Engine: Service and Repair

ENGINE ASSEMBLY


AWD : 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.
- Never start working until exhaust system and engine coolant are cool enough.
- If items or work required are not covered by the engine section, refer to the applicable sections.
- Always use the support point specified for lifting.
- Use either 2-pole 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.
- For supporting points for lifting and jacking point at rear axle, Garage Jack and Safety Stand and 2-Pole Lift.

REMOVAL

Outline
At first, remove the engine and the transmission assembly, and front final drive with front suspension member from vehicle downward. Then separate the engine from the transmission.

Preparation
1. Release fuel pressure. Testing and Inspection.
2. Drain engine coolant from radiator. Changing Engine Coolant.

CAUTION:
- Perform this step when engine is cold.
- Never spill engine coolant on drive belts.
3. Disconnect both battery cables. Procedures.
4. Remove crankshaft position sensor (POS) from transmission. Component.

CAUTION:
- Handle carefully to avoid dropping and shocks.
- Never disassemble.
- Never allow metal powder to adhere to magnetic part at sensor tip.
- Never place sensors in a location where they are exposed to magnetism.
5. Remove the following parts:
- Front and rear engine undercover (power tool)
- Air duct (inlet), air duct and air cleaner case assembly: Component Removal and Installation.
- Front road wheels and tires (power tool)
- Front cross bar: Component.

Engine Room LH
1. Disconnect heater hoses, and install plugs to avoid leakage of engine coolant. Component.
2. Disconnect wire bonding from exhaust manifold cover to vehicle.
3. Disconnect vacuum hose between vehicle and engine and set it aside.
4. Discharge refrigerant from A/C circuit. Service and Repair.
5. Remove A/C piping from A/C compressor, and temporarily fasten it on vehicle with a rope. Service and Repair.

Engine Room RH
1. Disconnect fuel feed hose and EVAP hose. Component Removal and Installation.

CAUTION:
Fit plugs onto disconnected hose to prevent fuel leakage.
2. Disconnect ground cable (between vehicle and right bank cylinder head).
3. Disconnect vacuum hose between vehicle and engine and set it aside.
4. Disconnect reservoir tank of power steering oil pump from engine, and move it aside for easier work.

CAUTION:
When temporarily securing, keep reservoir tank upright to avoid a fluid leakage.

Vehicle inside
Follow procedure below to disconnect engine room harness connectors at passenger room side, and temporarily secure them on engine.
1. Remove passenger-side kicking plate, dash side finisher, and glove box. Locations Service and Repair and Instrument Panel.
2. Disconnect engine room harness connectors at unit sides TCM, ECM, and other.
3. Disengage intermediate fixing point. Pull out engine room harnesses to engine room side, and temporarily secure them on engine.

CAUTION:
- When pulling out harnesses, take care not to damage harnesses and connectors.
- After temporarily securing, cover connectors with vinyl or similar material to protect against foreign material adhesion.

Vehicle Underbody
1. Remove A/T fluid cooler hoses and power steering oil pump oil cooler hoses.
- Install plug to avoid leakage of A/T fluid and power steering fluid.
2. Disconnect heated oxygen sensor 2 harness. Testing and Inspection Component.
3. Remove exhaust front tube with power tool. Testing and Inspection Component.
4. Disconnect steering lower joint at power steering gear assembly side, and release steering lower shaft. Service and Repair.
5. Separate steering outer sockets from steering knuckle. Removal and Installation.
6. Remove A/T control rod at A/T shift selector side. Then temporarily secure it on transmission, so that it does not sag. A/T Shift Selector Removal and Installation.
7. Remove rear plate cover from oil pan. Then remove bolts fixing drive plate to torque converter. Component and Transmission Assembly.
8. Remove bolts fixing the transmission assembly to lower rear side of oil pan. Component.
9. Remove lower ends of left and right strut from transverse link. Component.
10. Remove transverse link mounting bolts at knuckle side. Component.
11. Remove front stabilizer at transverse link side. Component.
12. Remove rear propeller shaft. Component.
13. Remove front drive shaft (both side). Front Drive Shaft.

Removal Work





1. Use manual lift table caddy (commercial service tool) or equivalently rigid tool such as transmission jack. Securely support bottom of suspension member and transmission assembly.

CAUTION:
Put a piece of wood or something similar as the supporting surface, secure a completely stable condition.
2. Remove engine rear member mounting bolts.
3. Remove front suspension member mounting nuts and bolts with power tool. Component.
4. Carefully lower jack, or raise lift to remove engine, transmission and front suspension member assembly.
When performing work, observe the following caution:

CAUTION:
- Confirm there is no interference with vehicle.
- Check that all connection points have been disconnected.
- Keep in mind the center of vehicle gravity changes. If necessary, use jack(s) to support vehicle at rear jacking point(s) to prevent it from falling it off the lift.

Separation Work





1. Install engine slingers into front of cylinder head (left bank) and front of cylinder head (right bank).

Slinger bolts: 33.4 Nm (3.4 kg-m, 25 ft-lb)

2. Remove engine mounting insulators (RH and LH) under side nut with power tool.
3. Lift with hoist and separate engine, transmission assembly, the transfer assembly and the front final drive assembly from front suspension member.

CAUTION:
Avoid damage to and oil/grease smearing or spills onto engine mounting insulator.
4. Remove alternator. Removal and Installation.
5. Remove starter motor. Disassembly and Assembly.
6. Remove front propeller shaft from the front final drive assembly. Component.
7. Separate engine from transmission assembly. Transmission Assembly.
8. Remove the front final drive assembly from oil pan. Front Final Drive Assembly.
9. Remove engine mounting insulators (RH and LH) and brackets (RH and LH) from engine with power tool.
10. Remove rear engine mounting member and engine mounting insulator (rear) from transmission.

INSTALLATION
Note the following, and install in the reverse order of removal.
- Do not allow engine mounting insulator to be damage and careful no engine oil gets on it.
- For a location with a positioning pin, insert it securely into hole of mating part.





- When installing engine mounting brackets (RH and LH) on cylinder block, tighten two upper bolts (shown as "A" in the figure) first.
Then tighten two lower bolts (shown as "B" in the figure).

NOTE:
Figure shows left bank.

INSPECTION AFTER INSTALLATION

Inspection for Leakage

The following are procedure for checking fluids leakage, lubricates leakage, and exhaust gases leakage.
- Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Maintenance.
- 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.
- Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including engine oil and engine coolant.
- Bleed air from lines and hoses of applicable lines, such as in cooling system.
- After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary.