Engine: Service and Repair
ENGINE ASSEMBLY
Removal and Installation
WARNING:
^ Situate vehicle on a flat and solid surface.
^ Place chocks at front and back of rear wheels.
CAUTION:
^ Always be careful to work safely, avoid forceful or uninstructed operations.
^ Do not start working until exhaust system and engine coolant are cooled sufficiently.
^ Always use the support point specified for lifting.
^ Use either 2-point lift type or separate type lift. If board-on type is used for unavoidable reasons, support at the 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 "Garage Jack and Safety Stand".
REMOVAL
Preparation
1. Drain engine coolant. Refer to "DRAINING ENGINE COOLANT".
2. Partially drain A/T fluid. Refer to "Changing A/T Fluid".
3. Release fuel pressure. Refer to "FUEL PRESSURE RELEASE".
4. Remove the engine hood. Refer to "Removal and Installation of Hood Assembly".
5. Remove the cowl extension. Refer to "Removal and Installation".
6. Remove engine room cover using power tools.
7. Remove the air duct and air cleaner case assembly "REMOVAL".
8. Disconnect vacuum hose between vehicle and engine and set it aside.
9. Remove the radiator assembly and hoses. Refer to "REMOVAL".
10. Remove the drive belts. Refer to "Removal".
11. Remove the fan blade. Refer to "REMOVAL".
12. Disconnect the engine room harness from the fuse box and set it aside.
13. Disconnect the ECM.
14. Disconnect the engine room harness from the engine side and set it aside.
15. Disconnect the engine harness grounds.
16. Disconnect the power steering reservoir tank from engine and move it aside.
17. Disconnect power steering oil pump from engine. Move it aside and secure it using suitable wire or rope. Refer to "REMOVAL".
18. Remove the A/C compressor bolts and set the compressor aside. Refer to "REMOVAL".
19. Disconnect brake booster vacuum line.
20. Disconnect EVAP line.
21. Disconnect the fuel hose at the engine side connection. Refer to "REMOVAL".
22. Disconnect the heater hoses at cowl, and install plugs to avoid leakage of engine coolant.
23. Remove the A/T oil level indicator and indicator tube upper bolts.
24. Remove front final drive assembly (4x4 only). Refer to "REMOVAL".
25. Remove exhaust manifolds. Refer to "REMOVAL".
26. Install engine slingers into left bank cylinder head and right bank cylinder head.
Engine slinger torque: 45.0 Nm (4.6 kg-m, 33 ft. lbs.)
27. Remove the A/T. Refer to "Removal and Installation (4x2)" or "Removal and Installation (4x4)".
28. Lift using a hoist and secure the engine in position.
29. Remove engine assembly from vehicle, avoid interference with vehicle body.
CAUTION:
^ Before and during this lifting, always check if any harnesses are left connected.
30. Remove the parts that may restrict installation of engine to engine stand.
NOTE: This procedure is described assuming that you use an engine stand mounting to the surface to which the transmission mounts.
a. Remove drive plate.
^ Holding crankshaft pulley bolt, lock crankshaft to remove drive plate bolts.
^ Loosen bolts diagonally.
CAUTION:
^ Be careful not to damage drive plate. Especially avoid deforming and damaging of signal plate teeth (circumference position).
^ Place the drive plate with signal plate surface facing other than downward.
^ Keep magnetic materials away from signal plate.
CAUTION: Use an engine stand that has a load capacity [approximately 240 kg (529 lbs.) or more] large enough for supporting the engine weight.
^ If the load capacity of the stand is not adequate, remove the following parts beforehand to reduce the potential risk of overturning the stand.
^ Remove fuel tube and fuel injector assembly. Refer to "REMOVAL".
^ Remove intake manifold. Refer to "REMOVAL".
^ Remove ignition coil. Refer to "REMOVAL".
^ Remove rocker cover. Refer to "REMOVAL".
^ Other removable brackets.
CAUTION: Before removing the hanging chains, make sure the engine stand is stable and there is no risk of overturning.
31. Remove alternator. Refer to "REMOVAL".
32. Remove engine mounting insulator and bracket using power tool.
INSTALLATION
Installation is 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.
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The following are procedures for checking fluid leaks, lubricant leaks and exhaust gases leaks.
^ Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Refer to "Fluids and Lubricants".
^ 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.
NOTE: If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after hydraulic pressure rises.
^ 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.
Summary of the inspection items: