Engine Removal and Installation

ENGINE ASSEMBLY

Components:

REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
2. REMOVE FRONT WHEEL RH
3. REMOVE NO. 1 ENGINE UNDER COVER
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
a) Remove the drain plug and gasket, and drain ATF.
b) Install a new gasket and drain plug.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
11. DRAIN TRANSFER OIL
12. REMOVE FRONT WIPER ARM HEAD CAP
13. REMOVE FRONT WIPER ARM RH
14. REMOVE FRONT WIPER ARM LH
15. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
16. REMOVE WIPER LINK ASSEMBLY
17. REMOVE NO. 1 COWL TOP TO COWL BRACE INNER
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 NO. 2 AIR CLEANER INLET
24. REMOVE AIR CLEANER CASE
25. REMOVE AIR CLEANER BRACKET
26. REMOVE NO. 1 AIR CLEANER INLET
27. REMOVE NO. 1 V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT
28. REMOVE GENERATOR ASSEMBLY
29. REMOVE ENGINE MOVING CONTROL ROD
30. REMOVE ENGINE MOUNTING STAY NO. 2 RH
31. REMOVE NO. 2 GENERATOR BRACKET
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 NO. 1 FUEL VAPOR FEED HOSE
37. DISCONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY
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 NO. 1 OIL COOLER INLET HOSE
43. DISCONNECT NO. 1 OIL COOLER OUTLET HOSE

44. DISCONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE

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 (for 4WD)
SST 09930-00010
49. REMOVE EXHAUST PIPE ASSEMBLY CENTER (for 4WD)
50. REMOVE EXHAUST PIPE ASSEMBLY FRONT (for 2WD)
51. REMOVE EXHAUST PIPE ASSEMBLY FRONT (for 2WD)
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
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
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 LH

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 NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
67. REMOVE MANIFOLD STAY
68. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH (for 2WD)
69. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (for 4WD)
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 (for 4WD)
73. REMOVE RACK AND PINION POWER STEERING GEAR ASSEMBLY (for 4WD)
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 front.

c) 4WD: Remove the 2 bolts and separate the engine mounting insulator RR.
75. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH
76. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for 2WD)
77. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD)
78. REMOVE STARTER ASSEMBLY
79. REMOVE ENGINE MOUNTING BRACKET FRONT
80. REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD)
81. REMOVE TRANSFER STIFFENER PLATE RH (for 4WD)
82. REMOVE AUTOMATIC TRANSMISSION WITH TRANSFER (for 4WD)
83. REMOVE DRIVE SHAFT BEARING BRACKET (for 2WD)
84. REMOVE ENGINE MOUNTING BRACKET REAR (for 4WD)
85. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
86. INSTALL ENGINE STAND
87. REMOVE NO. 2 ENGINE HANGER
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 NO. 3 MANIFOLD CONVERTER INSULATOR
94. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
95. REMOVE NO. 2 MANIFOLD STAY
96. REMOVE NO. 2 EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
97. REMOVE ENGINE MOUNTING BRACKET RH
98. REMOVE PUMP BRACKET
99. REMOVE NO. 1 GENERATOR BRACKET
100. REMOVE NO. 1 COMPRESSOR MOUNTING BRACKET
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

INSTALLATION
1. INSTALL KNOCK SENSOR
2. 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.)
3. INSTALL THERMOSTAT
4. INSTALL WATER INLET
5. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET
6. INSTALL NO. 1 GENERATOR BRACKET
Torque: 58 Nm (591 kgf-cm, 43 ft. lbs.)
7. INSTALL PUMP BRACKET
Torque: 32 Nm (326 kgf-cm, 24 ft. lbs.)
8. INSTALL ENGINE MOUNTING BRACKET RH
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)
9. INSTALL NO. 2 EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
10. INSTALL NO. 2 MANIFOLD STAY
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
11. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
12. INSTALL NO. 3 MANIFOLD CONVERTER INSULATOR
13. INSTALL IGNITION COIL ASSEMBLY
14. INSTALL WATER OUTLET
15. INSTALL INTAKE MANIFOLD
16. INSTALL INTAKE AIR SURGE TANK
17. INSTALL EMISSION CONTROL VALVE SET
18. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
19. INSTALL DRIVE SHAFT BEARING BRACKET (for 2WD)
Torque: 64 Nm (650 kgf-cm, 47 ft. lbs.)
20. INSTALL ENGINE MOUNTING BRACKET REAR (for 4WD)
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
21. INSTALL AUTOMATIC TRANSMISSION WITH TRANSFER (for 4WD)
22. INSTALL TRANSFER STIFFENER PLATE RH (for 4WD)
23. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD)
24. INSTALL ENGINE MOUNTING BRACKET FRONT
25. INSTALL STARTER ASSEMBLY
26. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
27. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 2WD)
28. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD)
29. 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 front with the nut.
Torque: 87 Nm (887 kgf-cm, 64 ft. lbs.)

c) 4WD: Install the engine mounting insulator rear with the 2 bolts.
Torque: 75 Nm (765 kgf-cm, 55 ft. lbs.)
30. INSTALL RACK AND PINION POWER STEERING GEAR ASSEMBLY (for 4WD)
Torque: 70 Nm (714 kgf-cm, 52 ft. lbs.)
31. INSTALL STABILIZER BAR FRONT (for 4WD)
Torque: 17 Nm (173 kgf-cm, 13 ft. lbs.)
32. 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.)
33. INSTALL VANE PUMP V BELT
34. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH (for 2WD)
35. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (for 4WD)
36. INSTALL MANIFOLD STAY
37. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
38. 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:
85 Nm (867 kgf-cm, 63 ft. lbs.) for Bolt A
32 Nm (329 kgf-cm, 24 ft. lbs.) for Bolt B
32 Nm (329 kgf-cm, 24 ft. lbs.) for Bolt C

d) Install the front suspension member brace rear RH and LH with the 6 bolts and the 2 nuts.
Torque:
85 Nm (867 kgf-cm, 63 ft. lbs.) for Bolt A
32 Nm (329 kgf-cm, 24 ft. lbs.) for Bolt B
32 Nm (329 kgf-cm, 24 ft. lbs.) for Bolt C
39. INSTALL STEERING INTERMEDIATE SHAFT ASSEMBLY
40. INSTALL FRONT AXLE ASSEMBLY LH
41. INSTALL FRONT AXLE ASSEMBLY RH

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

42. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 LH
43. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 RH

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

44. INSTALL TIE ROD ASSEMBLY LH
45. INSTALL TIE ROD ASSEMBLY RH

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

46. INSTALL SPEED SENSOR FRONT LH
47. INSTALL SPEED SENSOR FRONT RH

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

48. INSTALL FRONT AXLE HUB LH NUT
49. INSTALL FRONT AXLE HUB RH NUT

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

50. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
51. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

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

52. INSTALL EXHAUST PIPE ASSEMBLY FRONT (for 2WD)
53. INSTALL EXHAUST PIPE ASSEMBLY FRONT (for 4WD)
54. INSTALL EXHAUST PIPE ASSEMBLY CENTER (for 4WD)
55. INSTALL PROPELLER SHAFT (for 4WD)
56. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY
57. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY
58. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
59. INSTALL GENERATOR BELT ADJUSTING BAR
60. INSTALL NO. 2 GENERATOR BRACKET
61. INSTALL ENGINE MOUNTING STAY NO. 2 RH
62. INSTALL ENGINE MOVING CONTROL ROD
63. INSTALL GENERATOR ASSEMBLY
64. INSTALL NO. 1 V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT
65. INSPECT DRIVE BELT DEFLECTION AND TENSION
66. INSTALL NO. 1 AIR CLEANER INLET
67. INSTALL AIR CLEANER BRACKET
68. INSTALL AIR CLEANER CASE
69. INSTALL NO. 2 AIR CLEANER INLET
70. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

71. CONNECT VACUUM HOSE
72. INSTALL V-BANK COVER SUB-ASSEMBLY
73. INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER FRONT
74. INSTALL NO. 1 COWL TOP TO COWL BRACE INNER
75. INSTALL WIPER LINK ASSEMBLY
76. INSTALL FRONT WIPER ARM LH
77. INSTALL FRONT WIPER ARM RH
78. INSTALL FRONT WHEEL RH
79. ADD TRANSFER OIL (for 4WD)
80. INSPECT TRANSFER OIL (for 4WD)
81. ADD AUTOMATIC TRANSAXLE FLUID
82. ADD ENGINE OIL
83. ADD COOLANT
84. ADD POWER STEERING FLUID
85. BLEED POWER STEERING FLUID
86. INSPECT AUTOMATIC TRANSAXLE FLUID
87. CHECK FOR ENGINE OIL LEAKS
88. CHECK FOR ENGINE COOLANT LEAKS
89. CHECK POWER STEERING FLUID LEAKAGE
90. INSPECT FOR FUEL LEAKS
91. CHECK FOR EXHAUST GAS LEAKS
92. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
93. INSPECT STEERING WHEEL CENTER POINT
94. INSPECT IGNITION TIMING
95. INSPECT ENGINE IDLE SPEED
96. INSPECT CO/HC
97. CHECK ABS SPEED SENSOR SIGNAL