Engine: Service and Repair

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, refer to the applicable sections.
^ 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 engine coolant. Refer to "DRAINING ENGINE COOLANT".
2. Partially drain A/T fluid. Refer to "Changing the Automatic Transmission Fluid".
3. Release fuel pressure. Refer to "FUEL PRESSURE RELEASE".
4. Remove the engine hood. Refer to "Removal and Installation of Hood Assembly".
5. Remove engine room cover using power tools.
6. Remove the air duct and air cleaner case assembly.
7. Disconnect vacuum hose between vehicle and engine and set it aside.
8. Remove the radiator assembly and hoses.
9. Remove the drive belts.
10. Remove the engine cooling fan. Refer to "ENGINE COOLING FAN".
11. Disconnect the engine room harness from the engine side and set it aside for easier work.
12. Disconnect the engine harness grounds.
13. Disconnect the reservoir tank for power steering from engine and move it aside for easier work.
14. Disconnect power steering oil pump from engine. Move it from its location and secure with a rope for easier work.
15. Remove the A/C compressor bolts and set aside. Refer to "REMOVAL" (MTC).
16. Disconnect brake booster vacuum line.
17. Disconnect EVAP line.
18. Disconnect the fuel hose at the engine side connection.
19. Disconnect the heater hoses at cowl, and install plugs to avoid leakage of engine coolant.
20. Remove the A/T oil level indicator and indicator tube.
21. Remove front final drive assembly (4WD).
22. Remove three-way catalyst.





23. Install engine slingers into left bank and right bank.
Engine slinger torque: 28.0 Nm (2.9 kg-m, 21 ft. lbs.)
24. Remove transmission. Refer to "Removal and Installation (2WD)" or "Removal and Installation (4WD)".
25. Lift with hoist and secure the engine in position.
26. Remove engine assembly from vehicle, avoiding interference with vehicle body.

CAUTION: Before and during this lifting, always check if any harnesses are left connected.

27. Remove the parts that may restrict installation of engine to engine stand.

NOTE: The procedure is described assuming that you use a engine holding the surface, to which transmission is installed.

a. Remove drive plate.
^ Holding crankshaft pulley bolts, lock crankshaft to remove drive plate bolts.
^ Loosen bolts diagonally





CAUTION:
^ Be careful not to damage drive plate. Especially avoid deforming and damaging of signal plate teeth (circumference position).
^ Place the drive plate with signal plate surface facing other than downward.
^ Keep magnetic materials away from signal plate.

CAUTION: Use an engine stand that has a load capacity [approximately 240 kg (529 lbs.) 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 fuel tube and fuel injector assembly.
- Remove intake manifold.
- Remove rocker cover.
- Other removable brackets.

CAUTION: Before removing the hanging chains, make sure the engine stand is stable and there is no risk of overturning.

28. Remove alternator.
29. Remove engine mounting insulator bracket (upper) with power tool.

INSTALLATION
Installation is in the reverse order of removal.

INSPECTION AFTER INSTALLATION
^ Before starting engine, check the levels of engine coolant, engine oil and working fluid. If less 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 fuel piping, check for fuel leakage at 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.
^ Warm up engine thoroughly to make sure there is no leakage of engine coolant, engine oil, working fluid, fuel and exhaust gas.
^ Bleed air from passages in pipes and tubes of applicable lines, such as in cooling system.
^ After cooling down engine, again check amounts of engine coolant, engine oil and working fluid. Refill to specified level, if necessary.





^ Summary of the inspection items