Removal and Installation

ENGINE ASSEMBLY


Removal and Installation


WARNING:
- Situate the vehicle on a flat and solid surface.
- Place chocks at the 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, and 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 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 much as possible. 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 the center of gravity.
- For supporting points for lifting and jacking point at rear axle, Garage Jack and Safety Stand and 2-Pole Lift.

NOTE:
When removing/installing only the engine mounting, the hold engine assembly as instructed bellow:
1. Remove food assembly. Exploded View.
2. Install engine slinger on both front right and front left sides of the engine.





3. Hoist the slinger to obtain room for engine assembly.

CAUTION:
Use an engine lifter to prevent the engine slinger from falling and damaging the rocker cover.

REMOVAL

Outline
At first, remove the engine, transmission, transfer and front final drive assembly with front suspension member facing downward. Then separate the engine from transmission.

Preparation
1. Remove engine cover, engine room cover (RH and LH), battery cover and brake master cylinder cover. Exploded View.
2. Release fuel pressure. Testing and Inspection.
3. Remove the following parts:
- Engine undercover (power tool)
- Front road wheel and tires (power tool)
- Cowl top cover: Exploded View.
- Air duct, air cleaner case assembly and PCV hose: Exploded View.
- Drive belts: Removal and Installation.
- Front cross bar: Exploded View.
4. Disconnect both battery cables. Exploded View.
5. Drain engine coolant from radiator. Draining.

CAUTION:
Perform this step when engine is cold.
6. Discharge refrigerant from A/C circuit. Service and Repair.
7. Remove radiator hoses (upper and lower). Exploded View.

Engine Room LH
1. Disconnect heater hose at engine 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. Exploded View.
3. Disconnect vacuum hose from brake booster. Exploded View.
4. Disconnect ground cable.

Engine Room RH
1. Disconnect all clips and connectors of the engine room harness from engine side.
2. Disconnect fuel feed hose and EVAP service port hose. Exploded View.

CAUTION:
Fit plugs onto disconnected hoses to prevent fuel leakage.
3. 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 fluid leakage.

Vehicle Inside
Follow the procedure below to disconnect engine room harness connectors at passenger room side, and temporarily secure them on engine.
1. Remove glove box assembly and instrument assist lower panel. Exploded View.
2. Disconnect engine room harness connectors at unit sides and other locations.
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 adhesion of foreign materials.

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 ground cable from exhaust manifold cover (bank 2).
3. Disconnect heated oxygen sensor 2 harness.
4. Remove three way catalyst and exhaust front tube. Exploded View and Exploded View.
5. Remove rear propeller shaft. Exploded View.
6. Disconnect lower joint at power steering gear assembly side, and release lower shaft. Exploded View or Exploded View.
7. Disengage A/T control rod at A/T shift selector side. Then, temporarily secure it on the transmission assembly, so that it does not sag. Exploded View.
8. Preparation for the separation work of transaxle is as per the following:
- Remove rear plate cover from oil pan (upper). Then remove bolts fixing drive plate to torque converter. Exploded View.
- Remove transmission joint bolts that pierce at oil pan (upper) lower rear side. Exploded View.
9. Remove front stabilizer connecting rod. Exploded View.
10. Remove front wheel sensor for ABS from steering knuckle. Exploded View
11. Remove brake caliper assembly with piping connected from steering knuckle. Temporarily secure it on the vehicle side with a rope to avoid load on it. Exploded View
12. Separate upper link from steering knuckle. Exploded View.
13. Separate shock absorber from transverse link. Exploded View.

Removal Work





1. Use a manual lift table caddy (commercial service tool) or an equivalently rigid tool such as a transmission jack. Securely support bottom of suspension member and the transmission assembly.

CAUTION:
Use a piece of wood or a similar item as the supporting surface to secure a completely stable condition.
2. Loosen rear engine mounting member mounting bolts.
3. Loosen front suspension member mounting bolts. Exploded View.
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 items:

CAUTION:
- Confirm there is no interference with the vehicle.
- Check that all connection points have been disconnected.
- Keep in mind that the center of gravity of the vehicle changes. If necessary, use jack(s) to support the vehicle at rear jacking point(s) to prevent it from falling 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 (bank 1)
2 : Engine rear slinger (bank 2)
White arrow : Engine front

Slinger bolts : 45.0 Nm (4.6 kg-m, 33 ft-lb)





2. Hang the lifting hook of a two-point engine lifter (commercial service tool) (A) from the front and rear engine slingers to hoist engine and flywheel housing assembly.
- For the flywheel housing side, use a webbing slinger (B) or an equivalent to hoist the assembly horizontally.

CAUTION:
Always hoist the engine by using a two-point engine lifter
(i.e. hoisting the front and rear slingers from one point in the air), or the rocker cover and parts around the engine may be damaged due to the fall of the engine slinger.
3. Remove power steering oil pump from engine side. .
4. Remove engine mounting insulators (RH and LH) under side nuts with power tool.
5. Lift with hoist and separate the engine, transmission, transfer and front final drive assembly from front suspension member.

CAUTION:
- Before and during this lifting, always check that any harnesses are left connected.
- Never damage engine mounting insulator and avoid oil/grease smearing or spills onto engine mounting insulator.
6. Remove alternator. .
7. Separate the engine from the transmission assembly. Overhaul.
8. Remove front propeller shaft. .
9. Remove the front final drive assembly from oil pan (upper). .
10. Remove each engine mounting insulator and each engine mounting bracket from the engine with power tool.

INSTALLATION
Note the following item, 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 matching part.
- For a part with a specified installation orientation, refer to component figure in Exploded View.





- When installing engine mounting bracket (RH and LH) on cylinder block, tighten two upper bolts (A) first. Then tighten two lower bolts
(B).

White arrow : Engine front


NOTE:
This figure shows an example of bank 2.





- When installing engine mounting bracket (rear) on transfer, tighten two upper bolts (B) first. Then tighten two lower bolts (C).

A : Rear view

- When installing engine mounting insulator (rear) on engine mounting bracket (rear), tighten upper bolts (D) first. Then tighten lower bolts (E).





- Tighten rear engine mounting member bolts in numerical order as shown in the figure.

White arrow : Vehicle front

- Check that all engine mounting insulators are seated properly, then tighten mounting nuts and bolts.