Engine: Service and Repair
Removal and Installation
2WD MODEL
WARNING:
^ Situate vehicle on a flat and solid surface.
^ Place chocks at front and back of rear wheels.
^ For engines not equipped with engine slingers, attach proper slingers and bolts.
CAUTION:
^ Always be careful to work safely, avoid forceful or uninstructed operations.
^ Do not start working until exhaust system and engine coolant are cool enough.
^ If items or work required are not covered, refer to the applicable sections.
^ Always use the support point specified for lifting.
^ Use either 2-point lift type or separate type lift as best you can. If board-on type is used for unavoidable reasons, support at the rear axle jacking point with transmission jack or similar tool before starting work, in preparation for the backward shift of center of gravity.
REMOVAL
Outline
At first, remove engine and transmission assembly with suspension member downward. Then separate engine from transmission.
Preparation
1. Release fuel pressure.
2. Disconnect both battery cables.
3. Remove engine cover, battery cover and LH/RH front tire.
4. Remove front and rear engine undercover and front cross bar with power tool.
5. Drain engine coolant from radiator drain plug.
6. Remove caul top cover RH.
7. Remove air duct and air cleaner case assembly.
8. Remove radiator upper and lower hoses.
Engine Room
1. Disconnect heater hose from vehicle-side, and fit a plug onto hose end to prevent engine coolant leak.
2. Disconnect grounding wire (between vehicle to LH cylinder head).
3. Disconnect battery plus harness at vehicle side and temporarily fasten it on engine.
4. Disconnect engine room harness connectors shown in the figure.
5. Disconnect A/C piping from A/C compressor, and temporarily fasten it on vehicle with a rope.
6. Disconnect two body ground cables.
7. Disconnect brake booster vacuum hose.
8. Disconnect fuel feed hose and EVAP hose.
CAUTION: Fit plugs onto disconnected hoses to prevent fuel leak.
9. Remove power steering oil pump reservoir tank and piping from vehicle, and temporarily secure them on engine.
CAUTION: When temporarily securing, keep them upright to avoid a fluid leak.
Passenger Room Side
1. Follow procedure below to disconnect engine room harness connectors at passenger room side, and temporarily secure them on engine.
a. Remove passenger-side kicking plate, dashboard side trim, and glove box.
b. Disconnect engine room harness connectors at unit sides ECM and other.
c. Disengage intermediate fixing point. Pull out engine room harnesses to engine room side, and temporarily secure them on engine.
CAUTION:
^ When pulling out harnesses, take care not to damage harnesses and connectors.
^ After temporarily securing, cover connectors with vinyl or similar material to protect against foreign material adhesion.
Vehicle Underbody
1. Remove A/T fluid cooler hoses and power steering oil pump oil cooler hoses.
2. Remove exhaust front tube.
3. Disconnect steering lower joint, and release steering shaft.
4. Separate transmission and propeller shaft.
5. Disengage shift control linkage at selector lever side. Then, temporarily secure it on transmission, so that it does not sag.
6. Remove rear plate cover from upper oil pan. Then, remove bolts fixing drive plate to torque converter.
7. Remove bolts fixing transmission to lower rear side of upper oil pan.
8. Remove front stabilizer.
9. Remove LH and RH tie-rod ends from steering knuckle.
10. Remove lower ends of LH and RH struts from lower arms.
11. Remove LH and RH lower arms from suspension member.
Removal Work
1. Use a manual lift table caddy (commercial service tool) or equivalently rigid tool such as a transmission jack. Securely support bottom of suspension member and transmission.
CAUTION: Put a piece of wood or something similar as the supporting surface, secure a completely stable condition.
2. Remove rear member mounting bolt.
3. Remove suspension member mounting bolt and nut.
4. Carefully lower jack to remove engine, transmission, and suspension member assembly. When performing work, observe the following:
CAUTION:
^ Confirm there is no interference with vehicle.
^ Make sure all connection points have been disconnected.
^ Keep in mind the center of vehicle gravity changes. If necessary, use jack(s) to support vehicle at rear jacking point(s) to prevent it from falling it off the lift.
Separation Work
1. Install engine slingers into front of right bank cylinder head and rear of left bank cylinder head.
Slinger bolts: 28.0 Nm (2.9 kg-m, 21 ft. lbs.)
2. Remove power steering oil pump from engine side.
3. Remove engine mounting insulator under side nut with power tool.
4. Lift with hoist and separate engine and transmission assembly from suspension member.
CAUTION:
^ Before and during this lifting, always check if any harnesses are left connected.
^ Avoid damage to and oil/grease smearing or spills onto engine mounting insulator.
5. Remove alternator.
6. Remove starter motor.
7. Separate engine from transmission assembly.
8. Remove engine mounting insulator and bracket with power tool.
INSTALLATION
Install in the reverse order of removal paying attention to the following. For a location with a positioning pin, insert it securely into hole of mating part.
^ For a part with a specified installation orientation, refer to component figure.
^ When installing engine mounting bracket on cylinder block, tighten two upper bolts (shown as A in figure) first. Then tighten two lower bolts (shown as B in figure). (LH and RH sides)
^ Tighten rear member mounting bolts in numerical order shown in figure.
INSPECTION AFTER INSTALLATION
^ Before starting engine, check the levels of engine coolant, engine oil and working fluid. If less than required quantity, fill to the specified level.
^ Use procedure below to check for fuel leakage.
- Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
^ Run engine to check for unusual noise and vibration.
^ Warm up engine thoroughly to make sure there is no leakage of engine coolant, engine oil, working fluid, fuel and exhaust gas.
^ Bleed air from passages in pipes and tubes of applicable lines, such as in cooling system.
^ After cooling down engine, again check amounts of engine coolant, engine oil and working fluid. Refill to specified level, if necessary.
^ Summary of the inspection items: