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.

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

REMOVAL

1.Release the fuel pressure. Testing and Inspection.
2.Disconnect the battery negative terminal and disconnect the batter negative harness from the engine.
Removal and Replacement.
3.Remove engine under cover. Service and Repair.
4.Drain the engine coolant. Service and Repair.
5.Partially drain the transmission fluid. Changing
6.Partially drain the transfer case fluid. .
7.Remove the engine hood. Service and Repair.
8.Remove the engine room cover, (if equipped) using power tool. Service and Repair.
9.Disconnect the vacuum hose between the vehicle and engine and set it aside.
10.Remove the radiator assembly and hoses. Removal and Installation.
11.Remove the drive belt. Removal And Installation.
12.Remove the fan blade. Removal and Installation (Crankshaft Driven Type).
13.Remove the battery positive harness.
14.Disconnect the engine room harness from the fuse box and set it aside.
15.Disconnect the ECM.
16.Disconnect the engine room harness from the engine side and set it aside.
17.Disconnect the engine harness grounds.
18.Disconnect the power steering reservoir tank from the engine and move it aside.
19.Disconnect the power steering oil pump from the engine. Move it aside and secure it using suitable wire or rope. Removal And Installation.
20.Remove the A/C compressor bolts and set the compressor aside. Service and Repair.
21.Disconnect the brake booster vacuum line.
22.Disconnect the EVAP line.
23.Disconnect the fuel hose at the engine side connection. Removal And Installation.
24.Disconnect the heater hoses at the cowl and engine.
25.Remove the engine and transmission oil level indicators and indicator tubes.
26.Remove the front fender protectors. Removal And Installation.
27.Remove the front final drive assembly. Removal And Installation.
28.Remove the exhaust manifolds. Removal And Installation.
29.Remove the A/T. Automatic Transmission.





30.Install the engine slingers into the left bank cylinder head (A)
and right bank cylinder head (B).
Engine slinger torque:45.0 Nm (4.6 kg-m, 33 ft-lb)
31.Lift using a hoist and secure the engine in position.
32.Remove engine mounting insulator bolts.
33.Remove the engine assembly from the vehicle, avoid interference with the vehicle body.

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

INSTALLATION

Installation is in the reverse order of removal.





- Tighten engine mounting bracket bolts in numerical order as shown.
Engine mounting bracket bolts: 49 Nm (5.0 kg-m, 36 ft-lb)


CAUTION:
- When replacing an engine or transmission you must make sure the dowels are installed correctly during re-assembly.
- 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: