Removal and Replacement
Engine Assembly Removal and Installation
Removal
1) Relieve fuel pressure. Service and Repair
2) Remove battery. Service and Repair
3) Remove battery tray (1) and battery bracket (2).
4) Remove engine cover.
5) Drain the following oils and fluids if necessary.
- Engine oil: Service and Repair
- Manual transmission oil (M/T model): Manual Transmission Oil Change
- A/T fluid (A/T model): Removal and Replacement
- P/S fluid: Removal and Replacement
- Transfer oil (4WD model):
- Motor shift type: Removal and Replacement
- Non-shift type: Removal and Replacement
- Front differential oil (4WD model): Front Differential Oil Change
6) Drain coolant. Draining
7) Remove air cleaner suction pipe. Air Cleaner Components
8) Remove air cleaner assembly and air cleaner outlet hose. Air Cleaner Assembly Removal and Installation
9) Remove accessory drive belt. Removal and Installation
10) Remove front bumper. Service and Repair
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. Removal and Installation
NOTE:
The A/C compressor may be damaged if it hits against or interferes with other parts.
Suspend the removed A/C compressor in a place where no damage will be caused during removal and installation of the engine assembly.
15) For M/T model, disconnect clutch fluid hose from clutch fluid pipe joint. Clutch Fluid Pipe Removal and Installation
16) For A/T model, disconnect A/T select cable from A/T. Service and Repair
17) For M/T model, remove transmission shift control lever from transmission. Transmission Shift Control Lever Removal and Installation
18) Remove exhaust pipe No.2. Exhaust System Components
19) Remove rear propeller shaft. Propeller Shaft Removal and Installation
20) With hose connected, remove A/C condenser assembly from radiator. A/C Condenser Assembly Removal and Installation
NOTE:
The A/C condenser may be damaged if it hits against or interferes with other parts.
Suspend the removed A/C condenser in a place where no damage will be caused during removal and installation of the 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. Front Suspension Frame, Stabilizer Bar and/or Bushing Components
24) Remove tie-rod ends, front drive shafts (4WD model) and ball joints from steering knuckles referring to Step 1) through 9) in "Removal" under Front Suspension Suspension Control Arm Removal and Installation
25) Remove steering lower shaft assembly from P/S gear case assembly. Steering Lower Shaft Assembly Removal and Installation
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:
The A/C compressor may be damaged if there is not adequate clearance when the engine is lowered.
Before lowering the engine, move the A/C compressor to vehicle body side to ensure that there is adequate clearance when the engine is lowered.
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.
31) Disconnect transmission if necessary.
- M/T model: Removal and Replacement
- A/T model: Removal and Replacement
32) For A/T model, remove oil cooler pipe if necessary. Oil Cooler Hose and Pipe Removal and Installation
33) Remove engine harness from engine assembly if necessary.
34) Remove engine mounting from engine front mounting bracket if necessary.
35) For M/T model, remove clutch cover and clutch disc if necessary. Clutch Cover, Clutch Disc and Flywheel Removal and Installation
36) For M/T model, remove flywheel if necessary. Flywheel / Drive Plate Removal and Installation
For A/T model, remove drive plate if necessary. Flywheel / Drive Plate Removal and Installation
Installation
1) For M/T model, install flywheel if removed. Flywheel / Drive Plate Removal and Installation
For A/T model, install drive plate if removed. Flywheel / Drive Plate Removal and Installation
2) For M/T model, install clutch cover and clutch disc if removed. Clutch Cover, Clutch Disc and Flywheel Removal and Installation
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 kgf-m, 8.5 lbf-ft)
Engine harness ground bolt (M8) (b): 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
4) Connect transmission to engine if removed.
- For M/T model: Removal and Replacement
- For A/T model: Removal and Replacement
5) Lift engine assembly with transmission and transfer (4WD model) into engine compartment using jack.
NOTE:
The A/C compressor may be damaged if there is not adequate clearance when the engine is raised.
Before raising the engine, move the A/C compressor to vehicle body side to ensure that there is adequate clearance when the engine is raised.
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.
6) Tighten engine rear mounting member bolts (2) to specified torque.
Tightening torque
Engine rear mounting member bolt (a): 55 Nm (5.6 kgf-m, 40.5 lbf-ft)
7) Tighten front suspension frame bolts to specified torque. Front Suspension Frame, Stabilizer Bar and/or Bushing Removal and Installation
8) Install steering lower shaft assembly to P/S gear case assembly. Steering Lower Shaft Assembly Removal and Installation
9) Install tie-rod ends, front drive shafts (4WD model) and ball joints to steering knuckles referring to "Removal" under Front Suspension Suspension Control Arm Removal and Installation
10) Install stabilizer bar joints to stabilizer bar. Front Suspension Frame, Stabilizer Bar and/or Bushing Components
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. A/C Condenser Assembly Removal and Installation
14) Install rear propeller shaft. Propeller Shaft Removal and Installation
15) Install exhaust pipe No.2. Exhaust System Components
16) For M/T model, install transmission shift control lever to transmission. Transmission Shift Control Lever Removal and Installation
17) For M/T model, connect clutch fluid hose and clutch fluid pipe joint. Clutch Fluid Pipe Removal and Installation
18) For A/T model, connect A/T select cable to A/T. Service and Repair
19) Install A/C compressor to engine assembly. Removal and Installation
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 kgf-m, 18.5 lbf-ft)
23) Install front bumper and radiator grille. Service and Repair
24) Install accessory drive belt. Removal and Installation
25) Install air cleaner assembly and air cleaner outlet hose. Air Cleaner Assembly Removal and Installation
26) Install air cleaner suction pipe. Air Cleaner Components
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: Service and Repair
- Manual transmission oil (M/T model): Manual Transmission Oil Change
- A/T fluid (A/T model): Removal and Replacement
- P/S fluid: Removal and Replacement
- Transfer oil (4WD model):
- Motor shift type: Removal and Replacement
- Non-shift type: Removal and Replacement
- Front differential oil (4WD model): Front Differential Oil Change
30) Install front tires.
31) Install engine cover.
32) Install battery tray and battery bracket.
33) Install battery. Service and Repair
34) Refill cooling system with coolant. Refilling
35) Check any leakage of coolant, oil, fuel and exhaust.
- Fuel leak: Fuel Leakage Check Procedure
- Coolant leak: Initial Inspection and Diagnostic Overview