Engine Assembly Removal and Installation

Engine Assembly Removal and Installation

Removal
1) Relieve fuel pressure.
2) Remove battery.
3) Remove battery tray (1) and battery bracket (2).





4) Remove engine cover.
5) Drain the following oils and fluids if necessary.
^ Engine oil:
^ Manual transmission oil (5M/T model):
^ A/T fluid (4 A/T model):
^ P/S fluid:
^ Transfer oil (4WD model):
^ Motor shift type:
^ Non-shift type:
^ Front differential oil (4WD model):
6) Drain coolant.
7) Remove air cleaner suction pipe.
8) Remove air cleaner assembly and air cleaner outlet hose.
9) Remove accessory drive belt.
10) Remove front bumper.
11) Disconnect the following electric wires and connectors.
^ ECM connector (1)
^ Radiator cooling fan motor connector (2)
^ Ground cable (3) and (4)
^ Connector (5) and terminal (6) in fuse box No.1
^ Connectors (7) in fuse box No.2
^ Front height sensor connector (8)
^ A/C compressor magnet clutch connector (9)
^ Engine harness connector (10)
12) Disconnect the following hoses.
^ Brake booster hose (11)
^ Heater inlet and outlet hoses (12)
^ Fuel hose (13)
^ EVAP canister purge hose (14)
^ Radiator lower hose (15)





13) Remove engine harness clamps
14) With hose connected, remove A/C compressor from its bracket.

CAUTION:
Suspend removed A/C compressor (1) with rope (2) or the like, at a place where no damage will be caused during removal and installation of engine assembly.





15) For 5 M/T model, disconnect clutch fluid hose from clutch fluid pipe joint.
16) For 4 A/T model, disconnect A/T select cable from A/T.
17) For 5 M/T model, remove transmission shift control lever from transmission.
18) Remove exhaust pipe No.2.
19) Remove rear propeller shaft.
20) With hose connected, remove A/C condenser assembly from radiator.

CAUTION:
Suspend removed A/C condenser (1) with rope (2) or the like, at a place where no damage will be caused during removal and installation of engine assembly.





21) Remove radiator with radiator support bracket (1) and filler neck bracket (2) from vehicle body.
22) With hose connected, remove P/S fluid reservoir (3) from vehicle body.





23) Remove stabilizer bar joints from stabilizer bar.
24) Remove tie-rod ends, front drive shafts (4WD model) and ball joints from steering knuckles.
25) Remove steering lower shaft assembly from P/S gear case assembly.
26) Support front suspension frame (1) and engine rear mounting member (2) using jack.
27) Remove front suspension frame bolts (3).
28) Remove engine rear mounting member bolts (4).





29) Before lowering engine, make sure that all hoses, electric wires and cables are disconnected from engine.
30) Lower engine assembly with transmission and transfer (4WD model) from engine compartment.

NOTE:
^ Lower engine assembly, transmission, transfer (4WD model), front suspension frame, drive shafts (4WD model), radiator, P/S gear case and engine rear mounting member all together.
^ Before lowering engine assembly, make clearance by raising A/C compressor and A/C condenser in order to avoid damage to them.

31) Disconnect transmission if necessary.
^ 5 M/T model:
^ 4 A/T model:
32) For 4 A/T model, remove oil cooler pipe if necessary.
33) Remove engine harness from engine assembly if necessary.
34) Remove engine mounting from engine front mounting bracket if necessary.
35) For 5 M/T model, remove clutch cover and clutch disc if necessary.
36) For 5 M/T model, remove flywheel if necessary.
For 4 A/T model, remove drive plate if necessary.

Installation
1) For 5 M/T model, install flywheel if removed.
For 4 A/T model, install drive plate if removed.
2) For 5 M/T model, install clutch cover and clutch disc if removed.
3) Install engine harness to engine assembly if removed.
^ Tighten engine harness ground bolts with engine harness ground cables to specified torque.
Tightening torque
Engine harness ground bolt (M6) (a): 11 Nm (1.1 kg-m, 8.5 lbf-ft)
Engine harness ground bolt (M8) (b): 25 Nm (2.5 kg-m, 18.5 lbf-ft)











4) Connect transmission to engine if removed.
^ For 5 M/T model:
^ For 4 A/T model:
5) Lift engine assembly with transmission and transfer (4WD model) into engine compartment using jack.

NOTE:
^ Lift engine assembly, transmission, transfer (4WD model), front suspension frame, drive shafts (4WD model), radiator, P/S gear case and engine rear mounting member all together.
^ Before lifting engine assembly, make clearance by raising A/C compressor and A/C condenser in order to avoid damage to them.

6) Tighten engine rear mounting member bolts (2) to specified torque.
Tightening torque
Engine rear mounting member bolt (a): 55 Nm (5.6 kg-m, 40.5 lbf-ft)
7) Tighten front suspension frame bolts to specified torque.








8) Install steering lower shaft assembly to P/S gear case assembly.
9) Install tie-rod ends, front drive shafts (4WD model) and ball joints to steering knuckles.
10) Install stabilizer bar joints to stabilizer bar.
11) Install P/S fluid reservoir to vehicle body.
12) Install radiator with radiator support bracket and filler neck bracket to vehicle body.
13) Install A/C condenser assembly to radiator.
14) Install rear propeller shaft.
15) Install exhaust pipe No.2.
16) For 5 M/T model, install transmission shift control lever to transmission.
17) For 5 M/T model, connect clutch fluid hose and clutch fluid pipe joint.
18) For 4 A/T model, connect A/T select cable to A/T.
19) Install A/C compressor to engine assembly.
20) Install engine harness clamps.
21) Install all other removed electric wires, connectors and hoses to original locations.
22) Connect battery ground cable to vehicle body.
Tightening torque
Battery ground terminal bolt (a): 25 Nm (2.5 kg-m, 18.5 lbf-ft)





23) Install front bumper and radiator grille.
24) Install accessory drive belt.
25) Install air cleaner assembly and air cleaner outlet hose.
26) Install air cleaner suction pipe.
27) Make sure that all electric wires, connectors and hoses are installed at original locations.
28) Make sure that all removed components are installed at original locations.
29) Fill all drained oils and fluids.
^ Engine oil:
^ Manual transmission oil (5M/T model):
^ A/T fluid (4M/T model):
^ P/S fluid:
^ Transfer oil (4WD model):
^ Motor shift type:
^ Non-shift type:
^ Front differential oil (4WD model):
30) Install front tires.
31) Install engine cover.
32) Install battery tray and battery bracket.
33) Install battery.
34) Refill cooling system with coolant.
35) Check any leakage of coolant, oil, fuel and exhaust.
^ Fuel leak:
^ Coolant leak: