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, Pantograph Jack Garage Jack And Safety Stand, "Garage Jack and
Safety Stand".
NOTE:
When removing/installing only the engine mounting, the hold engine assembly as instructed bellow:
1. Remove hood assembly. Exploded View.
2. Remove the following components and related parts:
- Battery. Exploded View.
- Battery tray.
- Power steering reservoir tank bracket. Service and Repair.
- Air cleaner case assembly and air duct. Exploded View.





3. Install engine slinger on both front right and front left sides of the engine.

A : Engine front slinger (bank 2)
B : Engine front slinger (bank 1)

Slinger bolts:
Tightening torque: 45.0 N-m (4.6 kg-m, 33 ft-lb)





4. 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 transmission and transfer assembly, steering gear and front final drive facing downward.
Then remove the engine.

Preparation
1. Remove engine cover. Exploded View.
2. Release fuel pressure. Testing and Inspection.
3. Remove battery and tray. Exploded View.
4. Remove the following components and related parts:
- Hood assembly. Exploded View.
- Front under cover. Exploded View.
- Front road wheel and tires. Exploded View.
5. Drain engine oil. Draining.
6. Drain engine coolant. Draining Engine Coolant.
CAUTION:
- Perform this step when engine is cold.
- Never spill engine coolant on drive belts.
7. Drain power steering fluid. Service and Repair.

Engine Room Front
1. Remove drive belt. Exploded View.
2. Remove fan shroud. Exploded View.
3. Remove cooling fan and fan coupling. Exploded View.
4. Remove radiator hoses (upper and lower).
5. Remove radiator.

Vehicle Underbody
1. Remove exhaust front tube. Exploded View.
2. Remove protector A and B. Exploded View.
3. Remove front suspension rear cross member. (2WD models) or
(4WD models).
4. Remove oil cooler. Exploded View.
5. Remove A/T assembly. (2WD models) or Exploded View Removal And Installation, "4WD :
Exploded View" (4WD models).
6. Remove steering gear assembly. Exploded View.
7. Remove front final drive assembly. Front Final Drive Assembly.
8. Remove exhaust manifold. Exploded View.
9. Remove alternator. Exploded View.

Engine Room LH
1. Remove air cleaner and air duct. Exploded View.
2. Remove A/C compressor. Exploded View.
3. Disconnect fuel feed hose and EVAP hose. Exploded View.
CAUTION:
Fit plugs onto disconnected hoses to prevent fuel leakage.

Engine Room RH
1. Remove power steering oil pump and reservoir tank. Exploded View.
2. Disconnect heater hose at heater core side, and fit a plug onto hose end to prevent engine coolant leakage.
3. Disconnect ground cable.
4. Disconnect all clips and connectors of the engine harness from vehicle side.

Removal Work
1. Install alternator bracket. Exploded View.
- Temporarily tighten mounting bolts.
2. Remove intake manifold. Exploded View.
3. Remove starter motor. Exploded View.
4. Install engine slingers.










Slinger bolts:
Tightening torque: 45.0 N-m (4.6 kg-m, 33 ft-lb)

5. Lift using a hoist and secure the engine in position.
6. Remove engine mounting bracket (LH, RH) and engine mounting insulator (LH, RH). Exploded View, "Exploded View".





7. Remove the engine from the vehicle, avoid interference with the vehicle body.

CAUTION:
- Before and during 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.

INSTALLATION
Install 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.