ENGINE ASSEMBLY

MECHANICAL

9. Engine Assembly 10) Remove the intercooler. <Ref. to IN(STi)-11,

REMOVAL, Intercooler.>
A: REMOVAL 11) Disconnect the following connectors and cable.
1) Set the vehicle on a lift. (1) Engine harness connector
2) Open the front hood fully, and then support with
the hood stay.
3) Collect the refrigerant from A/C system.
4) Release the fuel pressure.
(1) Disconnect the fuel pump relay connector.

ME-00027

(2) Engine ground terminal

FU-00262

(2) Start the engine, and run until stalls.

(3) After the engine stalls, crank it for 5 seconds
more.
(4) Turn the ignition switch to OFF.
5) Remove the filler cap.
6) Disconnect the ground cable from battery.
ME-00028

(3) Engine harness connector

FU-00009

7) Remove the radiator from vehicle. <Ref. to

ME-00029
CO(H4DOTC)-22, REMOVAL, Radiator.>
8) Remove the coolant filler tank. <Ref. to (4) Generator connector, terminal and A/C
CO(H4DOTC)-32, REMOVAL, Coolant Filler compressor connectors
Tank.>
9) Disconnect the A/C pressure hoses from A/C
compressor. (B)

(A)

ME-00030

(A) A/C compressor connector

ME-00707
(B) Generator connector and terminal

ME(STi)-32
 ENGINE ASSEMBLY
MECHANICAL

(5) Clutch release spring (3) Remove the pipe with bracket from intake
manifold.

ME-00032
ME-00036
12) Disconnect the following hoses.
(1) Brake booster vacuum hose (4) Remove the power steering pump from en-
gine.

ME-00033
ME-00037
(2) Heater inlet outlet hose
13) Remove the power steering pump from brack- (5) Remove the power steering tank from
et. bracket by pulling it upward.
(1) Loosen the lock bolt and slider bolt, and
then remove the front side V-belt. <Ref. to
ME(STi)-41, FRONT SIDE BELT, REMOVAL,
V-belt.>
(2) Disconnect the power steering switch con-
nector.

ME-00038

(6) Place the power steering pump on right side

wheel apron.

ME-00035

ME-00039

14) Lift-up the vehicle.

ME(STi)-33
 ENGINE ASSEMBLY
MECHANICAL

15) Remove the center exhaust pipe. <Ref. to (3) Screw the 6 mm dia. bolt into release fork
EX(H4DOTC)-8, REMOVAL, Center Exhaust shaft, and remove it.
Pipe.>
16) Remove the nuts which hold the lower side of
transmission to engine.

(A)

(B)

ME-00040

17) Remove the nuts which install the front cushion

rubber onto front crossmember.

ME-00043

(A) Shaft
(B) Bolt

ME-00041 (4) Raise the release fork, and then unfasten

the release bearing tabs to free release fork.
18) Lower the vehicle.
19) Separate the clutch release fork from release NOTE:
bearing. Step (4) is required to prevent interference with en-
gine when removing the engine from transmission.
(1) Remove the clutch operating cylinder from
transmission. 20) Remove the pitching stopper.
(2) Remove the plug using a 10 mm hexagon
wrench.

MT-00069

ME-00042

ME(STi)-34
 ENGINE ASSEMBLY
MECHANICAL

21) Disconnect the fuel delivery hose, return hose (2) Remove the bolts which hold the right upper
and evaporation hose. side of transmission to engine.
NOTE:
• Catch fuel from the hose into container.
• Disconnect the hose with its end wrapped with
cloth to prevent fuel from splashing.

ME-00050

25) Remove the engine from vehicle.

(1) Slightly raise the engine.
(2) Raise the transmission with garage jack.
ME-00045 (3) Move the engine horizontally until the main-
22) Support the engine with a lifting device and shaft is withdrawn from clutch cover.
wire ropes. (4) Slowly move the engine away from engine
compartment.
NOTE:
Be careful not to damage adjacent parts or body
panels with crank pulley, oil pressure gauge, etc.
26) Remove the front cushion rubbers.
B: INSTALLATION
1) Install the clutch release fork and bearing onto
transmission.
(1) Remove the release bearing from clutch
ME-00047 cover with flat type screw driver.
23) Support the transmission with a garage jack.
NOTE:
Before moving the engine away from transmission,
check to be sure no work has been overlooked. Do-
ing this is very important in order to facilitate re-in-
stallation and because transmission lowers under
its own weight.

ME-00051

(2) Install the release bearing on transmission.

ME-00048

24) Separation of the engine and transmission.

(1) Remove the starter. <Ref. to SC(H4SO)-7,
REMOVAL, Starter.>

ME(STi)-35
 ENGINE ASSEMBLY
MECHANICAL

(3) Install the release fork into release bearing (5) Insert the release fork shaft into release
tab. fork.
CAUTION:
(A) Make sure the cutout portion of release fork
shaft contacts spring pin.

(B) (A)

(C)

(B)
ME-00052

(A) Release fork

(B) Release bearing ME-00054

(4) Apply grease to the specified points.

(A) Release fork
• Spline FX2200
• Shaft SUNLIGHT 2 (B) Release shaft
(C) Spring pin

(6) Tighten the plug.

Tightening torque:
44 N·m (4.5 kgf-m, 32.5 ft-lb)

(A)

ME-00055

(B) 2) Install the front cushion rubbers to engine.

Tightening torque:
35 N·m (3.6 kgf-m, 25.8 ft-lb)
3) Install the engine onto transmission.
ME-00053 (1) Position the engine in engine compartment,
and then align it with the transmission.
(A) Spline (FX2200) NOTE:
(B) Shaft (SUNLIGHT 2) Be careful not to damage the adjacent parts or
body panels with crank pulley, oil pressure gauge,
etc.
(2) Apply a small amount of grease to the
splines of mainshaft.

ME(STi)-36
 ENGINE ASSEMBLY
MECHANICAL

4) Tighten the bolts which hold the right upper side 8) Install the power steering pump on bracket.
of transmission to engine. (1) Install the power steering tank on bracket.
Tightening torque:
50 N·m (5.1 kgf-m, 36.9 ft-lb)

ME-00038

(2) Install the power steering pump.

ME-00050
Tightening torque:
5) Remove the lifting device and wire ropes. 20.1 N·m (2.05 kgf-m, 14.8 ft-lb)
6) Remove the garage jack.

ME-00037
ME-00047
(3) Install the power steering pipe bracket on
7) Install the pitching stopper. intake manifold RH.
Tightening torque:
T1: 50 N·m (5.1 kgf-m, 37 ft-lb)
T2: 58 N·m (5.9 kgf-m, 43 ft-lb)

T1

T2 ME-00036

(4) Connect the power steering switch connec-

tor.
MT-00085

ME-00035

ME(STi)-37
 ENGINE ASSEMBLY
MECHANICAL

(5) Install the front side V-belt, and adjust it. 16) Install the air intake system.
<Ref. to ME(STi)-41, FRONT SIDE BELT, IN- (1) Install the intercooler. <Ref. to IN(STi)-11,
STALLATION, V-belt.> INSTALLATION, Intercooler.>
9) Lift-up the vehicle. (2) Install the air cleaner element and air clean-
10) Tighten the nuts which hold the lower side of er upper cover.
transmission to engine. (3) Install the engine harness connector brack-
Tightening torque: et.
50 N·m (5.1 kgf-m, 36.9 ft-lb) (4) Install the filler hose to air cleaner case.
17) Install the A/C pressure hoses.
NOTE:
Use new O-rings.
Tightening torque:
25 N·m (2.5 kgf-m, 18.1 ft-lb)

ME-00040

11) Tighten the nuts which install the front cushion

rubber onto crossmember.
Tightening torque:
85 N·m (8.7 kgf-m, 62.7 ft-lb) ME-00707
NOTE:
Make sure the front cushion rubber mounting bolts 18) Install the radiator. <Ref. to CO(H4DOTC)-23,
(A) and locator (B) are securely installed. INSTALLATION, Radiator.>
19) Install the coolant filler tank. <Ref. to
CO(H4DOTC)-32, INSTALLATION, Coolant Filler
Tank.>
20) Install the window washer tank.
21) Install the battery in the vehicle, and then con-
nect the cables.
22) Fill coolant.
<Ref. to CO(H4DOTC)-17, FILLING OF ENGINE
COOLANT, REPLACEMENT, Engine Coolant.>
(B) (A) (A) (B)
23) Charge the A/C system with refrigerant.
ME-00056 <Ref. to AC-21, OPERATION, Refrigerant Charg-
ing Procedure.>
12) Install the center exhaust pipe. 24) Remove the front hood stay, and close the front
<Ref. to EX(H4DOTC)-9, INSTALLATION, Center hood.
Exhaust Pipe.> 25) Take off the vehicle from lift arms.
13) Lower the vehicle.
14) 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
15) 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

ME(STi)-38