Subaru Forester 1998-05

Engine

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NOTE
Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer systems and may require the computer to undergo a relearning process, once the negative battery cable is reconnected.

Removal & Installation



2.5L Engine
Non-Turbo Engines

CAUTION
The fuel injection system remains under pressure after the engine has been turned OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Relieve the fuel system pressure.
  2.  
  3. Drain the engine oil and coolant.
  4.  
  5. Discharge and recover the air conditioning system.
  6.  
  7. Remove or disconnect the following:

    Negative battery cables and battery
     
    Engine undercover
     
    Radiator hoses and fan motor harness
     
    Radiator
     
    Air conditioning compressor and cap the lines
     
    Air intake duct
     
    Air cleaner element and upper cover
     
    Evaporative Emissions (EVAP) canister and bracket
     
    Front Oxygen (O 2 S) sensor
     

  8.  
  9. If equipped with California emissions specifications, disconnect the rear O 2 S sensor.
  10.  
  11. Remove or disconnect the following:

    Engine ground terminal
     
    Crankshaft Position (CKP) sensor connector
     
    Camshaft Position (CMP) sensor connector
     
    Knock Sensor (KS) connector
     
    Alternator connector and terminal
     
    Air conditioning compressor connectors, if equipped
     
    Accelerator cable
     
    Cruise control cable, if equipped
     
    Brake booster hose
     
    Heater inlet and outlet hoses
     
    Alternator drive belt
     
    Wires from the spark plugs on the left side of the engine
     
    Power steering pump line bracket
     
    Power steering pump, leaving the lines connected and position it aside
     
    Exhaust Y-pipe
     
    Lower starter nuts
     
    Lower engine-to-transmission nuts
     
    Front engine mount-to-crossmember nuts
     
    Starter
     

  12.  
  13. If equipped with an automatic transmission, perform the following:
    1. Remove the torque converter service hole plug.
    2.  
    3. Matchmark the torque converter-to-driveplate.
    4.  
    5. Rotate the engine to remove the torque converter-to-driveplate bolts as they become accessible.
    6.  

  14.  
  15. Remove or disconnect the following:

    Flywheel cover, if equipped with a manual transmission
     
    Pitching stopper
     
    Fuel delivery, return and evaporation hoses
     

  16.  
  17. Support the engine with a suitable lifting device attached to the engine lifting eyes.
  18.  
  19. Slightly raise the engine.
  20.  
  21. Raise the transmission with a floor jack.
  22.  
  23. If equipped with a manual transmission, pull the engine forward then up and out of the vehicle to clear the transmission mainshaft.
  24.  
  25. If equipped with an automatic transmission, pull the engine forward then up and out of the vehicle.
  26.  

To install:

  1. If equipped with a manual transmission, apply a small amount of grease to the splines of the mainshaft.
  2.  
  3. Position the engine in the engine compartment and align it with the transmission.
  4.  
  5. Install the engine. Torque the upper bolts to 34-40 ft. lbs. (44-54 Nm).
  6.  
  7. Remove the lifting device and floor jack.
  8.  
  9. Install or connect the following:

    Pitching stopper. Torque the bolts to 49 ft. lbs. (67 Nm) on the body side and 40 ft. lbs. (54 Nm) on the bracket side.
     
    Flywheel cover, if equipped with a manual transmission
     

  10.  
  11. If equipped with an automatic transmission, perform the following:
    1. Align the matchmarks, install the torque converter-to-driveplate bolts while rotating the engine and tighten to 20 ft. lbs. (26 Nm).
    2.  
    3. Install the service hole cover.
    4.  

  12.  
  13. Install or connect the following:

    EVAP canister and bracket
     
    Power steering pump. Tighten the retainer bolts to 22-36 ft. lbs. (29-47 Nm).
     
    Accessory drive belt
     
    Starter. Torque the bolts to 34-40 ft. lbs. (44-52 Nm).
     
    Lower engine-to-transmission nuts. Tighten them to 34-40 ft. lbs. (44-52 Nm).

    Click image to see an enlarged view

    Fig. Be sure to tighten the front cushion rubber mounting bolts in the innermost elliptical hole in the front crossmember

     



    Lower engine mounting nuts. Tighten them to 61 ft. lbs. (83 Nm) in the inner most elliptical hole in the front crossmember so the clearance is 0.16-0.24 in. (4-6mm).
     
    Exhaust Y-pipe with new gaskets and nuts
     
    Brake booster hose
     
    Heater inlet and outlet hoses
     
    Accelerator cable
     
    Cruise control cable, if equipped
     
    Engine harness connectors
     
    Engine ground terminal
     
    CKP sensor connector
     
    CMP sensor connector
     
    Knock sensor connector
     
    Alternator connector and terminal
     
    Air conditioning compressor connectors, if equipped
     
    Front O 2 S sensor, and if removed, the rear O 2 S sensor.
     
    Air cleaner element and cover
     
    Air conditioning lines with new O-rings, if equipped. Torque the bolts to 23 ft. lbs. (31 Nm).
     
    Radiator
     
    Engine undercover
     
    Negative battery cable
     

  14.  
  15. Fill the crankcase to the proper level with clean engine oil.
  16.  
  17. Fill and bleed the cooling system.
  18.  
  19. Charge the air conditioning system using an approved recovery/recycling machine.
  20.  
  21. If equipped, check the automatic transmission fluid level and add Dexron®II if necessary.
  22.  
  23. Start the engine and allow it to reach normal operating temperature. Check for leaks.
  24.  

  1. Open the hood to the full open position and support it with the hood stay.
  2.  
  3. Properly relieve the fuel system pressure. Remove the fuel cap.
  4.  
  5. Properly disarm the SRS system.
  6.  
  7. Discharge the air conditioning system.
  8.  
  9. Disconnect the negative battery cable.
  10.  
  11. Drain the engine oil. Drain the cooling system.
  12.  
  13. Remove the air intake duct, air cleaner case and air intake chamber.
  14.  
  15. Remove the under cover. Remove the radiator.
  16.  
  17. Disconnect the air conditioning pressure hoses from the compressor.
  18.  
  19. Disconnect the front and rear oxygen sensor electrical connectors, the engine ground cable, the engine harness connector, the alternator connector and terminal, the air conditioning compressor electrical connector and the power steering switch connector.
  20.  
  21. Disconnect the brake booster hose and the heater hoses.
  22.  
  23. Remove the front side V-belt. Remove the power steering pipe and bracket. Remove the reservoir tank. Remove the power steering pump and position it aside.
  24.  
  25. Remove the front and center exhaust pipes.
  26.  
  27. Remove the lower transmission to engine retaining nuts.
  28.  
  29. Remove the front cushion rubber onto front crossmember retaining nuts.
  30.  
  31. If equipped with automatic transmission, remove the service plug hole cap. Remove the torque converter to drive plate retaining bolts.
  32.  
  33. Remove the pitching stopper. Disconnect the fuel hoses from the fuel pipes.
  34.  
  35. Remove the clip and disconnect the evaporator hose from the pipe.
  36.  
  37. Position the engine lifting fixture in place. Support the transmission using a suitable jack.
    NOTE
    Before separating the engine from the transmission, check to be sure nothing has been overlooked that will stop the engine from being removed. This is very important in order to facilitate reinstallation and because the transmission lowers under its own weight.

  38.  
  39. Separate the engine from the transmission.
  40.  
  41. Remove the starter.
  42.  
  43. If equipped with automatic transmission, install tool ST498277200, with will hold the torque converter in place.
  44.  
  45. Remove the upper right side bolts that retain the transmission to the engine.
  46.  
  47. Slightly raise the engine. Raise the transmission, using the suitable jack. Move the engine horizontally until the mainshaft is withdrawn from the clutch cover. Carefully remove the engine from the vehicle.
  48.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Torque the upper transmission to engine retaining bolts to 36.9 ft. lbs.
  4.  
  5. Torque the lower transmission to engine retaining bolts to 36.9 ft. lbs.
  6.  
  7. If equipped, tighten the torque converter to drive plate bolts to 18.1 ft. lbs.
  8.  
  9. Fill the engine with the proper grade and type engine oil.
  10.  
  11. Fill and bleed the cooling system.
  12.  
  13. Charge the air conditioning system.
  14.  
  15. If equipped. Adjust the clutch cable as required.
  16.  
  17. If equipped, check the automatic transmission fluid level, correct as required using the proper grade and type transmission fluid.
  18.  
  19. Start the engine and allow it to reach normal operating temperature. Check for leaks and correct as required.
  20.  

Turbo Engines

CAUTION
The fuel injection system remains under pressure after the engine has been turned OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Relieve the fuel system pressure.
  2.  
  3. Drain the engine oil and coolant.
  4.  
  5. Discharge and recover the air conditioning system.
  6.  
  7. Disconnect the negative battery cable.
  8.  
  9. Remove the radiator.
  10.  
  11. Remove the coolant filler tank.
  12.  
  13. Disconnect the air conditioning hoses from the compressor and cap the lines.
  14.  
  15. Remove the intercooler as follows:
    1. Disconnect the Positive Crankcase Ventilation (PCV) hose from the pipe.
    2.  
    3. Remove the PCV pipe from the intercooler.
    4.  
    5. Disconnect the air by-pass valve hose.
    6.  
    7. Remove the intercooler-to-bracket bolts.
    8.  
    9. Loosen the clamps that connect the intercooler to the turbocharger and throttle body.
    10.  
    11. Disconnect the intercooler duct from the turbocharger and remove the intercooler.
    12.  

  16.  
  17. Disconnect the following:

    Engine harness connector
     
    Engine ground terminal
     
    Left and right engine ground cables
     
    Alternator connector and terminal
     
    Air conditioning compressor connectors, if equipped
     
    Accelerator cable, on vehicles equipped with a manual transmission
     
    Clutch release spring, if equipped with a manual transmission
     
    Brake booster hose
     
    Heater inlet and outlet hoses
     

  18.  
  19. Loosen the power steering pump lock bolt and slider bolt. Remove the power steering belt.
  20.  
  21. Disconnect the power steering switch connector.
  22.  
  23. Remove the pipe with the bracket from the intake manifold and remove the power steering pump.
  24.  
  25. Remove the power steering tank from its bracket by pulling it up.
  26.  
  27. Place the power steering pump on the right wheel apron.
  28.  
  29. Remove the transmission cooler lines from the frame, if equipped with an automatic transmission.
  30.  
  31. Remove the center exhaust pipe.
  32.  
  33. Remove the lower transmission-to-engine nuts.
  34.  
  35. Remove the nuts which attach the front mount rubber to the crossmember.
  36.  
  37. On vehicles equipped with a manual transmission, perform the following:
    1. Remove the clutch operating cylinder from the transmission.
    2.  
    3. Remove the plug using a 10mm wrench

      Click image to see an enlarged view

      Fig. Remove the plug using a 10mm wrench-2004 DOHC engine



      Click image to see an enlarged view

      Fig. Screw the 6mm bolt into the release fork and remove it-2004 DOHC engine

    4.  
    5. Screw the 6mm bolt into the release fork and remove it.
    6.  
    7. Raise the release fork and unfasten the release bearing tabs to free the fork.
    8.  

  38.  
  39. If equipped with an automatic transmission, perform the following:
    1. Remove the torque converter service hole plug.
    2.  
    3. Matchmark the torque converter-to-driveplate.
    4.  
    5. Rotate the engine to remove the torque converter-to-driveplate bolts as they become accessible.
    6.  

  40.  
  41. Remove the pitching stopper.
  42.  
  43. Disconnect the fuel delivery, return and evaporation hoses
  44.  
  45. Remove the fuel filter and bracket.
  46.  
  47. Support the engine with a suitable lifting device attached to the engine lifting eyes.
  48.  
  49. Support the transmission with a floor jack.
  50.  
  51. Remove the starter.
  52.  
  53. Install tool ST 498277200 to the converter housing to prevent the converter from falling.
  54.  
  55. Remove the upper engine-to-transmission bolts.
  56.  
  57. If equipped with a manual transmission, pull the engine forward then up and out of the vehicle to clear the transmission mainshaft.
  58.  
  59. If equipped with an automatic transmission, pull the engine forward then up and out of the vehicle.
  60.  

To install:

  1. If equipped with a manual transmission, perform the following:
    1. Remove the release bearing from the clutch cover using a flat bladed tool.
    2.  
    3. Install the release bearing onto the transmission.
    4.  
    5. Install the release fork into the release bearing tab.
    6.  
    7. Apply a small amount of grease to the splines of the mainshaft.
    8.  
    9. Insert the release fork shaft into the release fork. Make sure the cutout portion of the release fork shaft contacts the spring pin.

      Click image to see an enlarged view

      Fig. Release fork and related components- 2004 DOHC engine

    10.  
    11. Install the plug and tighten to 32 ft. lbs. (44 Nm).
    12.  

  2.  
  3. Install the front mount rubber to the engine and tighten to 26 ft. lbs. (35 Nm).
  4.  
  5. Position the engine in the engine compartment and align it with the transmission.
  6.  
  7. Install the engine. Torque the upper bolts to 37 ft. lbs. (50 Nm).
  8.  
  9. Remove the lifting device and floor jack.
  10.  
  11. Install the pitching stopper. Torque the bolts to 43 ft. lbs. (58 Nm) on the body side and 37 ft. lbs. (50 Nm) on the bracket side.
  12.  
  13. Installation is the reverse of removal, please keep in mind the following torque specifications:
    1. Torque converter-to-driveplate bolts while rotating the engine and tighten to 18 ft. lbs. (25 Nm).
    2.  
    3. Power steering pump. Tighten the retainer bolts to 14 ft. lbs. (20 Nm).
    4.  
    5. Lower engine-to-transmission nuts. Tighten them to 37 ft. lbs. (50 Nm).
    6.  
    7. Engine-to-crossmember nuts to 63 ft. lbs. (85 Nm).
    8.  

  14.  
  15. Fill the crankcase to the proper level with clean engine oil.
  16.  
  17. Fill and bleed the cooling system.
  18.  
  19. Charge the air conditioning system using an approved recovery/recycling machine.
  20.  
  21. If equipped, check the automatic transmission fluid level and add Dexron®II if necessary.
  22.  
  23. Start the engine and allow it to reach normal operating temperature. Check for leaks.
  24.  

  1. Open the hood to the full open position and support it with the hood stay.
  2.  
  3. Remove the collector cover.
  4.  
  5. Properly relieve the fuel system pressure. Remove the fuel cap.
  6.  
  7. Properly disarm the SRS system.
  8.  
  9. Discharge the air conditioning system.
  10.  
  11. Disconnect the negative battery cable.
  12.  
  13. Drain the engine oil. Drain the cooling system.
  14.  
  15. Remove the radiator. Remove the coolant filler tank.
  16.  
  17. Remove the secondary air pump.
  18.  
  19. Disconnect the air conditioning pressure hoses from the compressor.
  20.  
  21. Remove the intercooler.
  22.  
  23. Disconnect the right and left engine ground cables, the engine harness connector, the alternator connector and terminal, the air conditioning compressor electrical connector and the power steering switch connector.
  24.  
  25. Disconnect the brake booster hose and the heater hoses.
  26.  
  27. Remove the front side V-belt. Remove the power steering pipe and bracket. Remove the reservoir tank. Remove the power steering pump and position it aside.
  28.  
  29. Raise and support the vehicle safely. Remove the transmission cooler line from the frame, if equipped.
  30.  
  31. Remove the center exhaust pipe.
  32.  
  33. Remove the lower transmission to engine retaining nuts.
  34.  
  35. Remove the front cushion rubber onto front crossmember retaining nuts.
  36.  
  37. If equipped with automatic transmission, remove the service plug hole cap. Remove the torque converter to drive plate retaining bolts.
  38.  
  39. Remove the pitching stopper. Disconnect the fuel hoses from the fuel pipes.
  40.  
  41. Position the engine lifting fixture in place. Support the transmission using a suitable jack.
    NOTE
    Before separating the engine from the transmission, check to be sure nothing has been overlooked that will stop the engine from being removed. This is very important in order to facilitate reinstallation and because the transmission lowers under its own weight.

  42.  
  43. Separate the engine from the transmission.
  44.  
  45. Remove the starter.
  46.  
  47. If equipped with automatic transmission, install tool ST498277200, with will hold the torque converter in place.
  48.  
  49. Remove the upper right side bolts that retain the transmission to the engine.
  50.  
  51. Slightly raise the engine. Raise the transmission, using the suitable jack. Move the engine horizontally until the mainshaft is withdrawn from the clutch cover. Carefully remove the engine from the vehicle.
  52.  

To install:

  1. Installation is the reverse of the removal procedure.
  2.  
  3. Torque the upper transmission to engine retaining bolts to 36.9ft. lbs.
  4.  
  5. Torque the lower transmission to engine retaining bolts to 36.9ft. lbs.
  6.  
  7. If equipped, tighten the torque converter to drive plate bolts to 18.1 ft. lbs.
  8.  
  9. Fill the engine with the proper grade and type engine oil.
  10.  
  11. Fill and bleed the cooling system.
  12.  
  13. Charge the air conditioning system.
  14.  
  15. If equipped. Adjust the clutch cable as required.
  16.  
  17. If equipped, check the automatic transmission fluid level, correct as required using the proper grade and type transmission fluid.
  18.  
  19. Start the engine and allow it to reach normal operating temperature. Check for leaks and correct as required.
  20.  

DOHC Engines

CAUTION
The fuel injection system remains under pressure after the engine has been turned OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil and coolant.
  6.  
  7. Discharge and recover the air conditioning system.
  8.  
  9. Disconnect the negative battery cable.
  10.  
  11. Remove the radiator.
  12.  
  13. Remove the coolant filler tank.
  14.  
  15. Disconnect the air conditioning hoses from the compressor and cap the lines.
  16.  
  17. Remove the intercooler as follows:
    1. Disconnect the Positive Crankcase Ventilation (PCV) hose from the pipe.
    2.  
    3. Remove the PCV pipe from the intercooler.
    4.  
    5. Disconnect the air by-pass valve hose.
    6.  
    7. Remove the intercooler-to-bracket bolts.
    8.  
    9. Loosen the clamps that connect the intercooler to the turbocharger and throttle body.
    10.  
    11. Disconnect the intercooler duct from the turbocharger and remove the intercooler.
    12.  

  18.  
  19. Disconnect the following:

    Engine harness connector
     
    Engine ground terminal
     
    Left and right engine ground cables
     
    Alternator connector and terminal
     
    Air conditioning compressor connectors, if equipped
     
    Accelerator cable, on models equipped with a manual transmission
     
    Clutch release spring, if equipped with a manual transmission
     
    Brake booster hose
     
    Heater inlet and outlet hoses
     

  20.  
  21. Loosen the power steering pump lock bolt and slider bolt. Remove the power steering belt.
  22.  
  23. Disconnect the power steering switch connector.
  24.  
  25. Remove the pipe with the bracket from the intake manifold and remove the power steering pump.
  26.  
  27. Remove the power steering tank from its bracket by pulling it up.
  28.  
  29. Place the power steering pump on the right wheel apron.
  30.  
  31. Remove the transmission cooler lines from the frame, if equipped with an automatic transmission.
  32.  
  33. Remove the center exhaust pipe.
  34.  
  35. Remove the lower transmission-to-engine nuts.
  36.  
  37. Remove the nuts which attach the front mount rubber to the crossmember.
  38.  
  39. On models equipped with a manual transmission, perform the following:
    1. Remove the clutch operating cylinder from the transmission.
    2.  
    3. Remove the plug using a 10mm wrench
    4.  


      Click image to see an enlarged view

      Fig. Remove the plug using a 10mm wrench-DOHC engines



      Click image to see an enlarged view

      Fig. Screw the 6mm bolt into the release fork and remove it - DOHC engines

    5. Screw the 6mm bolt into the release fork and remove it.
    6.  
    7. Raise the release fork and unfasten the release bearing tabs to free the fork.
    8.  

  40.  
  41. If equipped with an automatic transmission, perform the following:
    1. Remove the torque converter service hole plug.
    2.  
    3. Matchmark the torque converter-to-driveplate.
    4.  
    5. Rotate the engine to remove the torque converter-to-driveplate bolts as they become accessible.
    6.  

  42.  
  43. Remove the pitching stopper.
  44.  
  45. Disconnect the fuel delivery, return and evaporation hoses
  46.  
  47. Remove the fuel filter and bracket.
  48.  
  49. Support the engine with a suitable lifting device attached to the engine lifting eyes.
  50.  
  51. Support the transmission with a floor jack.
  52.  
  53. Remove the starter.
  54.  
  55. Install tool ST 498277200 to the converter housing to prevent the converter from falling.
  56.  
  57. Remove the upper engine-to-transmission bolts.
  58.  
  59. If equipped with a manual transmission, pull the engine forward then up and out of the vehicle to clear the transmission mainshaft.
  60.  
  61. If equipped with an automatic transmission, pull the engine forward then up and out of the vehicle.
  62.  

To install:

  1. If equipped with a manual transmission, perform the following:
    1. Remove the release bearing from the clutch cover using a flat bladed tool.
    2.  
    3. Install the release bearing onto the transmission.
    4.  
    5. Install the release fork into the release bearing tab.
    6.  
    7. Apply a small amount of grease to the splines of the mainshaft.
    8.  
    9. Insert the release fork shaft into the release fork. Make sure the cutout portion of the release fork shaft contacts the spring pin.
    10.  


      Click image to see an enlarged view

      Fig. Release fork and related components-DOHC engines

    11. Install the plug and tighten to 32 ft. lbs. (44 Nm).
    12.  

  2.  
  3. Install the front mount rubber to the engine and tighten to 26 ft. lbs. (35 Nm).
  4.  
  5. Position the engine in the engine compartment and align it with the transmission.
  6.  
  7. Install the engine. Torque the upper bolts to 37 ft. lbs. (50 Nm).
  8.  
  9. Remove the lifting device and floor jack.
  10.  
  11. Install the pitching stopper. Torque the bolts to 43 ft. lbs. (58 Nm) on the body side and 37 ft. lbs. (50 Nm) on the bracket side.
  12.  
  13. Installation is the reverse of removal, please keep in mind the following torque specifications:
    1. Torque converter-to-driveplate bolts while rotating the engine and tighten to 18 ft. lbs. (25 Nm).
    2.  
    3. Power steering pump. Tighten the retainer bolts to 14 ft. lbs. (20 Nm).
    4.  
    5. Lower engine-to-transmission nuts. Tighten them to 37 ft. lbs. (50 Nm).
    6.  
    7. Engine-to-crossmember nuts to 63 ft. lbs. (85 Nm).
    8.  

  14.  
  15. Fill the crankcase to the proper level with clean engine oil.
  16.  
  17. Fill and bleed the cooling system.
  18.  
  19. Charge the air conditioning system using an approved recovery/recycling machine.
  20.  
  21. If equipped, check the automatic transmission fluid level and add Dexron®II if necessary.
  22.  
  23. Start the engine and allow it to reach normal operating temperature. Check for leaks.
  24.  

SOHC Engines

CAUTION
The fuel injection system remains under pressure after the engine has been turned OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil and coolant.
  6.  
  7. Discharge and recover the air conditioning system.
  8.  
  9. Remove or disconnect the following:

    Negative battery cables and battery
     
    Engine undercover
     
    Radiator hoses and fan motor harness
     
    Radiator
     
    Air conditioning compressor and cap the lines
     
    Air intake duct
     
    Air cleaner element and upper cover
     
    Evaporative Emissions (EVAP) canister and bracket
     
    Front Oxygen (O2S) sensor
     

  10.  
  11. If equipped with California emissions specifications, disconnect the rear O2S sensor.
  12.  
  13. Remove or disconnect the following:

    Engine ground terminal
     
    Crankshaft Position (CKP) sensor connector
     
    Camshaft Position (CMP) sensor connector
     
    Knock Sensor (KS) connector
     
    Alternator connector and terminal
     
    Air conditioning compressor connectors, if equipped
     
    Accelerator cable
     
    Cruise control cable, if equipped
     
    Brake booster hose
     
    Heater inlet and outlet hoses
     
    Alternator drive belt
     
    Wires from the spark plugs on the left side of the engine
     
    Power steering pump line bracket
     
    Power steering pump, leaving the lines connected and position it aside
     
    Exhaust Y-pipe
     
    Lower starter nuts
     
    Lower engine-to-transmission nuts
     
    Front engine mount-to-crossmember nuts
     
    Starter
     

  14.  
  15. If equipped with an automatic transmission, perform the following:
    1. Remove the torque converter service hole plug.
    2.  
    3. Matchmark the torque converter-to-driveplate.
    4.  
    5. Rotate the engine to remove the torque converter-to-driveplate bolts as they become accessible.
    6.  

  16.  
  17. Remove or disconnect the following:

    Flywheel cover, if equipped with a manual transmission
     
    Pitching stopper
     
    Fuel delivery, return and evaporation hoses
     

  18.  
  19. Support the engine with a suitable lifting device attached to the engine lifting eyes.
  20.  
  21. Slightly raise the engine.
  22.  
  23. Raise the transmission with a floor jack.
  24.  
  25. If equipped with a manual transmission, pull the engine forward then up and out of the vehicle to clear the transmission mainshaft.
  26.  
  27. If equipped with an automatic transmission, pull the engine forward then up and out of the vehicle.
  28.  

To install:

  1. If equipped with a manual transmission, apply a small amount of grease to the splines of the mainshaft.
  2.  
  3. Position the engine in the engine compartment and align it with the transmission.
  4.  
  5. Install the engine. Torque the upper bolts to 37 ft. lbs. (50 Nm).
  6.  
  7. Remove the lifting device and floor jack.
  8.  
  9. Install or connect the following:

    Pitching stopper. Torque the bolts to 43 ft. lbs. (58 Nm) on the body side and 37 ft. lbs. (50 Nm) on the bracket side.
     
    Flywheel cover, if equipped with a manual transmission
     

  10.  
  11. If equipped with an automatic transmission, perform the following:
    1. Align the matchmarks, install the torque converter-to-driveplate bolts while rotating the engine and tighten to 18 ft. lbs. (25 Nm).
    2.  
    3. Install the service hole cover.
    4.  

  12.  
  13. Install or connect the following:

    EVAP canister and bracket
     
    Power steering pump. Tighten the retainer bolts to 14 ft. lbs. (20 Nm).
     
    Accessory drive belt
     
    Starter. Torque the bolts to 34-40 ft. lbs. (44-52 Nm).
     
    Lower engine-to-transmission nuts. Tighten them to 36 ft. lbs. (50 Nm).
     



    Click image to see an enlarged view

    Fig. Be sure to tighten the front cushion rubber mounting bolts in the innermost elliptical hole in the front crossmember-2001 Models



    Lower engine mounting nuts. Tighten them to 61 ft. lbs. (83 Nm) in the inner most elliptical hole in the front crossmember so the clearance is 0.16-0.24 in. (4-6mm).
     
    Exhaust Y-pipe with new gaskets and nuts
     
    Brake booster hose
     
    Heater inlet and outlet hoses
     
    Accelerator cable
     
    Cruise control cable, if equipped
     
    Engine harness connectors
     
    Engine ground terminal
     
    CKP sensor connector
     
    CMP sensor connector
     
    Knock sensor connector
     
    Alternator connector and terminal
     
    Air conditioning compressor connectors, if equipped
     
    Front O2S sensor, and if removed, the rear O2S sensor.
     
    Air cleaner element and cover
     
    Air conditioning lines with new O-rings, if equipped. Torque the bolts to 23 ft. lbs. (31 Nm).
     
    Radiator
     
    Engine undercover
     
    Negative battery cable
     

  14.  
  15. Fill the crankcase to the proper level with clean engine oil.
  16.  
  17. Fill and bleed the cooling system.
  18.  
  19. Charge the air conditioning system using an approved recovery/recycling machine.
  20.  
  21. If equipped, check the automatic transmission fluid level and add Dexron®II if necessary.
  22.  
  23. Start the engine and allow it to reach normal operating temperature. Check for leaks.
  24.  


CAUTION
The fuel injection system remains under pressure after the engine has been turned OFF . Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Relieve the fuel system pressure.
  4.  
  5. Drain the engine oil and coolant.
  6.  
  7. Discharge and recover the air conditioning system.
  8.  
  9. Remove or disconnect the following:

    Negative battery cables and battery
     
    Air cleaner assembly
     
    Engine undercover
     
    Radiator hoses and fan motor harness
     
    Radiator
     
    Air conditioning compressor and cap the lines
     
    Air cleaner case stay
     
    Front Oxygen (O2S) sensor
     

  10.  
  11. If equipped with California emissions specifications, disconnect the rear O2S sensor.
  12.  
  13. Remove or disconnect the following:

    Engine ground terminal
     
    Crankshaft Position (CKP) sensor connector
     
    Camshaft Position (CMP) sensor connector
     
    Knock Sensor (KS) connector
     
    Alternator connector and terminal
     
    Air conditioning compressor connectors, if equipped
     
    Accelerator cable
     
    Cruise control cable, if equipped
     
    Pressure Switch
     
    Brake booster hose
     
    Heater inlet and outlet hoses
     
    Resonator chamber
     
    Front side V-belt
     
    Pipe with bracket from the intake manifold
     
    Power steering pump, leaving the lines connected and position it aside
     
    Exhaust Y-pipe
     
    Lower starter nuts
     
    Lower engine-to-transmission nuts
     
    Front engine mount-to-crossmember nuts
     

  14.  
  15. If equipped with an automatic transmission, perform the following:
    1. Remove the torque converter service hole plug.
    2.  
    3. Matchmark the torque converter-to-driveplate.
    4.  
    5. Rotate the engine to remove the torque converter-to-driveplate bolts as they become accessible.
    6.  

  16.  
  17. Remove or disconnect the following:

    Flywheel cover, if equipped with a manual transmission
     
    Pitching stopper
     
    Fuel delivery, return and evaporation hoses
     

  18.  
  19. Support the engine with a suitable lifting device attached to the engine lifting eyes.
  20.  
  21. Slightly raise the engine.
  22.  
  23. Raise the transmission with a floor jack.

    Starter
     
    Upper engine-to-transmission bolts
     

  24.  
  25. If equipped with a manual transmission, pull the engine forward then up and out of the vehicle to clear the transmission mainshaft.
  26.  
  27. If equipped with an automatic transmission, pull the engine forward then up and out of the vehicle.
  28.  

To install:

  1. If equipped with a manual transmission, apply a small amount of grease to the splines of the mainshaft.
  2.  
  3. Position the engine in the engine compartment and align it with the transmission.
  4.  
  5. Install the engine. Torque the upper bolts to 37 ft. lbs. (50 Nm).
  6.  
  7. Remove the lifting device and floor jack.
  8.  
  9. Install or connect the following:

    Pitching stopper. Torque the bolts to 43 ft. lbs. (58 Nm) on the body side and 37 ft. lbs. (50 Nm) on the bracket side.
     
    Starter
     
    Flywheel cover, if equipped with a manual transmission
     

  10.  
  11. If equipped with an automatic transmission, perform the following:
    1. Align the matchmarks, install the torque converter-to-driveplate bolts while rotating the engine and tighten to 18 ft. lbs. (25 Nm).
    2.  
    3. Install the service hole cover.
    4.  

  12.  
  13. Install or connect the following:

    Power steering pump. Tighten the retainer bolts to 14 ft. lbs. (20 Nm).
     
    Power steering switch connector
     
    Accessory drive belt
     
    Resontaor chamber and tighten the bolts to 24 ft. lbs. (33 Nm)
     
    Lower engine-to-transmission nuts. Tighten them to 36 ft. lbs. (50 Nm).
     



    Click image to see an enlarged view

    Fig. Attach a suitable lift device to the engine



    Click image to see an enlarged view

    Fig. Be sure to tighten the front cushion rubber mounting bolts in the innermost elliptical hole in the front crossmember-2002-04 Models



    Lower engine mounting nuts. Tighten them to 63 ft. lbs. (85 Nm) in the inner most elliptical hole in the front crossmember so the clearance is 0.16-0.24 in. (4-6mm).
     
    Exhaust Y-pipe with new gaskets and nuts
     
    Brake booster hose
     
    Heater inlet and outlet hoses
     
    Accelerator cable
     
    Cruise control cable, if equipped
     
    Engine harness connectors
     
    Engine ground terminal
     
    CKP sensor connector
     
    CMP sensor connector
     
    Knock sensor connector
     
    Alternator connector and terminal
     
    Air conditioning compressor connectors, if equipped
     
    Front O2S sensor, and if removed, the rear O2S sensor.
     
    Air cleaner element and cover
     
    Air conditioning lines with new O-rings, if equipped. Torque the bolts to 18 ft. lbs. (25 Nm).
     
    Radiator
     
    Engine undercover
     
    Negative battery cable
     

  14.  
  15. Fill the crankcase to the proper level with clean engine oil.
  16.  
  17. Fill and bleed the cooling system.
  18.  
  19. Charge the air conditioning system using an approved recovery/recycling machine.
  20.  
  21. If equipped, check the automatic transmission fluid level and add Dexron®II if necessary.
  22.  
  23. Start the engine and allow it to reach normal operating temperature. Check for leaks.
  24.  

 
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