Removal And Installation
ENGINE ASSEMBLY
Removal and Installation
WARNING:
- Situate 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.
- Do not start working until exhaust system and engine coolant are cooled sufficiently.
- 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-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, Pantograph Jack Garage Jack And Safety Stand 2-Pole Lift.
REMOVAL
Preparation
1. Drain the engine coolant. Changing Engine Coolant.
2. Drain the engine oil. Removal and Replacement.
3. Disconnect the battery negative and positive terminal. Removal and Replacement.
4. Release the fuel pressure. Testing and Inspection.
5. Remove the engine hood. Removal And Installation Of Hood Assembly.
6. Remove the cowl extension. Service and Repair.
7. Remove the engine room cover using power tools.
8. Remove the air duct and air cleaner case assembly. Removal And Installation.
9. Remove the radiator assembly and hoses. Removal and Installation.
NOTE:
Cap or plug opening(s) to prevent fluid from spilling.
10. Remove the drive belt. Removal and Replacement.
11. Remove the fan blade. Removal and Installation.
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 the engine and move it aside.
17. Disconnect the power steering oil pump from the engine. Move it aside and secure it. Power Steering Oil Pump, "Removal and Installation"
18. Remove the A/C compressor bolts and set the compressor aside. Service and Repair (ATC).
19. Disconnect the brake booster vacuum line.
20. Disconnect the EVAP line.
21. Disconnect the fuel hose at the engine side connection. Removal And Installation.
NOTE:
Cap or plug opening(s) to prevent fluid from spilling.
22. Disconnect the heater hoses at the cowl, and install plugs to avoid leakage of engine coolant.
NOTE:
Cap or plug opening(s) to prevent fluid from spilling.
23. Remove the A/T oil level indicator and indicator tube upper bolts.
24. Remove the front final drive assembly (4WD only). Front Final Drive M205.
NOTE:
Cap or plug opening(s) to prevent fluid from spilling.
25. Remove the exhaust manifolds. Removal And Installation.
26. Install the engine slingers into the left bank cylinder head and right bank cylinder head.
27. Disconnect and remove the crankshaft position sensor (POS). Exploded View.
28. Remove the A/T. Automatic Transmission or Automatic Transmission.
29. Lift using a hoist and secure the engine in position.
30. Remove the engine assembly from the vehicle, avoid interference with the vehicle body.
CAUTION:
- Before and during lifting, always check if any harnesses are left connected.
31. Remove the parts that may restrict installation of the engine to the engine stand.
NOTE:
This procedure is described assuming that you use an engine stand mounting to the surface to which the transmission mounts.
a. Before removing the drive plate, put a match mark (A) on the crankshaft and drive plate for alignment during installation.
b. Remove the drive plate.
- Holding the crankshaft pulley bolt, lock the crankshaft to remove the drive plate bolts.
- Loosen the bolts diagonally.
CAUTION:
- Be careful not to damage the drive plate. Especially avoid deforming and damaging of the signal plate teeth
(circumference position).
- Place the drive plate with the signal plate surface facing other than downward.
- Keep magnetic materials away from the signal plate.
CAUTION:
Use an engine stand that has a load capacity [approximately 240kg (529 lb) 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 the fuel tube and fuel injector assembly. Removal And Installation.
- Remove the intake manifold. Removal And Installation.
- Remove the ignition coil. Removal And Installation.
- Remove the rocker cover. Removal And Installation.
- Other removable brackets.
CAUTION:
Before removing the hanging chains, make sure the engine stand is stable and there is no risk of overturning.
32. Remove the generator, if necessary. Service and Repair.
33. Remove the engine mounting insulator and bracket using power tool, if necessary.
INSTALLATION
Installation is in the reverse order of removal.
- Tighten engine mounting bracket bolts in numerical order as shown.
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
- Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Maintenance.
- 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 make sure there is no leakage of fuel, exhaust gas, or any oils/fluids including engine oil and engine coolant.
- Bleed air from passages in lines and hoses, such as in cooling system.
- After cooling down engine, again check oils/fluids including engine oil and engine coolant. Refill to specified level, if necessary.
- Summary of the inspection items:
