Engine: Service and Repair

Engine Assembly Removal and Installation

Removal
1) Relieve fuel pressure.
2) Remove battery.
3) Disconnect ECM connectors.
4) Remove engine cover.

CAUTION:
When removing engine cover, be sure to lift up its front side to prevent breakage of engine cover claws.

5) Remove engine front under cover and engine rear under cover.
6) Drain engine oil.
7) Drain A/T fluid (5A/T model).
8) Drain front differential oil (4WD model).
9) Drain transfer oil (4WD model).
10) Drain coolant.
11) Drain P/S fluid. vie
12) Recover refrigerant from A/C system.
13) Remove air cleaner assembly and air cleaner suction pipe.
14) Disconnect suction hose and discharge hose from compressor.
15) Remove glove box (1) and instrument panel under cover (2).





16) Remove P/S reservoir tank (1) from bracket.
17) Remove fuse block (2) from bracket.
18) Remove engine wire harness clamps from vehicle body.
19) Disconnect the following electric wires and connectors.
^ Connector from relay box (3)
^ Ground terminal (4)
^ Radiator cooling fan connector (5)
^ Fuse block connector (6)
^ TCM connector (7)
^ 4WD Control Module connector (4WD model) (8)
^ Height sensor connector (9)




















20) Disconnect engine harness from cabin.
21) Disconnect the following hoses.
^ Brake booster hose (1)
^ Heater hoses (2)
^ Fuel feed hose (3)











22) Remove front bumper.
23) Remove liquid pipe (1) from condenser.





24) Disconnect steering lower shaft assembly from pinion shaft of P/S gear case assembly.
25) Remove exhaust center pipe and exhaust No.1 pipe.
26) Remove front propeller shaft (4WD model) and rear propeller shaft.
27) Remove front drive shaft.
28) Disconnect select cable from transmission range sensor and bracket (5A/T model).
29) Before removing engine with transmission, transfer, front suspension frame and engine rear mounting member from engine compartment, make sure all hoses, electric wires and cables from them are disconnected.
30) Support front suspension frame and engine rear mounting member using engine jack.
31) Remove front suspension frame mounting bolts and engine rear mounting member bolts.
32) Lower engine with transmission, transfer, front suspension frame and engine rear mounting member from engine compartment.
33) Remove engine harness from engine, transmission and transfer.
34) Disconnect high pressure hose and suction hose from P/S pump.
35) Disconnect transmission from engine (5A/T model).

NOTE:
Only when over hauling engine proceed to Step 36) - 43).

36) Using lifting device, support engine.
37) Remove intake manifold.
38) Remove exhaust manifold.
39) Remove starting motor.
40) Remove generator.
41) Remove P/S pump.
42) Remove A/C compressor.
43) Remove front suspension frame.

Installation
1) Using lifting device, support engine.
2) Install front suspension frame to engine.
3) Install A/C compressor.
4) Install P/S pump.
5) Install generator.
6) Install starting motor.
7) Install exhaust manifold.
8) Install intake manifold.
9) Connect transmission to engine (5A/T model).
10) Connect high pressure hose and suction hose to P/S pump.
11) Install engine harness to engine, transmission and transfer.
12) Lift engine with transmission, transfer, front suspension frame and engine rear mounting member into engine compartment.
13) Tighten front suspension frame bolt.
14) Remove engine jack.
15) Connect select cable to transmission range sensor and bracket (5A/T model).
16) Install front drive shaft.
17) Install front propeller shaft (4WD model) and rear propeller shaft.
18) Install exhaust center pipe and exhaust No.1 pipe.
19) Connect steering lower shaft assembly to pinion shaft of P/S gear case assembly.
20) Install liquid pipe (1) to condenser.
21) Install front bumper.
22) Connect suction hose and discharge hose to compressor.
23) Put back disconnected hoses, cables and electric wires for connection noting the following.
^ Tighten ground terminal bolts to specified torque.
Tightening torque
Ground terminal bolt (a): 11 Nm (1.1 kg-m, 8.5 lbf-ft)








24) Install glove box (1) and instrument panel under cover (2).





25) Install air cleaner assembly and air cleaner suction pipe.
26) Check to ensure that all removed parts are back in place.
27) Evacuate and charge the A/C system.
28) Refill P/S system.
29) Refill cooling system with coolant.
30) Refill transfer (4WD model).
31) Refill front differential (4WD model).
32) Refill A/T (5A/T model).
33) Refill engine with engine oil.
34) Install engine front under cover and engine rear under cover.
35) Install engine cover.
36) Connect ECM connectors.
37) Install battery.