Engine: Service and Repair
Engine Assembly Removal and InstallationRemoval
1. Relieve fuel pressure according to Fuel Pressure Relief Procedure.
2. Disconnect negative and positive cables at battery.
3. Disconnect ECM connectors.
4. Remove battery and battery tray with ECM.
5. Remove right and left side engine under covers.
6. Remove water pump and generator drive belt.
7. Drain engine oil.
8. Drain transaxle oil.
9. Drain transfer oil (4WD model).
10. Drain coolant.
11. Remove air cleaner assembly.
12. With hose connected, detach A/C compressor from its bracket.
CAUTION: Suspend removed A/C compressor at a place where no damage will be caused during removal and installation of engine assembly.
13. Remove condenser cooling fan from radiator.
14. Drain P/S fluid.
15. Disconnect P/S fluid reservoir hose (1) and then remove P/S fluid reservoir (2) from bracket.
16. Disconnect the following electric wires/connectors and each clamps.
^ Electric throttle body (1)
^ ECT sensor (2)
^ CMP sensor (3)
^ Ignition coil assembly (4)
^ Injector (5)
^ H02S (6)
^ A/F sensor (7)
^ Engine oil pressure switch (8)
^ CKP sensor (9)
^ Knock sensor (10)
^ Generator (11)
^ Starting motor (12)
^ Ground terminal (13) from cylinder block
^ Ground terminal (14) from exhaust manifold
^ Battery ground cable (15) from transaxle
^ Back-up light switch (16) (M/T model)
^ Torque sensor (17) (electric P/S model)
^ P/S motor (18) (electric P/S model)
^ P/S pump (19) (hydraulic P/S model)
^ Output shaft speed sensor (VSS) (20) (A/T model)
^ Solenoid valve (21) (A/T model)
^ Transmission range sensor (22) (A/T model)
^ Input shaft speed sensor (23) (A/T model)
^ IMT sensor (24)
17. Disconnect the following cables, and remove control cable bracket (25)
^ Gear select control cable (26) (M/T model)
^ Gear shift control cable (27) (M/T model)
^ A/T select cable with select cable bracket (28) (A/T model)
18. Disconnect the following hoses.
^ Brake booster hose (29) from intake manifold
^ Radiator inlet and outlet hoses from radiator
^ Heater inlet and outlet hoses (31) from heater core
^ Fuel feed hose (32) from fuel feed pipe
^ Purge hose (33) from purge valve
^ Clutch hose (30) from transaxle (M/T model)
^ A/T fluid cooler hoses (A/T model)
19. Disconnect right and left drive shaft joints from differential gear.
20. Remove exhaust center pipe.
21. Disconnect propeller shaft from transfer.
22. Disconnect steering lower shaft from pinion shaft.
23. Fix radiator to body with rope in order to avoid the radiator fall off when front lower cross member lowered.
24. Fix transaxle to suspension frame with rope in order to avoid the engine assembly inclines when engine assembly lowered.
25. Support front suspension frame and front lower cross member using jack at hatched parts (1) indicated in figure.
26. Remove engine right mounting (1), engine right mounting No.1 bracket (2) and engine left mounting bracket bolt and nuts(3).
27. Remove suspension frame mounting bolts (1) and front lower cross member bolts (2).
28. Lower engine with transaxle, front suspension frame, front lower cross member, transfer (4WD model) and steering gear case.
CAUTION: Before lowering engine, in order to avoid damage to A/C compressor, make clearance by rising it.
29. Disconnect steering gear case from suspension frame.
30. Disconnect transfer.
31. Disconnect transaxle from engine.
32. Remove clutch cover and clutch disk.
Installation
1. Install clutch cover and clutch disk.
2. Connect transaxle to engine.
3. Connect transfer to suspension frame.
4. Connect steering gear case to suspension frame.
5. Lift engine with transaxle, front suspension frame, front lower cross member, transfer (4WD model) and steering gear case into engine compartment with jack.
CAUTION: Before lifting engine, in order to avoid damage to A/C compressor, make clearance by rising it.
6. Tighten suspension frame mounting bolts and front lower cross member bolts, and then tighten bolts to specified torque.
Tightening torque
Suspension frame mounting bolt a: 150 Nm (15.0 kgf-m, 108.5 ft. lbs.)
Front lower cross member bolt b: 55 Nm (5.5 kgf-m, 40.0 ft. lbs.)
7. Install engine right mounting, engine right mounting No. 1 bracket and engine left mounting bracket, and then tighten bolts and nuts to specified torque.
8. Remove jack.
9. Connect steering lower shaft to pinion shaft.
10. Connect propeller shaft.
11. Install exhaust center pipe.
12. Connect right and left drive shaft joints to differential gear.
13. Reverse disconnected hoses, cables and electric wires for connection noting the following. Tighten bolts and nuts to specified torque.
Tightening torque
Starting motor terminal nut a: 11 Nm (1.1 kgf-m, 8.0 ft. lbs.)
Generator terminal nut b: 5 Nm (0.5 kgf-m, 4.0 ft. lbs.)
Battery ground bolt c: 25 Nm (2.5 kgf-m, 18.0 ft. lbs.)
Ground terminal bolt d: 11 Nm (1.1 kgf-m, 8.0 ft. lbs.)
14. Connect P/S fluid reservoir hose (1) and then install P/S fluid reservoir (2) to bracket.
15. Refill P/S fluid.
16. Install condenser cooling fan to radiator.
17. Install A/C compressor to its bracket (if removed).
18. Install air cleaner assembly.
19. Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
20. Refill coolant.
21. Refill transfer oil.
22. Refill transaxle oil.
23. Refill engine oil.
24. Install water pump and generator drive belt.
25. Install right and left side engine under covers.
26. Install battery and battery tray with ECM.
27. Connect ECM connectors.
28. Connect negative and positive cable at battery.
29. Verify that there is no fuel leakage, coolant leakage, oil leakage and exhaust gas leakage at each connection.