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".
NOTE:
- When removing components such as hoses, tube/lines, etc., cap or plug openings to prevent fluid from spilling.
- When removing/installing only the engine mounting, the hold engine assembly as instructed bellow:
1.Remove hood assembly. Refer to "Exploded View" Exploded View.
2.Remove the following components and related parts:
- Battery. Refer to "Exploded View" Exploded View.
- Battery tray.
- Power steering reservoir tank bracket. Refer to "Exploded View" Service and Repair.
- Air cleaner case assembly and air duct. Refer to "Exploded View" Exploded View.





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













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. Refer to "Exploded View" Exploded View.
2.Release fuel pressure. Refer to the following table:





3.Remove battery and tray. Refer to "Exploded View" Exploded View.
4.Remove the following components and related parts:
- Hood assembly. Refer to "Exploded View" Exploded View.
- Front under cover. Refer to "Exploded View" Exploded View.
- Front road wheel and tires. Refer to "Exploded View" Exploded View.
5.Drain engine oil. Refer to "Draining" Draining.
6.Drain engine coolant. Refer to "Draining" Draining Engine Coolant.

CAUTION:
- Perform this step when engine is cold.
- Never spill engine coolant on drive belts.
7.Drain power steering fluid. Refer to "Exploded View" Service and Repair.
Engine Room Front
1.Remove drive belt. Refer to "Exploded View" Exploded View.
2.Remove fan shroud. Refer to "Exploded View" Exploded View.
3.Remove cooling fan and fan coupling. Refer to "Exploded View" Exploded View.
4.Remove radiator hoses (upper and lower).
5.Remove radiator.
Vehicle Underbody
1.Remove exhaust front tube. Refer to "Exploded View" Exploded View.
2.Remove protector A and B. Refer to "FRONT TUBE ASSEMBLY : Exploded View" Exploded View.
3.Remove front suspension rear cross member. Refer to "2WD : Exploded View" Exploded View (2WD models) or
"4WD : Exploded View" Exploded View (4WD models).
4.Remove oil cooler. Refer to "Exploded View" Exploded View.
5.Remove A/T assembly. Refer to "2WD : Exploded View" Exploded View (2WD models)
6.Remove steering gear assembly. Refer to "Exploded View" Exploded View.
7.Remove front final drive assembly. Refer to "Exploded View" Exploded View.
8.Remove exhaust manifold. Refer to "Exploded View" Exploded View.
9.Remove alternator. Refer to "Exploded View" Exploded View.
Engine Room LH
1.Remove air cleaner and air duct. Refer to "Exploded View" Exploded View.
2.Remove A/C compressor. Refer to "Exploded View" Exploded View.
3.Disconnect fuel feed hose and EVAP hose. Refer to "Exploded View" Exploded View.

CAUTION:
Fit plugs onto disconnected hoses to prevent fuel leakage.
Engine Room RH
1.Remove power steering oil pump and reservoir tank. Refer to "Exploded View" 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. Refer to "Exploded View" Exploded View.
- Temporarily tighten mounting bolts.
2.Remove intake manifold. Refer to "Exploded View" Exploded View.
3.Remove starter motor. Refer to "Exploded View" Exploded View.
4.Install engine slingers.














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