Engine: Service and Repair
ENGINE ASSEMBLY
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 cool enough.
^ 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-pole 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, transmission assembly and front final drive with front suspension member from vehicle downward. Then separate engine from transmission.
Preparation
1. Release fuel pressure.
2. Drain engine coolant from radiator.
CAUTION:
^ Perform this step when engine is cold.
^ Do not spill engine coolant on drive belts.
3. Disconnect both battery terminal.
4. Remove crankshaft position sensor (POS) from transmission.
CAUTION:
^ Handle carefully to avoid dropping and shocks.
^ Do not disassemble.
^ Do not allow metal powder to adhere to magnetic part at sensor tip.
^ Do not place sensors in a location where they are exposed to magnetism.
5. Remove the following parts:
^ Hood assembly
^ Engine covers
^ Front and rear engine undercover
^ Air duct (inlet), air duct and air cleaner case assembly.
^ Drive belts
^ Radiator and radiator hoses (upper and lower).
^ Front road wheels and tires
Engine Room LH
1. Disconnect engine room harness from the engine side and set it aside for easier work.
2. Disconnect heater hoses, and install plugs to avoid leakage of engine coolant.
3. Disconnect ground cable from exhaust manifold cover to vehicle.
4. Disconnect vacuum hose between vehicle and engine and set it aside.
5. Discharge refrigerant from A/C circuit.
6. Remove A/C piping from A/C compressor, and temporarily fasten it on vehicle with a rope. Refer to ATC-139, Components. [1][2]Exploded Views
Engine Room RH
1. Disconnect fuel feed hose and EVAP hose.
CAUTION: Fit plugs onto disconnected hose to prevent fuel leak.
2. Disconnect engine room harness from the engine side and set it aside for easier work.
3. Disconnect ground cable from exhaust manifold cover to vehicle.
4. Disconnect vacuum hose between vehicle and engine and set it aside.
5. Disconnect reservoir tank of power steering oil pump from engine, and move it aside for easier work.
CAUTION: When temporarily securing, keep reservoir tank upright to avoid a fluid leak.
Vehicle Underbody
1. Remove front cross bar.
2. Disconnect power steering oil pump from engine. Move it from its location and secure with a rope for easier work.
3. Remove A/T fluid cooler tube.
4. Remove exhaust front tube and center muffler with power tool.
5. Remove RH and LH transverse link mounting bolts and nuts.
6. Disconnect stabilizer connecting rod lower.
7. Remove A/T control rod at control device assembly side. Then temporarily secure it on transmission, so that it does not sag.
8. Remove rear plate cover from oil pan. Then remove bolts fixing drive plate to torque converter.
9. Remove transmission joint bolts which pierce at oil pan lower rear side.
10. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft.
11. Remove rear propeller shaft.
^ After disconnection, plug the opening on transmission side.
12. Remove front drive shaft (both side).
13. Remove front propeller shaft.
14. Remove three way catalysts (both bank).
Removal Work
1. Install engine slingers into front of cylinder head (left bank) and front of cylinder head (right bank).
Slinger bolts: 33.4 Nm (3.4 kg-m, 25 ft. lbs.)
2. Lift with hoist and secure engine in position.
3. Use manual lift table caddy (commercial service tool) or equivalently rigid tool such as 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.
4. Remove engine rear member mounting bolts.
5. Remove front suspension member mounting nuts with power tool.
6. Carefully lower jack, or raise lift to remove engine, transmission front final drive and front suspension member assembly. When performing work, observe the following caution:
CAUTION:
^ Confirm there is no interference with vehicle.
^ Make sure that 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 failing it off the lift.
Separation Work
1. Change engine slinger installing to cylinder head (right bank).
NOTE: In order to keep secure position when hoisting engine.
Slinger bolts: 33.4 Nm (3.4 kg-m, 25 ft. lbs.)
2. Remove engine mounting insulators (RH and LH) under side nut with power tool.
3. Lift with hoist and separate engine and transmission assembly from front suspension member.
CAUTION:
^ Before and during this lifting, always make sure that any harnesses are left connected.
^ Avoid damage to and oil/grease smearing or spills onto engine mounting insulator.
4. Remove alternator.
5. Remove starter motor.
6. Separate engine from transmission assembly.
7. Remove front final drive from engine.
8. Remove engine mounting insulators (RH and LH) and brackets (RH and LH) from engine with power tool.
9. Remove engine rear member and engine mounting insulator (rear) from transmission.
INSTALLATION
Note the following, and install in the reverse order of removal.
^ Do not allow engine mounting insulator to be damage and careful no engine oil gets on it.
^ 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 brackets (RH and LH) on cylinder block, tighten two upper bolts (shown as A in the figure) first. Then tighten two lower bolts (shown as B in the figure).
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The followings are procedures for checking fluids leak lubricates leak and exhaust gases leak.
^ Before starting engine, check oil/fluid levels including engine coolant and engine oil. 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 fuel, exhaust gases, or any oil/fluids including engine oil and engine coolant.
^ Bleed air from lines and hoses of applicable lines, such as in cooling system.
^ After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary.
