Partial Engine Assembly Replacement
REPLACEMENT1. PREVENT GASOLINE FROM SPILLING OUT
2. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (2WD TYPE)
3. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (4WD TYPE)
4. DRAIN ENGINE COOLANT
5. DRAIN ENGINE OIL
6. REMOVE BATTERY
7. REMOVE HOOD SUB-ASSEMBLY
a. Disconnect the windshield washer hose.
b. Separate the 2 hood supports.
c. Remove the 4 bolts and hood.
8. REMOVE V-BANK COVER
9. DISCONNECT VENTILATION HOSE NO.2
10. REMOVE AIR CLEANER ASSEMBLY
11. REMOVE RADIATOR SUPPORT SEAL UPPER
a. Remove the 11 clips and radiator support seal upper.
12. REMOVE RADIATOR ASSEMBLY
13. REMOVE FAN SHROUD
a. Unfasten the hose clamp, and disconnect the 2 oil cooler hoses from the fan shroud.
b. Remove the fan shroud.
14. LOOSEN FAN W/ FLUID COUPLING
15. REMOVE FAN AND GENERATOR V BELT
16. REMOVE FAN W/ FLUID COUPLING
a. Remove the 4 bolts and fan w/ fluid coupling.
17. REMOVE FAN PULLEY
18. SEPARATE VANE PUMP ASSEMBLY
19. REMOVE GENERATOR ASSEMBLY
20. SEPARATE COOLER COMPRESSOR ASSEMBLY
21. DISCONNECT FUEL PIPE SUB-ASSEMBLY NO.1
22. DISCONNECT FUEL PIPE SUB-ASSEMBLY NO.2
23. DISCONNECT HEATER WATER INLET HOSE B
24. DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
25. REMOVE INTAKE AIR SURGE TANK
26. SEPARATE ENGINE WIRE
a. Remove the front door scuff plate RH.
b. Remove the cowl side trim board RH.
c. Remove the glove compartment door.
d. Disconnect each connector for the ECM, four wheel drive control ECU (4WD only) and instrument panel wire before pulling out the engine wire into the engine room.
e. Disconnect the front differential connector.
27. SEPARATE ENGINE WIRE NO.2
a. Disconnect the ground cable from the cylinder block.
28. REMOVE ENGINE ASSEMBLY
a. Install the 2 engine hangers with the 4 bolts as shown in the illustration.
Part No.:
Engine hanger No. 1 12281-31070
Engine hanger No. 2 12282-31050
Bolt 91671-10825
Torque: 33 Nm (336 kgf-cm, 24 ft. lbs.)
b. Attach the engine sling device and hang the engine with the chain block.
c. Remove the 4 bolts and 4 nuts, and separate the engine mounting brackets from the frame brackets.
d. Lift the engine out of the vehicle carefully.
NOTICE: Make sure the engine is clear of all wiring and hoses.
e. Place the engine onto a working bench.
29. REMOVE DRIVE PLATE & RING GEAR SUB-ASSEMBLY
30. REMOVE ENGINE WIRE
31. REMOVE RADIATOR HOSE NO.1
32. REMOVE RADIATOR OUTLET, NO.2 HOSE CLAMP OR CLIP
33. REMOVE HEATER WATER INLET HOSE A
34. REMOVE HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
35. REMOVE VENTILATION HOSE
36. REMOVE VENTILATION HOSE NO.2
37. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Remove the 6 nuts, exhaust manifold and gasket.
38. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
a. Remove the 6 nuts, exhaust manifold and gasket.
39. REMOVE ENGINE MOUNTING BRACKET FRONT NO.1 RH
a. Remove the 4 bolts and engine mounting bracket w/ engine mounting insulator.
40. REMOVE ENGINE MOUNTING BRACKET FRONT NO.1 LH
a. Remove the 3 bolts and engine mounting bracket w/ engine mounting insulator.
41. REMOVE IDLER PULLEY SUB-ASSEMBLY NO.2
a. Remove the 2 bolts and 2 idler pulleys.
42. REMOVE IDLER PULLEY SUB-ASSEMBLY NO.1
a. Remove the bolt and idler pulley.
43. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
44. REMOVE WATER INLET
45. REMOVE BRACKET, OIL FILTER
a. Remove the 3 bolts, 2 nuts, oil filter bracket and gasket.
46. REMOVE INTAKE MANIFOLD
47. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
a. Remove the 2 bolts and 2 camshaft timing oil control valves.
48. REMOVE WATER BY-PASS JOINT RR
49. REMOVE OIL FILLER CAP SUB-ASSEMBLY
50. REMOVE OIL FILLER CAP HOUSING
a. Remove the 2 nuts, oil filler cap housing and gasket.
51. REMOVE IGNITION COIL ASSEMBLY
52. REMOVE SPARK PLUG
53. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY
54. REPLACE PARTIAL ENGINE ASSEMBLY
55. INSPECT INTAKE MANIFOLD FOR FLATNESS
a. Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder head and intake air surge tank.
Maximum warpage:
Intake air surge tank side: 0.8 mm (0.031 inch)
Cylinder head side: 0.2 mm (0.008 inch)
If warpage is greater than the maximum, replace the intake manifold.
56. INSPECT EXHAUST MANIFOLD FOR FLATNESS
a. Using a precision straight edge and feeler gauge, measure the warpage of the contact surface of the cylinder head.
Maximum warpage: 0.7 mm (0.028 inch)
If warpage is greater than the maximum, replace the exhaust manifold.
HINT: Maximum warpage of each installation surface: 0.3 mm (0.012 inch)
57. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY
58. INSTALL SPARK PLUG
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
59. INSTALL IGNITION COIL ASSEMBLY
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
60. INSTALL OIL FILLER CAP HOUSING
a. Install a new gasket and oil filler cap housing with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
61. INSTALL OIL FILLER CAP SUB-ASSEMBLY
62. INSTALL WATER BY-PASS JOINT RR
63. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
a. Insert the camshaft timing oil control valves to each cylinder head, and tighten the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
64. INSTALL INTAKE MANIFOLD
65. INSTALL BRACKET, OIL FILTER
a. Install a new gasket and oil filter bracket with the 3 bolts and 2 nuts.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
66. INSTALL WATER INLET
67. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
68. INSTALL IDLER PULLEY SUB-ASSEMBLY NO.1
69. INSTALL IDLER PULLEY SUB-ASSEMBLY NO.2
70. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 LH
a. Install the engine mounting bracket w/ engine mounting insulator with the 3 bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
71. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 RH
a. Install the engine mounting bracket w/ engine mounting insulator with the 4 bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
72. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
73. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
74. INSTALL VENTILATION HOSE NO.2
75. INSTALL VENTILATION HOSE
76. INSTALL HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
77. INSTALL HEATER WATER INLET HOSE A
78. INSTALL RADIATOR OUTLET, NO.2 HOSE CLAMP OR CLIP
79. INSTALL RADIATOR HOSE NO.1
80. INSTALL ENGINE WIRE
81. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY
82. INSTALL ENGINE ASSEMBLY
a. Attach the engine sling device and hang the engine with the chain block.
b. Lower the engine into the engine room carefully.
c. Attach the engine mounting brackets to the frame brackets.
d. Install the engine mounting brackets to the frame brackets with the 4 bolts and 4 nuts.
Torque: 38 Nm (387 kgf-cm, 28 ft. lbs.)
e. Remove the 4 bolts and 2 engine hangers.
83. INSTALL ENGINE WIRE NO.2
a. Install the ground cable to the cylinder block.
Torque: 13 Nm (133 kgf-cm, 9 ft. lbs.)
84. INSTALL ENGINE WIRE
a. Connect the front differential connector.
b. Insert the engine wire to the cabin space, and install the grommet.
c. Connect each connector for the ECM, four wheel drive control ECU (4WD only) and instrument panel wire.
d. Install the glove compartment door.
e. Install the cowl side trim board RH.
f. Install the front door scuff plate RH.
85. INSTALL INTAKE AIR SURGE TANK
86. CONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
87. CONNECT HEATER WATER INLET HOSE B
88. CONNECT FUEL PIPE SUB-ASSEMBLY NO.2
89. CONNECT FUEL PIPE SUB-ASSEMBLY NO.1
90. INSTALL COOLER COMPRESSOR ASSEMBLY
91. INSTALL GENERATOR ASSEMBLY
92. INSTALL VANE PUMP ASSEMBLY
93. INSTALL FAN PULLEY
94. INSTALL FAN W/ FLUID COUPLING
a. Temporarily install the fan w/ fluid coupling with the 4 nuts.
95. INSTALL FAN AND GENERATOR V BELT
96. FULLY TIGHTEN FAN W/ FLUID COUPLING
97. INSTALL FAN SHROUD
a. Put the fan shroud into the engine room.
b. Connect the 2 oil cooler hoses with the hose clamp.
98. INSTALL RADIATOR ASSEMBLY
99. INSTALL RADIATOR SUPPORT SEAL UPPER
100. INSTALL AIR CLEANER ASSEMBLY
101. CONNECT VENTILATION HOSE NO.2
102. INSTALL HOOD SUB-ASSEMBLY
a. Install the hood with the 4 bolts.
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
b. Tighten the 2 hood supports.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
c. Connect the windshield washer hose.
103. ADJUST HOOD SUB-ASSEMBLY
104. INSTALL BATTERY
105. ADD ENGINE OIL
106. ADD ENGINE COOLANT
107. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (2WD TYPE)
108. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (4WD TYPE)
109. CHECK FOR ENGINE COOLANT LEAKS
110. CHECK FOR FUEL LEAKS
111. CHECK FOR ENGINE OIL LEAKS
112. INSTALL V-BANK COVER
a. Install the V-bank cover with the 2 nuts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
113. INSPECT IGNITION TIMING
SST 09843-18040
114. INSPECT ENGINE IDLE SPEED
SST 09843-18030
115. INSPECT CO/HC