Part 1

ENGINE ASSEMBLY

COMPONENTS:

REMOVAL (STEPS 1-55)

1. REMOVE COOL AIR INTAKE DUCT SEAL
a. Remove the 11 clips and intake duct seal.

2. REMOVE ENGINE ROOM SIDE COVER LH
a. Remove the 5 clips and side cover.

3. REMOVE ENGINE ROOM SIDE COVER RH
a. Remove the 2 clips and side cover.

4. REMOVE V-BANK COVER SUB-ASSEMBLY
a. Raise the V-bank cover to disengage the clip on the rear of the cover. Raise the cover again to disengage the 2 clips on the front of the cover and remove the cover.

NOTICE: Attempting to disengage both front and rear clips at the same time may cause the cover to break.

5. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM
6. DISCHARGE FUEL SYSTEM PRESSURE
7. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
8. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
9. REMOVE FRONT WHEEL
10. REMOVE ENGINE UNDER COVER
11. REMOVE NO. 2 ENGINE UNDER COVER (for 2WD)

12. REMOVE ENGINE UNDER COVER REAR LH (for 2WD)
a. Remove the bolt and engine under cover LH.
13. REMOVE ENGINE UNDER COVER REAR RH (for 2WD)

HINT: Remove the RH side following the same procedures as with the LH side.

14. DRAIN ENGINE OIL
15. DRAIN ENGINE COOLANT
16. DRAIN FRONT DIFFERENTIAL OIL (for 4WD)
17. REMOVE FRONT EXHAUST PIPE ASSEMBLY
18. REMOVE PROPELLER SHAFT ASSEMBLY WITH CENTER BEARING

19. REMOVE NO. 1 INLET AIR CLEANER
a. Remove the bolt, clip and inlet air cleaner.
20. REMOVE AIR CLEANER CAP WITH AIR CLEANER HOSE

21. REMOVE AIR CLEANER CASE SUB-ASSEMBLY
a. Remove the 2 bolts, clamp and air cleaner case.
22. DISCONNECT UNION TO CHECK VALVE HOSE
a. Remove the clamp and disconnect the union to check valve hose.

23. DISCONNECT NO. 2 FUEL VAPOR FEED HOSE
a. Remove the clamp and disconnect the No. 2 fuel vapor feed hose.

24. DISCONNECT INLET RADIATOR HOSE
a. Remove the clamp and disconnect the inlet radiator hose.
25. DISCONNECT OUTLET RADIATOR HOSE
a. Remove the clamp and disconnect the outlet radiator hose.
26. DISCONNECT RADIATOR RESERVOIR TANK HOSE
a. Remove the clamp and disconnect the radiator reservoir tank hose.

27. DISCONNECT INLET HEATER WATER HOSE
a. Disconnect the inlet heater water hose.

28. DISCONNECT OUTLET HEATER WATER HOSE
a. Disconnect the outlet heater water hose.
29. REMOVE NO. 1 COOLER REFRIGERANT SUCTION HOSE
30. REMOVE DISCHARGE HOSE SUB-ASSEMBLY
31. REMOVE ECM COVER
32. DISCONNECT ENGINE WIRE
a. Disconnect the 6 ECM connectors.

b. Using a screwdriver, disconnect the connector holder.
c. Remove the engine room No. 1 relay block cover.

d. Remove the nut and disconnect the wire from the engine room No. 1 junction block.
e. Remove the nut and disconnect the battery positive (+) cable.
f. Disconnect the connector and remove the 4 clamps from body

g. Remove the bolt, clamp and engine wire No. 3.
h. Remove the bolt and disconnect the ground cable.
33. DISCONNECT FUEL MAIN TUBE

34. DISCONNECT NO. 3 FUEL HOSE
a. Remove the clamp and disconnect the No. 3 fuel hose.

35. REMOVE FRONT LOWER SUSPENSION MEMBER PROTECTOR (for 2WD)
a. Remove the 4 bolts and suspension member protector.
36. DISCONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY (for 2WD)
37. DISCONNECT NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (for 4WD)
38. SEPARATE FRONT SPEED SENSOR LH (for 4WD)
39. SEPARATE FRONT SPEED SENSOR RH (for 4WD)

HINT: Remove the RH side following the same procedures as with the LH side.

40. REMOVE FRONT AXLE HUB LH NUT (for 4WD)
41. REMOVE FRONT AXLE HUB RH NUT (for 4WD)

HINT: Remove the RH side following the same procedures as with the LH side.

42. REMOVE TIE ROD ASSEMBLY LH (for 4WD)
43. REMOVE TIE ROD ASSEMBLY RH (for 4WD)

HINT: Remove the RH side following the same procedures as with the LH side.

44. DISCONNECT HEIGHT CONTROL SENSOR LINK (for 2WD)
a. Remove the nut and disconnect the height control sensor link.

45. DISCONNECT HEIGHT CONTROL SENSOR LINK (for 4WD)
a. Remove the bolt and disconnect the height control sensor link.

46. REMOVE FRONT SHOCK ABSORBER ASSEMBLY LH (for 2WD)
a. Loosen the bolt while holding the nut. Separate the lower part of the front shock absorber from the front suspension lower arm.
47. REMOVE FRONT SHOCK ABSORBER ASSEMBLY RH (for 2WD)

HINT: Remove the RH side following the same procedures as for the LH side.

48. REMOVE FRONT SHOCK ABSORBER ASSEMBLY LH (for 4WD)
a. Loosen the bolt and separate the lower part of the front shock absorber from the front absorber bracket lower.
49. REMOVE FRONT SHOCK ABSORBER ASSEMBLY RH (for 4WD)

HINT: Remove the RH side following the same procedures as for the LH side.

50. REMOVE FRONT LOWER BALL JOINT ASSEMBLY LH (for 2WD)
a. Remove the 2 bolts from the front lower ball joint.
51. REMOVE FRONT LOWER BALL JOINT ASSEMBLY RH (for 2WD)

HINT: Remove the RH side following the same procedures as for the LH side.

52. REMOVE FRONT LOWER BALL JOINT ASSEMBLY LH (for 4WD)
a. Remove the 2 bolts from the front lower ball joint.
53. REMOVE FRONT LOWER BALL JOINT ASSEMBLY RH (for 4WD)

HINT: Remove the RH side following the same procedures as for the LH side.

54. SEPARATE FRONT AXLE ASSEMBLY LH (for 4WD)
55. SEPARATE FRONT AXLE ASSEMBLY RH (for 4WD)

HINT: Remove the RH side following the same procedures as with the LH side.