Removal and Replacement
ENGINE ASSEMBLYEM-79 Exploded View:
2WD: Removal and Installation
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.
^ Never start working until exhaust system and engine coolant are cool enough.
^ If items or work required are not covered by the engine Information, refer to the applicable Information.
^ 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.
^ For supporting points for lifting and jacking point at rear axle, refer to GI-29, "Garage Jack and Safely Stand and 2-Pole Lift". Service and Repair
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. Disconnect both battery cables.
3. Drain engine coolant from radiator.
CAUTION:
^ Perform this step when engine is cold.
^ Never spill engine coolant on drive belt.
4. Remove the following parts:
^ Radiator reservoir tank
^ Engine cover
^ Front road wheel and tires (power tool)
^ Engine undercover (power tool)
^ Cowl top cover
^ Air duct and air cleaner case assembly (RH and LH)
^ Cooling fan assembly
5. Discharge refrigerant from A/C circuit.
6. Remove radiator hoses (upper and lower).
Engine Room LH
1. Disconnect heater hose from vehicle-side, and fit a plug onto hose end to prevent engine coolant leakage.
2. Disconnect A/C piping from A/C compressor, and temporarily fasten it on vehicle with a rope.
3. Disconnect brake booster vacuum hose.
4. Disconnect ground cable.
Engine Room RH
1. Disconnect battery positive cable at vehicle side and temporarily fasten it on engine.
2. Disconnect all clips and connector of the engine room harness from engine back side.
3. Disconnect fuel feed hose (with damper) and EVAP hose.
CAUTION:
Fit plugs onto disconnected hoses to prevent fuel leakage.
4. 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 leakage.
Vehicle Inside
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 and dash side finisher.
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. Disconnect heated oxygen sensor 2 harness.
3. Remove three way catalyst and exhaust front tube.
4. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft.
5. Remove rear propeller shaft.
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 cover 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 connecting rod from transverse link.
10. Remove lower ends of left and right steering knuckle from transverse link.
11. Separate steering outer sockets from steering knuckle.
12. Remove transverse links mounting bolts at suspension member side.
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 bolts and 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.
^ Check 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 (bank 1) and rear of cylinder head (bank 2).
1: Engine front slinger
2: Engine rear upper slinger
3: Spacer
4: Engine rear lower slinger
A: Bank 1
B: Bank 2
<---: Engine front
Slinger bolts: 28.0 Nm (2.9 kg-m, 21 ft-lb)
^ To protect rocker cover against damage caused by tilting of engine slinger, insert spacer between cylinder head and engine rear lower slinger (3), in direction shown in the figure.
1: Engine rear upper slinger
<---: Engine front
NOTE:
Spacer (2) 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 check that any harnesses are left connected.
^ Never 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.
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 "2WD: Exploded View".
^ When installing engine mounting bracket (RH and LH) on cylinder block, tighten two upper bolts [shown as (B), in the figure] first. Then tighten two lower bolts [shown as (C) in the figure].
A: Example left
^ Check 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.
<---: Vehicle front
2WD: Inspection
INSPECTION AFTER INSTALLATION
Inspection for Leakage
The following are procedures for checking fluids leakage, lubricates leakage and exhaust gases leakage.
^ 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 check 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.
