Removal and Installation

ENGINE ASSEMBLY


AWD : Removal and Installation


WARNING:
- Situate the 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.

CAUTION:
- Always be careful to work safely, avoid forceful or uninstructed operations.
- Never start working until exhaust system and engine coolant are cool enough.
- If items or work required are not covered by the engine section, refer to the applicable sections.
- Always use the support point specified for lifting.
- Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for unavoidable reasons, support at 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 Garage Jack and Safety Stand and 2-Pole Lift.

REMOVAL

Outline
At first, remove the engine, the transmission assembly, the transfer assembly and the front final drive assembly with front suspension member downward. Then separate the engine, the transmission assembly, the transfer and the front final drive assembly.

Preparation
1. Release fuel pressure. Refer to Testing and Inspection.
2. Disconnect both battery terminals. Refer to Exploded View.
3. Drain engine coolant from radiator. Refer to Draining.

CAUTION:
- Perform this step when engine is cold.
- Never spill engine coolant on drive belt.
4. Remove the following parts:
- Radiator reservoir tank: Refer to Exploded View.
- Engine cover: Refer to Exploded View.
- Front road wheel and tires (power tool)
- Engine undercover (power tool)
- Front cross bar: Refer to Exploded View.
- Cowl top cover: Refer to Exploded View.
- Air duct and air cleaner case assembly: Refer to Exploded View.
5. Discharge refrigerant from A/C circuit. Refer to Refrigerant.
6. Remove radiator hoses (upper and lower). Refer to Exploded View.

Engine Room LH
1. Disconnect heater hose from vehicle-side, and fit a plug onto hose end to prevent engine coolant leakage.
2. Disconnect A/C piping from A/C compressor, and temporarily fasten it on vehicle with a rope. Refer to Exploded View.
3. Disconnect brake booster vacuum hose.
4. Disconnect ground cables.

Engine Room RH
1. Disconnect battery positive cable vehicle side and temporarily fasten it on engine.
2. Disconnect all clips and connectors of the engine room harness from engine back side.
3. Disconnect fuel feed hose (with damper) and EVAP hose. Refer to Exploded View.

CAUTION:
Fit plugs onto disconnected hoses to prevent fuel leakage.
4. Remove reservoir tank of power steering oil pump and piping from vehicle, and temporarily secure them on engine.

CAUTION:
When temporarily securing, keep the reservoir tank upright to avoid a fluid leakage.

Vehicle Inside
Follow procedure below to disconnect engine room harness connectors at passenger room side, and temporarily secure them on engine.
1. Remove passenger-side kicking plate and dash side finisher. Refer to Exploded View.
2. Disconnect engine room harness connectors at unit sides and other.
3. Disengage intermediate fixing point. Pull out engine room harnesses to engine room side, and temporarily secure them on engine.

CAUTION:
- When pulling out harnesses, take care not to damage harnesses and connectors.
- After temporarily securing, cover connectors with vinyl or similar material to protect against foreign material adhesion.

Vehicle Underbody
1. Remove A/T fluid cooler hoses and power steering oil pump oil cooler hoses.
- Install plug to avoid leakage of A/T fluid and power steering fluid.
2. Disconnect heated oxygen sensor 2 harness. Refer to Exploded View.
3. Remove three way catalyst and exhaust front tube. Refer to Exploded View.
3. Remove three way catalyst and exhaust front tube. Refer to Exploded View.
4. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft. Refer to Exploded View or Exploded View Removal and Installation, "WITH ELECTRIC MOTOR :Exploded View".
5. Remove rear propeller shaft. Refer to Exploded View.
6. Remove front drive shaft (both side). Refer to Exploded View.
7. Disengage A/T control rod at control device assembly side. Then, temporarily secure it on the transmission assembly, so that it does not sag. Refer to Service and Repair.
8. Preparation for the separation work of transaxle is as per the following:
- Remove rear plate cover from oil pan (upper). Then remove bolts fixing drive plate to torque converter. Refer to Exploded View.
- Remove transmission joint bolts that pierce at oil pan (upper) lower rear side. Refer to Exploded View, "Exploded View".
9. Remove front stabilizer connecting rod from transverse link. Refer to Exploded View.
10. Remove lower ends of left and right steering knuckle from transverse link. Refer to Exploded View Removal and Installation Transverse Link, "Exploded View".
11. Separate steering outer sockets from steering knuckle. Refer to Exploded View.
12. Remove transverse links mounting bolts at suspension member side. Refer to Exploded View.

Removal Work
1. Use a manual lift table caddy (commercial service tool) or an equivalently rigid tool such as a transmission jack. Securely support bottom of suspension member and transmission.






CAUTION:
Put a piece of wood or something similar as the supporting surface, secure a completely stable condition.
2. Remove rear engine mounting member bolts.
3. Remove front suspension member mounting bolts and nuts. Refer to Exploded View.
4. Carefully lower jack, or raise lift to remove the engine, transmission, transfer and front final drive assembly and front suspension member. When performing work, observe the following caution:

CAUTION:
- Confirm there is no interference with the vehicle.
- Check that all connection points have been disconnected.
- Keep in mind the center of the vehicle gravity changes. If necessary, use jack(s) to support the vehicle at rear jacking point(s) to prevent it from falling it off the lift.

Separation Work
1. Install engine slingers into front of cylinder head (bank 1) and rear of cylinder head (bank 2).






Slinger bolts:
Tightening Torque: 28.0 Nm (2.9 kg-m, 21 ft-lb)






- To protect rocker cover against damage caused by tilting of engine slinger, insert spacer between cylinder head and engine rear lower slinger (3), in direction shown in the figure.

NOTE:
Spacer (2) is a component part of engine rear upper slinger assembly.
2. Remove power steering oil pump from engine side.
3. Remove engine mounting insulators (RH and LH) under side nuts with power tool.
4. Lift with hoist and separate the engine, the transmission assembly, the transfer assembly and the front final drive assembly from front suspension member.

CAUTION:
- Before and during this lifting, always check if any harnesses are left connected.
- Never damage to and oil/grease smearing or spills onto engine mounting insulator.
5. Remove alternator.
6. Remove starter motor.
7. Remove front propeller shaft from the front final drive assembly side.
8. Separate the engine from the transmission assembly. Refer to Exploded View.
9. Remove the front final drive assembly from oil pan (upper).
10. Remove each engine mounting insulator and each engine mounting bracket from the engine with power tool.

INSTALLATION
Note the following item, and install in the reverse order of removal.
- Do not allow engine mounting insulator to be damage and careful no engine oil gets on it.
- For a location with a positioning pin, insert it securely into hole of mating part.
- For a part with a specified installation orientation, refer to component figure in Exploded View.
- When installing engine mounting bracket (RH and LH) on cylinder block, tighten two upper bolts (B) first. Then tighten two lower bolts
(C).
- Install engine mounting bracket (RH) (lower) (2) as per the following:
- Temporarily tighten mounting bolts [shown as (D), (E) and (F) in the figure].
- Tighten mounting bolts to the specified torque with following mounting surfaces touched.





- Engine mounting bracket (RH) (1) to engine mounting bracket
(RH) (lower) [shown as and in figure].
- Front final drive to engine mounting bracket (RH) (lower) [shown as in figure].
- Check all engine mounting insulators are seated properly, then tighten mounting nuts.





- Tighten rear engine mounting member bolts in numerical order as shown in the figure.