Engine Assembly, Removal

ENGINE ASSEMBLY

COMPONENTS:

REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
2. REMOVE FRONT WHEELS
3. REMOVE ENGINE UNDER COVER ASSEMBLY
a. w/engine under cover assembly
4. REMOVE ENGINE UNDER COVER NO. 1
5. REMOVE ENGINE UNDER COVER NO. 2
a. w/engine under cover No. 2
6. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH
7. REMOVE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH
8. REMOVE FRONT FENDER APRON SEAL LH
9. REMOVE FRONT FENDER APRON SEAL RH
10. DRAIN ENGINE COOLANT
11. DRAIN ENGINE OIL
12. DRAIN AUTOMATIC TRANSAXLE FLUID
13. DRAIN TRANSFER OIL (for 4WD)
14. REMOVE FR WIPER ARM RH
15. REMOVE FR WIPER ARM LH
16. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
17. REMOVE WINDSHIELD WIPER LINK ASSEMBLY
18. REMOVE COWL TOP PANEL SUB-ASSEMBLY OUTER
19. REMOVE V-BANK COVER SUB-ASSEMBLY
20. REMOVE BATTERY
21. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
22. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
23. REMOVE AIR CLEANER INLET No. 2
24. REMOVE AIR CLEANER CASE
25. REMOVE AIR CLEANER BRACKET
26. REMOVE AIR CLEANER INLET NO. 1
27. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1
28. REMOVE GENERATOR ASSEMBLY
29. REMOVE ENGINE MOVING CONTROL ROD
30. REMOVE ENGINE MOUNTING STAY No. 2 RH
31. REMOVE GENERATOR BRACKET No. 2
32. REMOVE GENERATOR BELT ADJUSTING BAR
33. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH
34. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY
35. DISCONNECT UNION TO CHECK VALVE HOSE
36. DISCONNECT FUEL VAPOR FEED HOSE
37. DISCONNECT FUEL PIPE SUB-ASSEMBLY NO. 1
38. DISCONNECT HEATER INLET WATER HOSE
39. DISCONNECT HEATER OUTLET WATER HOSE
40. DISCONNECT RADIATOR HOSE INLET
41. DISCONNECT RADIATOR HOSE OUTLET
42. DISCONNECT OIL COOLER INLET TUBE NO. 1
43. DISCONNECT OIL COOLER OUTLET TUBE NO. 1

44. DISCONNECT OIL RESERVOIR TO PUMP HOSE NO. 1
a. Remove the clamp and disconnect the oil reservoir to pump hose No. 1.

45. DISCONNECT STEERING GEAR OUTLET RETURN TUBE
a. Remove the clamp and disconnect the steering gear outlet return tube.
46. REMOVE GLOVE COMPARTMENT DOOR ASSEMBLY

47. SEPARATE ENGINE WIRE
a. Disconnect the engine wire harness from the ECM and the junction block.
b. Disconnect the engine wire harness from the engine room junction block.
1 Remove the nut and separate the wire harness.
2 Using a screwdriver, release the engine room junction block. Separate the engine wire by pulling it up-ward.
c. Remove the 2 nuts and pull out the engine wire harness.
d. Remove the body ground.
48. REMOVE PROPELLER SHAFT (for 4WD)
SST 09325-20010
49. REMOVE EXHAUST PIPE SUB-ASSEMBLY FRONT NO. 3
50. REMOVE EXHAUST PIPE ASSEMBLY FRONT
51. REMOVE EXHAUST PIPE SUPPORT BRACKET NO. 1
52. REMOVE FRONT STABILIZER LINK ASSEMBLY LH
53. REMOVE FRONT STABILIZER LINK ASSEMBLY RH
54. REMOVE FRONT AXLE HUB LH NUT
SST 09930-00010
55. REMOVE FRONT AXLE HUB RH NUT
SST 09930-00010

HINT: Perform the same procedure as above on the opposite side.

56. SEPARATE SPEED SENSOR FRONT LH
57. SEPARATE SPEED SENSOR FRONT RH

HINT: Perform the same procedure as above on the opposite side.

58. SEPARATE TIE ROD END SUB-ASSEMBLY LH
SST 09628-62011
59. SEPARATE TIE ROD END SUB-ASSEMBLY RH
SST 09628-62011

HINT: Perform the same procedure as above on the opposite side.

60. SEPARATE FRONT SUSPENSION ARM SUBASSEMBLY LOWER NO. 1 LH
61. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 RH

HINT: Perform the same procedure as above on the opposite side.

62. SEPARATE FRONT AXLE ASSEMBLY LH
63. SEPARATE FRONT AXLE ASSEMBLY RH

HINT: Perform the same procedure as above on the opposite side.

64. SEPARATE STEERING INTERMEDIATE SHAFT SUBASSEMBLY

65. SEPARATE HEIGHT CONTROL SENSOR LINK SUB-ASSEMBLY FRONT
a. Remove the nut and separate the height control sensor link from the front frame (w/air suspension).
66. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
a. Set the engine lifter.

b. Remove the 6 bolts and 2 nuts, then remove the frame side rail plates RH and LH.

c. Remove the 6 bolts and 2 nuts, then remove the front suspension member brace rear RH and LH.
d. Carefully remove the engine assembly from the vehicle.

e. Install the No. 2 engine hanger in the correct direction (shown in the illustration).
Torque: 20 Nm (199 kgf-cm, 14 ft. lbs.)

HINT: Refer to the chart below for bolt usage.

f. Attach the engine sling and hang the engine assembly with the chain block.
67. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1
68. REMOVE MANIFOLD STAY
69. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
70. REMOVE VANE PUMP V BELT
71. REMOVE VANE PUMP ASSEMBLY

a. Remove the 3 nuts and disconnect the PS pressure tube.

b. Remove the 2 bolts and the vane pump.
72. REMOVE STABILIZER BAR FRONT (for 4WD)
73. REMOVE POWER STEERING LINK ASSEMBLY (for 4WD)
74. REMOVE FRONT FRAME ASSEMBLY

a. Remove the 2 nuts and separate the engine mounting insulators RH and LH.

b. Remove the nut and separate engine mounting insulator FR.

c. Remove the 2 bolts and separate the engine mounting insulator RR.
75. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
SST 09520-01010, 09520-24010 (09520-32040)
76. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for 2WD)
77. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD)
SST 09520-01010, 09520-24010 (09520-32040)
78. REMOVE STARTER ASSEMBLY
79. REMOVE ENGINE MOUNTING BRACKET FR
80. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD)
81. REMOVE TRANSFER STIFFENER PLATE RH (for 4WD)
82. REMOVE AUTOMATIC TRANSMISSION W/TRANSFER (for 4WD)
83. REMOVE ENGINE MOUNTING BRACKET RR
84. REMOVE DRIVE PLATE & RING GEAR SUB-ASSEMBLY
SST 09213-54015 (91651-60855), 09330-00021
85. INSTALL ENGINE STAND
86. REMOVE ENGINE HANGER No. 2
87. REMOVE EMISSION CONTROL VALVE SET
88. REMOVE INTAKE AIR SURGE TANK
89. REMOVE INTAKE MANIFOLD
90. REMOVE WATER OUTLET
91. REMOVE IGNITION COIL ASSEMBLY
92. REMOVE MANIFOLD CONVERTER INSULATOR NO. 3
93. REMOVE EXHAUST MANIFOLD HEAT INSULATOR No. 2
94. REMOVE MANIFOLD STAY No. 2
95. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY No. 2
96. REMOVE ENGINE MOUNTING BRACKET RH
97. REMOVE PUMP BRACKET
98. REMOVE GENERATOR BRACKET NO. 1
99. REMOVE COMPRESSOR MOUNTING BRACKET NO. 1
100. REMOVE WATER INLET PIPE
101. REMOVE WATER INLET
102. REMOVE WATER INLET
103. REMOVE THERMOSTAT

104. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
a. Using a deep socket wrench 24 mm, remove the oil pressure switch.
105. REMOVE KNOCK SENSOR
106. REPLACE PARTIAL ENGINE ASSEMBLY