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.
- When lifting vehicle, ensure that the front and rear of the vehicle are well balanced.

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 procedures in 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 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".
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spilling.

REMOVAL

Preparation
1.Remove engine under cover. Service and Repair.
2.Drain engine oil. Removal and Replacement.
3.Remove engine oil filter.
4.Drain engine coolant. Service and Repair.
5.Release fuel pressure. Testing and Inspection.
6.Remove the engine hood. Service and Repair.
7.Disconnect the battery negative terminal. Removal and Replacement.
8.Remove engine room cover using power tool. Service and Repair.
9.Remove the air duct and resonator assembly and air cleaner case assembly. Removal And Installation.
10.Disconnect brake booster vacuum hose between vehicle and engine and set it aside.
11.Remove front grille. Service and Repair.
12.Remove the radiator assembly and hoses. Removal and Installation.
13.Remove the drive belts. Removal And Installation.
14.Remove the engine cooling fan and shroud. Removal and Installation (Crankshaft Driven Type).
15.Disconnect the engine room harness from the engine side and set it aside.
16.Disconnect the engine harness grounds.
17.Reposition the reservoir tank for power steering from engine compartment and move it aside.
18.Disconnect power steering oil pump from engine. Move it from its location and secure with a rope. Refer to
Removal And Installation.
19.Remove the A/C compressor bolts and reposition the A/C compressor. Service and Repair.
20.Disconnect EVAP line.
21.Disconnect the fuel hose at the engine side connection. Removal And Installation.
22.Disconnect the heater hoses at cowl.
23.Remove the A/T oil level indicator and indicator tube.
24.Remove front final drive assembly (4WD models). Front Final Drive R180A.
25.Remove three way catalyst. Removal And Installation.





26.Install engine slingers into left bank and right bank.
Engine slinger torque:28.0 Nm (2.9 kg-m, 21 ft-lb)
27.Remove front frame crossmember.
28.Remove transmission.
29.Remove engine mounting insulator bracket (upper) with power tool.
30.Lift with hoist and secure the engine in position.
31.Remove engine mount bracket bolts.
32.Remove engine assembly from vehicle, avoiding interference with vehicle body.

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

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 reassembly.
- Improper alignment caused by missing dowels may cause vibration, oil leaks or breakage of drivetrain components.

INSPECTION AFTER INSTALLATION

- Before starting engine, check oil/fluid levels including engine coolant and engine oil. 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.
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 engine, again check oil/fluid levels including engine oil and engine coolant. Refill to specified level, if necessary.
- Summary of the inspection items: