Partial Engine Assembly Replacement
PARTIAL ENGINE ASSEMBLY
REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE
2. REMOVE FRONT WHEELS
3. REMOVE ENGINE UNDER COVER NO.1
4. REMOVE FRONT FENDER LINER LH
5. REMOVE FRONT FENDER LINER RH
6. REMOVE FRONT FENDER APRON SEAL LH
7. REMOVE FRONT FENDER APRON SEAL RH
8. DRAIN COOLANT
9. DRAIN ENGINE OIL
10. DRAIN AUTOMATIC TRANSAXLE FLUID
11. DRAIN TRANSFER OIL (4WD DRIVE TYPE)
12. REMOVE FRONT WIPER ARM HEAD CAP
13. REMOVE FR WIPER ARM RH
14. REMOVE FR WIPER ARM LH
15. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
16. REMOVE WIPER LINK ASSEMBLY
17. REMOVE COWL TOP TO COWL BRACE INNER NO.1
18. REMOVE COWL TOP PANEL SUB-ASSEMBLY OUTER FRONT
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 NO.1
37. DISCONNECT FUEL PIPE SUB-ASSEMBLY NO.1
38. DISCONNECT HEATER WATER INLET HOSE B
39. DISCONNECT HEATER WATER OUTLET HOSE B
40. DISCONNECT RADIATOR HOSE INLET
41. DISCONNECT RADIATOR HOSE OUTLET
42. DISCONNECT OIL COOLER INLET HOSE NO.1
43. DISCONNECT OIL COOLER OUTLET HOSE NO.1
44. DISCONNECT OIL RESERVOIR TO PUMP HOSE NO.1
45. DISCONNECT 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 upward.
c. Pull out the engine wire harness.
d. Remove the body ground.
48. REMOVE PROPELLER SHAFT (4WD DRIVE TYPE)
SST 09325-20010
49. REMOVE EXHAUST PIPE ASSEMBLY CENTER (4WD DRIVE TYPE)
50. REMOVE EXHAUST PIPE ASSEMBLY FRONT (2WD DRIVE TYPE)
51. REMOVE EXHAUST PIPE ASSEMBLY FRONT (4WD DRIVE TYPE)
52. SEPARATE FRONT STABILIZER LINK ASSEMBLY LH
53. SEPARATE FRONT STABILIZER LINK ASSEMBLY RH
HINT: Perform the same procedure as above on the opposite side.
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 ASSEMBLY LH
SST 09628-62011
59. SEPARATE TIE ROD ASSEMBLY RH
SST 09628-62011
HINT: Perform the same procedure as above on the opposite side.
60. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY 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 ASSEMBLY
65. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
a. Set the engine lifter.
b. Remove the 6 bolts, the 2 nuts, the frame side rail plate RH and LH.
c. Remove the 6 bolts, the 2 nuts, 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 correct direction (shown in the illustration).
Part No.:
No. 2 engine hanger 12282-20020
Bolt 90080-11331
Torque: 20 Nm (199 kgf-cm, 14 ft. lbs.)
f. Attach the engine sling and hang the engine assembly with the chain block.
66. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1
67. REMOVE MANIFOLD STAY
68. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH (2WD DRIVE TYPE)
69. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (4WD DRIVE TYPE)
70. REMOVE VANE PUMP V BELT
71. REMOVE VANE PUMP ASSEMBLY
a. Remove the 2 nuts and disconnect the PS pressure tube.
b. Remove the 2 bolts and the vane pump.
72. REMOVE STABILIZER BAR FRONT (4WD DRIVE TYPE)
73. REMOVE RACK & PINION POWER STEERING GEAR ASSEMBLY (4WD DRIVE TYPE)
74. REMOVE FRONT FRAME ASSEMBLY
a. Remove the 2 nuts and separate engine mounting insulator RH and LH.
b. Remove the nut and separate the engine mounting insulator FR.
c. 4WD:
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 (2WD DRIVE TYPE)
77. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (4WD DRIVE TYPE)
78. REMOVE STARTER ASSEMBLY
79. REMOVE ENGINE MOUNTING BRACKET FR
80. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (2WD DRIVE TYPE)
81. REMOVE TRANSFER STIFFENER PLATE RH (4WD DRIVE TYPE)
82. REMOVE AUTOMATIC TRANSMISSION W/TRANSFER (4WD DRIVE TYPE)
83. REMOVE DRIVE SHAFT BEARING BRACKET (2WD DRIVE TYPE)
84. REMOVE ENGINE MOUNTING BRACKET RR (4WD DRIVE TYPE)
85. REMOVE DRIVE PLATE & RING GEAR SUB-ASSEMBLY
SST 09213-54015 (91651-60855), 09330-00021
86. INSTALL ENGINE STAND
87. REMOVE ENGINE HANGER NO.2
88. REMOVE EMISSION CONTROL VALVE SET
89. REMOVE INTAKE AIR SURGE TANK
90. REMOVE INTAKE MANIFOLD
91. REMOVE WATER OUTLET
92. REMOVE IGNITION COIL ASSEMBLY
93. REMOVE MANIFOLD CONVERTER INSULATOR NO.3
94. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2
95. REMOVE MANIFOLD STAY NO.2
96. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO.2
97. REMOVE ENGINE MOUNTING BRACKET RH
98. REMOVE PUMP BRACKET
99. REMOVE GENERATOR BRACKET NO.1
100. REMOVE COMPRESSOR MOUNTING BRACKET NO.1
101. REMOVE WATER INLET
102. REMOVE THERMOSTAT
103. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
a. Using a 27 mm deep socket wrench, remove the oil pressure switch.
104. REMOVE KNOCK SENSOR
105. REPLACE PARTIAL ENGINE ASSEMBLY
106. INSTALL KNOCK SENSOR
107. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
a. Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833-00080 THREE BOND 1344,
LOCTITE 242 or equivalent.
b. Using a 27 mm deep socket wrench, install the oil pressure switch.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
108. INSTALL THERMOSTAT
109. INSTALL WATER INLET
110. INSTALL COMPRESSOR MOUNTING BRACKET NO.1
111. INSTALL GENERATOR BRACKET NO.1
Torque: 58 Nm (591 kgf-cm, 43 ft. lbs.)
112. INSTALL PUMP BRACKET
Torque: 32 Nm (326 kgf-cm, 24 ft. lbs.)
113. INSTALL ENGINE MOUNTING BRACKET RH
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)
114. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO.2
115. INSTALL MANIFOLD STAY NO.2
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
116. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2
117. INSTALL MANIFOLD CONVERTER INSULATOR NO.3
118. INSTALL IGNITION COIL ASSEMBLY
119. INSTALL WATER OUTLET
120. INSTALL INTAKE MANIFOLD
121. INSTALL INTAKE AIR SURGE TANK
122. INSTALL EMISSION CONTROL VALVE SET
123. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY
SST 09213-54015 (91651-60855), 09330-00021
124. INSTALL DRIVE SHAFT BEARING BRACKET (2WD DRIVE TYPE)
Torque: 64 Nm (650 kgf-cm, 47 inch lbs.)
125. INSTALL ENGINE MOUNTING BRACKET RR (4WD DRIVE TYPE)
Torque: 64 Nm (653 kgf-cm, 47 inch lbs.)
126. INSTALL AUTOMATIC TRANSMISSION W/TRANSFER (4WD DRIVE TYPE)
127. INSTALL TRANSFER STIFFENER PLATE RH (4WD DRIVE TYPE)
128. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (2WD DRIVE TYPE)
129. INSTALL ENGINE MOUNTING BRACKET FR
130. INSTALL STARTER ASSEMBLY
131. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
132. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (2WD DRIVE TYPE)
133. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (4WD DRIVE TYPE)
134. INSTALL FRONT FRAME ASSEMBLY
a. Install the engine mounting insulator RH and LH with the 2 nuts.
Torque: 95 Nm (969 kgf-cm, 70 ft. lbs.)
b. Install the engine mounting insulator FR with the nut.
Torque: 87 Nm (887 kgf-cm, 64 ft. lbs.)
c. 4WD: Install the engine mounting insulator RR with the 2 bolts.
Torque: 75 Nm (765 kgf-cm, 55 ft. lbs.)
135. INSTALL RACK & PINION POWER STEERING GEAR ASSEMBLY (4WD DRIVE TYPE)
Torque: 70 Nm (714 kgf-cm, 52 ft. lbs.)
136. INSTALL STABILIZER BAR FRONT (4WD DRIVE TYPE)
Torque: 17 Nm (173 kgf-cm, 13 ft. lbs.)
137. INSTALL VANE PUMP ASSEMBLY
a. Temporarily tighten the bolt.
b. Install the adjusting strut to the engine mounting bracket RH with the bolt.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)
c. Connect the PS pressure tube with the 2 nuts.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)
138. INSTALL VANE PUMP V BELT
139. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH (2WD DRIVE TYPE)
140. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (4WD DRIVE TYPE)
141. INSTALL MANIFOLD STAY
142. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
143. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
a. Set the engine assembly with transaxle on the engine lifter.
b. Install the engine assembly to the vehicle.
c. Install the frame side rail plate RH and LH with the 6 bolts and the 2 nuts.
Torque:
Bolt A 85 Nm (867 kgf-cm, 63 ft. lbs.)
Bolt B 32 Nm (329 kgf-cm, 24 ft. lbs.)
Nut C 32 Nm (329 kgf-cm, 24 ft. lbs.)
d. Install the front suspension member brace rear RH and LH with the 6 bolts and the 2 nuts.
Torque:
Bolt A 85 Nm (867 kgf-cm, 63 ft. lbs.)
Bolt B 32 Nm (329 kgf-cm, 24 ft. lbs.)
Nut C 32 Nm (329 kgf-cm, 24 ft. lbs.)
144. INSTALL STEERING INTERMEDIATE SHAFT ASSEMBLY
145. INSTALL FRONT AXLE ASSEMBLY LH
146. INSTALL FRONT AXLE ASSEMBLY RH
HINT: Perform the same procedure as above on the opposite side.
147. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 LH
148. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH
HINT: Perform the same procedure as above on the opposite side.
149. INSTALL TIE ROD ASSEMBLY LH
150. INSTALL TIE ROD ASSEMBLY RH
HINT: Perform the same procedure as above on the opposite side.
151. INSTALL SPEED SENSOR FRONT LH
152. INSTALL SPEED SENSOR FRONT RH
HINT: Perform the same procedure as above on the opposite side.
153. INSTALL FRONT AXLE HUB LH NUT
154. INSTALL FRONT AXLE HUB RH NUT
HINT: Perform the same procedure as above on the opposite side.
155. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
156. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT: Perform the same procedure as above on the opposite side.
157. INSTALL EXHAUST PIPE ASSEMBLY FRONT (2WD DRIVE TYPE)
158. INSTALL EXHAUST PIPE ASSEMBLY FRONT (4WD DRIVE TYPE)
159. INSTALL EXHAUST PIPE ASSEMBLY CENTER (4WD DRIVE TYPE)
160. INSTALL PROPELLER SHAFT (4WD DRIVE TYPE)
161. CONNECT FUEL PIPE SUB-ASSEMBLY NO.1
162. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY
163. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
164. INSTALL GENERATOR BELT ADJUSTING BAR
165. INSTALL GENERATOR BRACKET NO.2
166. INSTALL ENGINE MOUNTING STAY NO.2 RH
167. INSTALL ENGINE MOVING CONTROL ROD
168. INSTALL GENERATOR ASSEMBLY
169. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
170. INSPECT DRIVE BELT DEFLECTION AND TENSION (REFERENCE)
171. INSTALL AIR CLEANER INLET NO.1
172. INSTALL AIR CLEANER BRACKET
173. INSTALL AIR CLEANER CASE
174. INSTALL AIR CLEANER INLET NO.2
175. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
176. CONNECT VACUUM HOSE
177. INSTALL V-BANK COVER SUB-ASSEMBLY
178. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER FRONT
179. INSTALL COWL TOP TO COWL BRACE INNER NO.1
180. INSTALL WIPER LINK ASSEMBLY
181. INSTALL FR WIPER ARM LH
182. INSTALL FR WIPER ARM RH
183. INSTALL FRONT WHEELS
184. ADD TRANSFER OIL (4WD DRIVE TYPE)
185. INSPECT TRANSFER OIL (4WD DRIVE TYPE)
186. ADD AUTOMATIC TRANSAXLE FLUID
187. ADD ENGINE OIL
188. ADD COOLANT
189. ADD POWER STEERING FLUID
190. BLEED POWER STEERING FLUID
191. INSPECT AUTOMATIC TRANSAXLE FLUID
192. CHECK FOR ENGINE OIL LEAKS
193. CHECK FOR ENGINE COOLANT LEAKS
194. CHECK POWER STEERING FLUID LEAKAGE
195. INSPECT FOR FUEL LEAKS
196. CHECK FOR EXHAUST GAS LEAKS
197. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
198. INSPECT STEERING WHEEL CENTER POINT
199. INSPECT IGNITION TIMING
SST 09843-18040
200. INSPECT ENGINE IDLE SPEED
SST 09843-18040
201. INSPECT CO/HC
202. CHECK ABS SPEED SENSOR SIGNAL