cruise control cable

     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

     Place pump on aprin

     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
6. With manual transmission, perform the following

1. Remove the clutch release spring

   Release Fork and Bearing

2. Separate the clutch release fork from release bearing
3. Remove the clutch operating cylinder from transmission

   Plug Removal

4. Remove the plug using a 10 mm hexagon wrench

   Release Fork Shaft

5. Screw the 6 mm diameter bolt into the release fork shaft and remove
6. Raise the release fork and unfasten the release bearing tabs to free release fork.

   NOTE: Step (F) is required to prevent interference with engine when removing the engine from transmission.

   Upper Bell Housing Bolts

   Lower Bell Housing Bolts

7. Remove or disconnect the following
   • Upper and lower bell housing bolts, which hold engine to bell housing

     WARNING
     Be sure not to pinch bodily appendages as engine may shift once mounts are disconnected!

     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 necessary to install a flex plate holding device to insure engine does not turn over while removing bolts.

   • Service hole plug

     Upper Dog Bone

   • Upper dog bone
   • Starter motor

Lifting Device

8. Support engine with a lifting device and wire ropes

   Floor Jack

9. Support transmission with a floor jack

   CAUTION
   Before separating the engine from the transmission, and out of engine compartment, be sure no wires, hoses, cables or connections are still connected to engine.

10. To separate engine from transmission, complete the following
    • Slightly raise engine
    • Raise transmission with floor jack
    • Move engine horizontally until main shaft is withdrawn from clutch cover (Manual Trans.)

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

11. Remove engine from vehicle
12. Remove front cushion rubbers

To Install:

1. Install front cushion rubbers. Torque specification: 35 Nm (26.0 ft. lbs.)

   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. (Manual Trans.)
3. Lower engine into engine bay and align it with transmission.
4. Install and tighten upper and lower transmission bell housing bolts Torque specification: 50 Nm (36.9 ft. lbs.)

   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
8. Upper dog bone Torque specification: T1: 50 Nm (36.9 ft. lbs.) T2: 58 Nm (43 ft. lbs.)
9. Torque converter clutch to drive plate. (AT model)

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

10. Torque converter to flex plate mating bolts Torque specification: 25 Nm (18.1 ft. lbs.)
11. Clog plug onto service hole
12. Upper and lower bell housing bolts Torque specification: 50 Nm (36.9 ft. lbs.)
13. Starter motor
14. Front cushion rubber to crossmember nuts Torque specification: 85 Nm (63 ft. lbs.)

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

15. Front and center exhaust pipe

    Remove Release Bearing from Clutch Cover

16. Remove the release bearing from clutch cover with flat type screw driver (w/manual Trans.)
17. Install the following items (w/manual Trans.)

    Release Fork and Bearing

18. Clutch release fork and bearing onto transmission

    Grease Points

19. Release fork shaft into release fork
20. Apply grease to the splines and pivot points

    CAUTION
    Make sure the cutout portion of release fork shaft contacts spring pin.

    Plug Installation

21. Install plug Torque to: 44 Nm (32.5 ft-lb)

    Clutch Release Spring

22. Install or connect the following:
    • Install the clutch release spring
    • Fuel delivery hose, return hose and evaporation hose
    • Heater inlet and outlet hoses
    • Brake booster vacuum hose
    • Engine ground terminals Torque specification: 14 Nm (10.1 ft. lbs.)
    • Power steering pump onto bracket
    • Power steering tank onto bracket
    • Power steering pump to bracket bolts Torque specification: 20.1 Nm (14.8 ft. lbs.)
    • Power steering switch connector
    • Front side V-belt (be sure to adjust)
    • Resonator chamber Torque specification: 32 Nm (24 ft. lbs.)
    • Engine harness connectors
    • Alternator connector and terminal
    • A/C compressor connectors
    • Power steering pressure switch
    • Accelerator cable (be sure to adjust)
    • Cruise control cables (be sure to adjust (with cruise control)
    • Air cleaner case support Torque specification: 16 Nm (11.6 ft. lbs.)
    • A/C pressure hoses Torque specification: 25 Nm (18.1 ft-lb)
    • Radiator to vehicle
    • ATF cooler pipe to body
    • Air intake duct and cleaner case
    • Coolant filler tank
    • Window washer solvent tank
    • Turbo intercooler (w/turbo)
    • Compartment under cover
    • Fuel filler cap
    • Battery and cables
23. Check and fill fluids
    • Engine oil
    • Automatic Trans. Fluid (AT model)
    • Engine coolant
24. Charge A/C system with refrigerant
25. Inspect work
26. Be sure pipes and hoses are installed correctly
27. Check for loose wires, etc.
28. After starting vehicle, check for leaks and correct if present
29. Remove front hood stay, and close front hood
30. Take off the vehicle from lift arms