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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.
- When lifting vehicle, ensure that the front and rear of the vehicle are well balanced.

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, follow the procedures in 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 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 [Lifting Point] Service and Repair.

NOTE:

When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spilling.

Removal

Preparation

1) Remove engine under cover, (if equipped). Refer to [Front Bumper: Removal and Installation] Service and Repair.
2) Drain engine oil. Refer to [Changing Engine Oil] Service and Repair.
3) Remove engine oil filter.
4) Drain engine coolant. Refer to [Changing Engine Coolant] Service and Repair.
5) Release fuel pressure. Refer to [Fuel Pressure Check: VQ40DE] Testing and Inspection.
6) Remove the engine hood. Refer to [Hood Assembly: Removal and Installation] Service and Repair.
7) Disconnect the battery negative terminal. Refer to [Battery: Removal and Installation] Removal and Replacement.
8) Remove engine room cover. Refer to [Engine Room Cover: Removal and Installation] Service and Repair.
9) Remove the air duct and resonator assembly and air cleaner case assembly. Refer to [Air Cleaner and Air Duct: Removal and Installation] Removal and Installation.
10) Disconnect brake booster vacuum hose between vehicle and engine and set it aside.
11) Remove front grille. Refer to [Front Grille: Removal and Installation] Service and Repair.
12) Remove the radiator assembly and hoses. Refer to [Radiator: Removal and Installation] Removal and Installation.
13) Remove the drive belts. Refer to [Drive Belts: Removal and Installation] Removal and Installation.
14) Remove the engine cooling fan and shroud. Refer to [Engine Cooling Fan: Removal and Installation (Crankshaft driven type)] Crankshaft Driven Type.
15) Disconnect the engine room harness from the engine side and set it aside.
16) Disconnect the engine harness grounds.
17) Reposition the reservoir tank for power steering from engine compartment and move it aside.
18) Disconnect power steering oil pump from engine. Move it from its location and secure with a rope. Refer to [Power Steering Oil Pump: Removal and Installation] Removal and Installation.
19) Remove the A/C compressor bolts and reposition the A/C compressor. Refer to [Compressor: Removal and Installation] Removal and Installation.
20) Disconnect EVAP line.
21) Disconnect the fuel hose at the engine side connection. Refer to [Fuel Injector and Fuel Tube: Removal and Installation [VQ40DE] Removal and Installation ].
22) Disconnect the heater hoses at cowl.
23) Remove the A/T oil level indicator and indicator tube.
24) Remove front final drive assembly (4WD models). Refer to [Front Final Drive Assembly: Removal and Installation] .
25) Remove three way catalyst. Refer to [Three Way Catalyst: Removal and Installation [VQ40DE] Catalytic Converter Removal and Installation ].
26) Install engine slingers into left bank and right bank.











27) Remove front frame crossmember.
28) Remove transmission. Refer to [Transmission Assembly: Removal and Installation from Vehicle (For 2WD Models)] Transmission Assembly Removal and Installation from Vehicle (For 2WD Models) (2WD M/T models), [Transmission Assembly: Removal and Installation from Vehicle (For 4WD Models)] Transmission Assembly Removal and Installation from Vehicle (For 4WD Models) (4WD M/T models), [Transmission Assembly: Removal and Installation for VQ40DE 2WD Models] Removal and Installation for VQ40DE 2WD Models (2WD A/T models), [Transmission Assembly: Removal and Installation for VQ40DE 4WD Models] Removal and Installation for VQ40DE 4WD Models (4WD A/T models).
29) Remove engine mounting insulator bracket (upper) with power tool.
30) Lift with hoist and secure the engine in position.
31) Remove engine mount bracket bolts.
32) Remove engine assembly from vehicle, avoiding interference with vehicle body.

CAUTION:
- Before and during this lifting, always check if any harnesses are left connected.

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 reassembly.
- 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. Refer to [Recommended Fluids and Lubricants [for USA and Canada] [1][2]Maintenance ] (United States and Canada). Refer to [Recommended Fluids and Lubricants [for Mexico] ] (Mexico).
- 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 and 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 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 oil/fluid levels including engine oil and engine coolant. Refill to specified level, if necessary.
- Summary of the inspection items:






*Power steering fluid, brake fluid, etc.

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