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.
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 applicable procedures.
- 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 at 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 Garage Jack and Safety Stand.
REMOVAL
Preparation
1. Drain the engine coolant. Refer to Changing Engine Coolant.
2. Partially drain the A/T fluid. Refer to Changing The A/T Fluid (ATF).
3. Release the fuel pressure. Refer to Testing and Inspection.
4. Remove the engine hood. Refer to Removal and Installation.
5. Remove the cowl extension. Refer to Service and Repair.
6. Remove the engine room cover using power tools.
7. Remove the air duct and air cleaner case assembly. Refer to Removal and Installation.
8. Disconnect the vacuum hose between the vehicle and engine and set it aside.
9. Remove the radiator assembly and hoses. Refer to Removal and Installation.
10. Remove the drive belts. Refer to Removal and Installation.
11. Remove the fan blade. Refer to Removal and Installation.
12. Disconnect the engine room harness from the fuse box and set it aside.
13. Disconnect the ECM.
14. Disconnect the engine room harness from the engine side and set it aside.
15. Disconnect the engine harness grounds.
16. Disconnect the power steering reservoir tank from the engine and move it aside.
17. Disconnect the power steering oil pump from the engine. Move it aside and secure it using suitable wire or rope. Refer to Removal and Replacement
18. Remove the A/C compressor bolts and set the compressor aside. Refer to Service and Repair (ATC).
19. Disconnect the brake booster vacuum line.
20. Disconnect the EVAP line.
21. Disconnect the fuel hose at the engine side connection. Refer to Removal and Installation.
22. Disconnect the heater hoses at the cowl, and install plugs to avoid leakage of engine coolant.
23. Remove the A/T oil level indicator and indicator tube upper bolts.
24. Remove the front final drive assembly (4WD only). Refer to .
25. Remove the exhaust manifolds. Refer to Removal and Installation.
26. Install the engine slingers into the left bank cylinder head and right bank cylinder head.
Engine slinger torque: 45.0 Nm (4.6 kg-m, 33 ft-lb)
27. Remove the A/T. Refer to Transmission Assembly or Transmission Assembly.
28. Lift using a hoist and secure the engine in position.
29. Remove the engine assembly from the vehicle, avoid interference with the vehicle body.
CAUTION:
- Before and during lifting, always check if any harnesses are left connected.
30. Remove the parts that may restrict installation of the engine to the engine stand.
NOTE:
This procedure is described assuming that you use an engine stand mounting to the surface to which the transmission mounts.
a. Before removing the drive plate, put a match mark (A) on the crankshaft and drive plate for alignment during installation.
b. Lock the drive plate using Tool (A).
Tool number : - (J-47245)
CAUTION:
- Do not damage the ring gear teeth or the signal plate teeth behind the ring gear when setting Tool (A).
- Keep magnetic materials away from signal plate.
NOTE:
Remove the bolts diagonally.
c. Remove the drive plate.
CAUTION:
- Never place drive plate with signal plate facing down.
- When handling the signal plate, take care not to damage or scratch it.
- Handle the signal plate in a manner that prevents it from becoming magnetized.
CAUTION:
Use an engine stand that has a load capacity [approximately 240kg (529 lb) or more] large enough for supporting the engine weight.
- If the load capacity of the stand is not adequate, remove the following parts beforehand to reduce the potential risk of overturning the stand.
- Remove the fuel tube and fuel injector assembly. Refer to Removal and Installation.
- Remove the intake manifold. Refer to Removal and Installation.
- Remove the ignition coil. Refer to Removal and Installation.
- Remove the rocker cover. Refer to Removal and Installation.
- Other removable brackets.
CAUTION:
Before removing the hanging chains, make sure the engine stand is stable and there is no risk of overturning.
31. Remove the generator. Refer to Service and Repair.
32. Remove the engine mounting insulator and bracket using power tool.
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 re-assembly.
- Improper alignment caused by missing dowels may cause vibration, oil leaks or breakage of drivetrain components.
INSPECTION AFTER INSTALLATION
- Before starting the engine, check oil/fluid levels including engine coolant and engine oil. If the levels are lower than required quantity, fill to the specified level.
- Use procedure below to check for fuel leakage.
- Turn ignition switch ON (with engine stopped). With fuel pressure applied to the fuel piping, check for fuel leakage at the 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 the engine, again check oil/fluid levels including engine oil and engine coolant. Refill to specified level if necessary.
- Summary of the inspection items:
