Engine Assembly - Removal and Installation
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 coolant are cool enough.
If items or work required are not covered by the engine main body section, refer to the applicable sections.
Always use the support point specified for lifting.
GUse either 2-point lift type or separate type lift as best you can. 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.
Outline
After removal of transmission, lift up engine assembly to remove it from vehicle.
ENGINE MOUNTINGS:
REMOVAL / Preparation
1. Release fuel pressure.
2. Remove engine cover, engine room cover and engine under cover with power tool.
3. Drain coolant from radiator drain plug.
4. Remove the following parts:
- Engine hood
- Front tower bar
- Battery
- Air duct (inlet)
- Air duct, air cleaner case assembly
- Drive belts
- Power valve vacuum tank
- Cooling fan and tubes
- Radiator assembly and hoses
- Water suction pipe
Engine Room LH
5. Disconnect engine room harness from the engine side and set it aside for easier work.
6. Disconnect heater hoses, and install plugs to avoid leakage of coolant.
7. Disconnect wire bonding exhaust manifold cover to vehicle.
8. Disconnect vacuum hose between vehicle and engine and set it aside.
9. Remove reservoir tank for cooling fan.
10. Remove A/C compressor from brackets, and install A/C compressor temporarily with ropes or equivalent to avoid applying any pressures on piping or disturbing installation or removal of any vehicle parts.
Engine Room RH
11. Disconnect fuel hose at the engine side connection.
12. Disconnect engine room harness from the engine side and set it aside for easier work.
13. Disconnect wire bonding exhaust manifold cover to vehicle.
14. Disconnect vacuum hose between vehicle and engine and set it aside.
15. Disconnect reservoir tank for power steering from engine and move it aside for easier work.
16. Move away relay case.
Vehicle Underbody
17. Disconnect power steering pump from engine. Move it from its location and secure with a rope for easier work.
18. Remove pipe of cooler for automatic transmission.
19. Remove exhaust front tube.
20. Disconnect steering lower joint, and release steering shaft.
21. Disconnect propeller shaft.
After disconnection, plug the opening on transmission side.
Removal
22. Remove transmission assembly.
23. Install engine slingers into front of left bank cylinder head and rear of right bank cylinder head.
Slinger Bolts-Tightening Torque:...........30.4 - 36.3 Nm (3.1 - 3.7 kg/m, 23 - 26 ft. lbs.)
24. Lift with hoist and secure the engine in position.
25. Remove engine mounting nuts on bottom surface.
26. Carefully lift up engine assembly, avoiding interference with vehicle body, move it away and upward.
27. With engine assembly lifted up, remove rear end of exhaust manifold to avoid contact with vehicle.
28. Remove engine assembly from vehicle.
CAUTION: Before and during this lifting, always check if any harnesses are left connected.
Avoid damage to and oil/grease smearing or spills onto engine mount insulator.
INSTALLATION
Install in the reverse order of removal.
Where positioning pin is used, be sure to securely insert it into the hole of mating part.
ENGINE MOUNT BRACKETS:
When installing front engine mount bracket to cylinder block, first tighten two bolts on upper side. Then, tighten two bolts on lower side. (The same applies to both right and left.)
INSPECTION AFTER INSTALLATION
Before starting engine, check the levels of coolant, lubrications, working oils, and of air conditioner refrigerant. If less than required quantity, fill to the specified level.
Run engine to check for unusual noise and vibration.
Warm up engine thoroughly to make sure there is no leakage of coolant, lubricants, working oil, fuel, and exhaust gas.
Bleed air from passages in pipes and tubes of applicable lines.