Engine: Service and Repair

Removal and Installation

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 described in PARTS CATALOG.

CAUTION:
^ Always be careful to work safely, avoid forceful or uninstructed operations.
^ Do not start working until exhaust system and engine coolant are cooled sufficiently.
^ If items or work required are not covered by the engine section, refer to the applicable sections.
^ Always use the support point specified for lifting.
^ Use either 2-point lift type or separate type lift. 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.
^ For supporting points for lifting and jacking point at rear axle, refer to "Garage Jack and Safety Stand".

REMOVAL
Preparation
1. Drain the engine coolant. Refer "DRAINING ENGINE COOLANT".
2. Partially drain the A/T fluid. Refer to "Changing A/T Fluid".
3. Release the fuel pressure. Refer to "FUEL PRESSURE RELEASE".
4. Remove the engine hood. Refer to "Removal and Installation of Hood Assembly".
5. Remove the cowl extension.





6. Remove the engine room cover using power tools.
7. Remove the air duct and air cleaner case assembly "REMOVAL".
8. Disconnect the vacuum hose between the vehicle and engine and set it aside.
9. Remove the radiator assembly and hoses.
10. Remove the drive belts.
11. Remove the fan blade.
12. Disconnect the engine room harness from the fuse box and set it aside.
13. Disconnect the ECM.
14. Disconnect the engine room harness from the engine side and set it aside.
15. Disconnect the engine harness grounds.
16. Disconnect the power steering reservoir tank from the engine and move it aside.
17. Disconnect the power steering oil pump from the engine. Move it aside and secure it using suitable wire or rope.
18. Remove the A/C compressor bolts and set the compressor aside.
19. Disconnect the brake booster vacuum line.
20. Disconnect the EVAP line.
21. Disconnect the fuel hose at the engine side connection.
22. Disconnect the heater hoses at cowl, and install plugs to avoid leakage of engine coolant.
23. Remove the A/T oil level indicator and indicator tube upper bolts.
24. Remove the front final drive assembly (4x4 only).
25. Remove the exhaust manifolds.
26. Install the engine slingers into the left bank cylinder head and right bank cylinder head.
Engine slinger torque: 45.0 Nm (4.6 kg-m, 33 ft. lbs.)





27. Remove the A/T. Refer to "Removal and Installation (4x2)" or "Removal and Installation (4x4)".
28. Lift using hoist and secure the engine in position.
29. Remove the engine assembly from the vehicle, avoid interference with the vehicle body

CAUTION: Before and during lifting, always check if any harnesses are left connected.

30. Remove the parts that may restrict installation of the engine to the engine stand.

NOTE: This procedure is described assuming that you use an engine stand mounting to the surface to which the transmission mounts.

a. Remove the drive plate.
^ Holding the crankshaft pulley bolt, lock the crankshaft to remove the drive plate bolts.
^ Loosen the bolts diagonally.





CAUTION:
^ Be careful not to damage the drive plate. Especially avoid deforming and damaging of the signal plate teeth (circumference position).
^ Place the drive plate with the signal plate surface facing other than downward.
^ Keep magnetic materials away from the signal plate.

CAUTION:
Use an engine stand that has a load capacity [approximately 240 kg (529 lbs.) or more] large enough for supporting the engine weight.
^ If the load capacity of the stand is not adequate, remove the following parts beforehand to reduce the potential risk of overturning the stand.
^ Remove the fuel tube and fuel injector assembly.
^ Remove the intake manifold.
^ Remove the ignition coil.
^ Remove the rocker cover.
^ Other removable brackets.

CAUTION: Before removing the hanging chains, make sure the engine stand is stable and there is no risk of overturning.

31. Remove the alternator.
32. Remove the engine mounting insulator and bracket using power tool.

INSTALLATION
Installation is in the reverse order of removal.

CAUTION:
^ When replacing an engine or transmission you must make sure the dowels are installed correctly during re-assembly.
^ Improper alignment caused by missing dowels may cause vibration, oil leaks or breakage of drivetrain components.

INSPECTION AFTER INSTALLATION
^ Before starting the engine, check oil/fluid levels including engine coolant and engine oil. If the levels are lower than required quantity, fill to the specified level. Refer to "RECOMMENDED FLUIDS AND LUBRICANTS".
^ Use procedure to check for fuel leakage.
^ Turn ignition switch ON (with engine stopped). With fuel pressure applied to the fuel piping, check for fuel leakage at the 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 fuel, exhaust gas, or any oils/fluids including engine oil and engine coolant.
^ Bleed air from passages in lines and hoses, such as in cooling system.
^ After cooling down the engine, again check oil/fluid levels including engine oil and engine coolant. Refill to specified level if necessary.





^ Summary of the inspection items