Engine: Service and Repair
ENGINE ASSEMBLY2WD Models:
Removal and Installation (2WD Models)
WARNING:
^ Situate the 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 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 the engine and the transmission assembly with front suspension member downward. Then separate the 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 terminals.
4. Remove the following parts:
^ Engine cover.
^ Front road wheel and tires
^ Front and rear engine undercover
^ Front cross bar.
^ Cowl top cover (right).
^ Air duct and air cleaner case assembly.
5. Discharge refrigerant from A/C circuit.
6. Remove radiator hoses (upper and lower).
Engine Room
1. Disconnect heater hose from vehicle-side, and fit a plug onto hose end to prevent engine coolant leak.
2. Disconnect grounding cable (between vehicle to left bank cylinder head).
3. Disconnect battery positive cable harness at vehicle side and temporarily fasten it on engine.
4. Disconnect A/C piping from A/C compressor, and temporarily fasten it on vehicle with a rope.
5. Disconnect engine room harness connectors shown in the figure.
6. Disconnect two body ground cables.
7. Disconnect brake booster vacuum hose.
8. Disconnect fuel feed hose (with damper) and EVAP hose.
CAUTION: Fit plugs onto disconnected hoses to prevent fuel leak.
9. Remove reservoir tank of power steering oil pump and piping from vehicle, and temporarily secure them on engine.
CAUTION: When temporarily securing, keep the reservoir tank upright to avoid a fluid leak.
Passenger Room Side
Follow procedure below to disconnect engine room harness connectors at passenger room side, and temporarily secure them on engine.
1. Remove passenger-side kicking plate, dash side finisher, and glove box.
2. Disconnect engine room harness connectors at unit sides TCM, ECM and other.
3. 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.
^ Install plug to avoid leakage of A/T fluid and power steering fluid.
2. Remove exhaust front tube and center muffler.
3. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft.
4. Remove tunnel stay.
5. Remove rear propeller shaft.
^ After disconnection, plug the opening on transmission assembly side.
6. Disengage A/T control rod at control device assembly side. Then, temporarily secure it on the transmission assembly, so that it does not sag.
7. Remove rear plate from oil pan (upper). Then remove bolts fixing drive plate to torque converter.
8. Remove transmission joint bolts which pierce at oil pan (upper) lower rear side.
9. Remove front stabilizer.
10. Separate steering outer sockets from steering knuckle.
11. Separate transverse links from suspension member and vehicle body.
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 the transmission assembly.
CAUTION: Put a piece of wood or something similar as the supporting surface, secure a completely stable condition.
2. Remove rear engine mounting member bolts.
3. Remove front suspension member mounting nuts.
4. Carefully lower jack, or raise lift to remove the engine, the transmission assembly and front suspension member. When performing work, observe the following caution:
CAUTION:
^ Confirm there is no interference with the 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 the vehicle at rear jacking point(s) to prevent it from failing it off the lift.
Separation Work
1. Install engine slingers into front of cylinder head (right bank) and rear of cylinder head (left bank).
Slinger bolts: 28.0 Nm (2.9 kg-m, 21 ft. lbs.)
^ To protect rocker cover against damage caused by tilting of engine slinger, insert spacer between cylinder head and engine rear lower slinger, in direction shown in the figure.
NOTE: Spacer is a component part of engine rear upper slinger assembly.
2. Remove power steering oil pump from engine side.
3. Remove engine mounting insulators (RH and LH) under side nuts with power tool.
4. Lift with hoist and separate the engine and the 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.
5. Remove alternator.
6. Remove starter motor.
7. Separate the engine from the transmission assembly.
8. Remove each engine mounting insulator and each engine mounting bracket from the engine with power tool.
9. Remove rear engine mounting member and engine mounting insulator (rear) from the transmission assembly
INSTALLATION
Note the following, and install in the reverse order of removal.
^ Do not allow engine mounting insulator to be damage and careful no 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 in EM-113, Components (2WD Models).
^ When installing engine mounting bracket (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).
^ Make sure all engine mounting insulators are seated properly, then tighten mounting nuts.
^ Tighten rear engine mounting member bolts in numerical order as shown in the figure.
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The following 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.
