Partial Engine ASSY: Replacement
- DISCHARGE FUEL SYSTEM PRESSURE (See FUEL SYSTEM )
- REMOVE FRONT WHEELS
- REMOVE ENGINE UNDER COVER NO. 1
- REMOVE FRONT FENDER LINER LH
- REMOVE FRONT FENDER LINER RH
- REMOVE FRONT FENDER APRON SEAL LH
- REMOVE FRONT FENDER APRON SEAL RH
- DRAIN COOLANT (See ENGINE COOLANT )
- DRAIN ENGINE OIL (See OIL FILTER SUB-ASSY )
- DRAIN AUTOMATIC TRANSAXLE FLUID (See TRANSMISSION WIRE (U151E/U151F) )
- DRAIN TRANSFER OIL (4WD DRIVE TYPE)
- REMOVE FRONT WIPER ARM HEAD CAP
- REMOVE FR WIPER ARM RH (See WINDSHIELD WIPER MOTOR ASSY )
- REMOVE FR WIPER ARM LH (See WINDSHIELD WIPER MOTOR ASSY )
- REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY (See WINDSHIELD WIPER MOTOR ASSY )
- REMOVE WIPER LINK ASSY (See WINDSHIELD WIPER MOTOR ASSY )
- REMOVE COWL TOP TO COWL BRACE INNER NO. 1 (See REPLACEMENT )
- REMOVE COWL TOP PANEL SUB-ASSY OUTER FRONT (See REPLACEMENT )
- REMOVE V-BANK COVER SUB-ASSY (See VALVE CLEARANCE )
- REMOVE BATTERY
- REMOVE AIR CLEANER CAP SUB-ASSY (See REPLACEMENT )
- REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSY
- REMOVE AIR CLEANER INLET NO. 2 (See REPLACEMENT )
- REMOVE AIR CLEANER CASE (See REPLACEMENT )
- REMOVE AIR CLEANER BRACKET (See REPLACEMENT )
- REMOVE AIR CLEANER INLET NO. 1 (See REPLACEMENT )
- REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1 (See DRIVE BELT )
- REMOVE GENERATOR ASSY (See REPLACEMENT )
- REMOVE ENGINE MOVING CONTROL ROD (See REPLACEMENT )
- REMOVE ENGINE MOUNTING STAY NO. 2 RH (See REPLACEMENT )
- REMOVE GENERATOR BRACKET NO. 2 (See REPLACEMENT )
- REMOVE GENERATOR BELT ADJUSTING BAR (See REPLACEMENT )
- SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (See REPLACEMENT )
- SEPARATE TRANSMISSION CONTROL CABLE ASSY (See TRANSMISSION CONTROL CABLE ASSY (ATM) )
- DISCONNECT UNION TO CHECK VALVE HOSE
- DISCONNECT FUEL VAPOR FEED HOSE NO. 1
- DISCONNECT FUEL PIPE SUB-ASSY NO. 1 (See FUEL SYSTEM )
- DISCONNECT HEATER WATER INLET HOSE B
- DISCONNECT HEATER WATER OUTLET HOSE B
- DISCONNECT RADIATOR HOSE INLET
- DISCONNECT RADIATOR HOSE OUTLET
- DISCONNECT OIL COOLER INLET HOSE NO. 1
- DISCONNECT OIL COOLER OUTLET HOSE NO. 1
- DISCONNECT OIL RESERVOIR TO PUMP HOSE NO. 1
- DISCONNECT STEERING GEAR OUTLET RETURN TUBE
- REMOVE GLOVE COMPARTMENT DOOR ASSY
- SEPARATE ENGINE WIRE
- Disconnect the engine wire harness from the ECM and the junction block.
- Disconnect the engine wire harness from the engine room junction block.
- Remove the nut and separate the wire harness.
- Using a screwdriver, release the engine room junction block. Separate the engine wire by pulling it upward.
- Pull out the engine wire harness.
- Remove the body ground.
- REMOVE PROPELLER SHAFT (4WD DRIVE TYPE) (See
OVERHAUL
)
SST 09325-20010
- REMOVE EXHAUST PIPE ASSY CENTER (4WD DRIVE TYPE) (See REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY )
- REMOVE EXHAUST PIPE ASSY FRONT (2WD DRIVE TYPE) (See REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY )
- REMOVE EXHAUST PIPE ASSY FRONT (4WD DRIVE TYPE) (See REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY )
- SEPARATE FRONT STABILIZER LINK ASSY LH (See OVERHAUL )
- SEPARATE FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
- REMOVE FRONT AXLE HUB LH NUT (See
OVERHAUL
)
SST 09930-00010
- REMOVE FRONT AXLE HUB RH NUT
SST 09930-00010
HINT:
Perform the same procedure as above on the opposite side.
- SEPARATE SPEED SENSOR FRONT LH (See OVERHAUL )
- SEPARATE SPEED SENSOR FRONT RH
HINT:
Perform the same procedure as above on the opposite side.
- SEPARATE TIE ROD ASSY LH (See
OVERHAUL
)
SST 09628-62011
- SEPARATE TIE ROD ASSY RH
SST 09628-62011
HINT:
Perform the same procedure as above on the opposite side.
- SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO. 1 LH (See OVERHAUL )
- SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO. 1 RH
HINT:
Perform the same procedure as above on the opposite side.
- SEPARATE FRONT AXLE ASSY LH (See OVERHAUL )
- SEPARATE FRONT AXLE ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
- SEPARATE STEERING INTERMEDIATE SHAFT ASSY (See OVERHAUL )
- REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
- Set the engine lifter.
- Remove the 6 bolts, the 2 nuts, the frame side rail plate RH and LH.
- Remove the 6 bolts, the 2 nuts, the front suspension member brace rear RH and LH.
- Carefully remove the engine assembly from the vehicle.
- Install the No. 2 engine hanger in correct direction (shown in
Fig 6).
Part No.:
No. 2 engine hanger 12282-20020
Bolt 90080-11331
Torque: 20 N.m (199 kgf.cm, 14 ft.lbf)
- Attach the engine sling and hang the engine assembly with the chain block.
- REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1
- REMOVE MANIFOLD STAY
- REMOVE EXHAUST MANIFOLD SUB-ASSY RH (2WD DRIVE TYPE) (See REPLACEMENT )
- REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSY (4WD DRIVE TYPE) (See REPLACEMENT )
- REMOVE VANE PUMP V BELT (See DRIVE BELT )
- REMOVE VANE PUMP ASSY
- Remove the 2 nuts and disconnect the PS pressure tube.
- Remove the 2 bolts and the vane pump.
- REMOVE STABILIZER BAR FRONT (4WD DRIVE TYPE)
- REMOVE RACK & PINION POWER STEERING GEAR ASSY (4WD DRIVE TYPE)
- REMOVE FRONT FRAME ASSY
- Remove the 2 nuts and separate engine mounting insulator RH and LH.
- Remove the nut and separate the engine mounting insulator FR.
- 4WD:
Remove the 2 bolts and separate the engine mounting insulator RR.
- REMOVE FRONT DRIVE SHAFT ASSY LH (See
OVERHAUL
)
SST 09520-01010, 09520-24010 (09520-32040)
- REMOVE FRONT DRIVE SHAFT ASSY RH (2WD DRIVE TYPE) (See OVERHAUL )
- REMOVE FRONT DRIVE SHAFT ASSY RH (4WD DRIVE TYPE) (See OVERHAUL )
- REMOVE STARTER ASSY (See REPLACEMENT )
- REMOVE ENGINE MOUNTING BRACKET FR (See REPLACEMENT )
- REMOVE AUTOMATIC TRANSAXLE ASSY (2WD DRIVE TYPE) (See REPLACEMENT )
- REMOVE TRANSFER STIFFENER PLATE RH (4WD DRIVE TYPE) (See REPLACEMENT )
- REMOVE AUTOMATIC TRANSMISSION W/TRANSFER (4WD DRIVE TYPE) (See REPLACEMENT )
- REMOVE DRIVE SHAFT BEARING BRACKET (2WD DRIVE TYPE)
- REMOVE ENGINE MOUNTING BRACKET RR (4WD DRIVE TYPE)
- REMOVE DRIVE PLATE & RING GEAR SUB-ASSY (See
ENGINE REAR OIL SEAL )
SST 09213-54015 (91651-60855), 09330-00021
- INSTALL ENGINE STAND
- REMOVE ENGINE HANGER NO. 2
- REMOVE EMISSION CONTROL VALVE SET (See VALVE CLEARANCE )
- REMOVE INTAKE AIR SURGE TANK (See VALVE CLEARANCE )
- REMOVE INTAKE MANIFOLD (See REPLACEMENT )
- REMOVE WATER OUTLET (See REPLACEMENT )
- REMOVE IGNITION COIL ASSY
- REMOVE MANIFOLD CONVERTER INSULATOR NO. 3
- REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 2
- REMOVE MANIFOLD STAY NO. 2
- REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSY NO. 2 (See REPLACEMENT )
- REMOVE ENGINE MOUNTING BRACKET RH
- REMOVE PUMP BRACKET
- REMOVE GENERATOR BRACKET NO. 1
- REMOVE COMPRESSOR MOUNTING BRACKET NO. 1 (See REPLACEMENT )
- REMOVE WATER INLET
- REMOVE THERMOSTAT
- REMOVE ENGINE OIL PRESSURE SWITCH ASSY
- Using a 27 mm deep socket wrench, remove the oil pressure switch.
- REMOVE KNOCK SENSOR (See REPLACEMENT )
- REPLACE PARTIAL ENGINE ASSY
- INSTALL KNOCK SENSOR (See REPLACEMENT )
- INSTALL ENGINE OIL PRESSURE SWITCH ASSY
- Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive:
Part No. 08833-00080 THREE BOND 1344,
LOCTITE 242 or equivalent.
- Using a 27 mm deep socket wrench, install the oil pressure switch.
Torque: 15 N.m (153 kgf.cm, 11 ft.lbf)
- Apply adhesive to 2 or 3 threads of the oil pressure switch.
- INSTALL THERMOSTAT (See THERMOSTAT )
- INSTALL WATER INLET (See THERMOSTAT )
- INSTALL COMPRESSOR MOUNTING BRACKET NO. 1 (See REPLACEMENT )
- INSTALL GENERATOR BRACKET NO. 1
Torque: 58 N.m (591 kgf.cm, 43 ft.lbf)
- INSTALL PUMP BRACKET
Torque: 32 N.m (326 kgf.cm, 24 ft.lbf)
- INSTALL ENGINE MOUNTING BRACKET RH
Torque: 54 N.m (551 kgf.cm, 40 ft.lbf)
- INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSY NO. 2 (See REPLACEMENT )
- INSTALL MANIFOLD STAY NO. 2
Torque: 49 N.m (500 kgf.cm, 36 ft.lbf)
- INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 2 (See REPLACEMENT )
- INSTALL MANIFOLD CONVERTER INSULATOR NO. 3 (See REPLACEMENT )
- INSTALL IGNITION COIL ASSY (See VALVE CLEARANCE )
- INSTALL WATER OUTLET (See REPLACEMENT )
- INSTALL INTAKE MANIFOLD (See REPLACEMENT )
- INSTALL INTAKE AIR SURGE TANK (See VALVE CLEARANCE )
- INSTALL EMISSION CONTROL VALVE SET (See VALVE CLEARANCE )
- INSTALL DRIVE PLATE & RING GEAR SUB-ASSY (See
ENGINE REAR OIL SEAL )
SST 09213-54015 (91651 -60855), 09330-00021
- INSTALL DRIVE SHAFT BEARING BRACKET (2WD DRIVE TYPE)
Torque: 64 N.m (650 kgf.cm, 47 in.lbf)
- INSTALL ENGINE MOUNTING BRACKET RR (4WD DRIVE TYPE)
Torque: 64 N.m (653 kgf.cm, 47 in.lbf)
- INSTALL AUTOMATIC TRANSMISSION W/TRANSFER (4WD DRIVE TYPE) (See AUTOMATIC TRANSAXLE ASSY (U151E/U151F) )
- INSTALL TRANSFER STIFFENER PLATE RH (4WD DRIVE TYPE) (See AUTOMATIC TRANSAXLE ASSY (U151E/U151F) )
- INSTALL AUTOMATIC TRANSAXLE ASSY (2WD DRIVE TYPE) (See AUTOMATIC TRANSAXLE ASSY (U151E/U151F) )
- INSTALL ENGINE MOUNTING BRACKET FR (See AUTOMATIC TRANSAXLE ASSY (U151E/U151F) )
- INSTALL STARTER ASSY (See REPLACEMENT )
- INSTALL FRONT DRIVE SHAFT ASSY LH (See OVERHAUL )
- INSTALL FRONT DRIVE SHAFT ASSY RH (2WD DRIVE TYPE) (See OVERHAUL )
- INSTALL FRONT DRIVE SHAFT ASSY RH (4WD DRIVE TYPE) (See OVERHAUL )
- INSTALL FRONT FRAME ASSY
- Install the engine mounting insulator RH and LH with the 2 nuts.
Torque: 95 N.m (969 kgf.cm, 70 ft.lbf)
- Install the engine mounting insulator FR with the nut.
Torque: 87 N.m (887 kgf.cm, 64 ft.lbf)
- 4WD:
Install the engine mounting insulator RR with the 2 bolts.
Torque: 75 N.m (765 kgf.cm, 55 ft.lbf)
- Install the engine mounting insulator RH and LH with the 2 nuts.
- INSTALL RACK & PINION POWER STEERING GEAR ASSY (4WD DRIVE TYPE)
Torque: 70 N.m (714 kgf.cm, 52 ft.lbf)
- INSTALL STABILIZER BAR FRONT (4WD DRIVE TYPE)
Torque: 17 N.m (173 kgf.cm, 13 ft.lbf)
- INSTALL VANE PUMP ASSY
- Temporarily tighten the bolt.
- Install the adjusting strut to the engine mounting bracket RH with the bolt.
Torque: 44 N.m (449 kgf.cm, 32 ft.lbf)
- Connect the PS pressure tube with the 2 nuts.
Torque: 7.8 N.m (80 kgf.cm, 69 in.lbf)
- INSTALL VANE PUMP V BELT (See DRIVE BELT )
- INSTALL EXHAUST MANIFOLD SUB-ASSY RH (2WD DRIVE TYPE) (See REPLACEMENT )
- INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSY (4WD DRIVE TYPE) (See REPLACEMENT )
- INSTALL MANIFOLD STAY (See REPLACEMENT )
- INSTALL EXHAUST MANIFOLD HEAT INSULATOR N0.1 (See REPLACEMENT )
- INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
- Set the engine assembly with transaxle on the engine lifter.
- Install the engine assembly to the vehicle.
- Install the frame side rail plate RH and LH with the 6 bolts and the 2 nuts.
Torque:
Bolt A: 85 N.m (867 kgf.cm, 63 ft.lbf)
Bolt B: 32 N.m (329 kgf.cm, 24 ft.lbf)
Nut C: 32 N.m (329 kgf.cm, 24 ft.lbf)
- Install the front suspension member brace rear RH and LH with the 6 bolts and the 2 nuts.
Torque:
Bolt A: 85 N.m (867 kgf.cm, 63 ft.lbf)
Bolt B: 32 N.m (329 kgf.cm, 24 ft.lbf)
Nut C: 32 N.m (329 kgf.cm, 24 ft.lbf)
- INSTALL STEERING INTERMEDIATE SHAFT ASSY (See OVERHAUL )
- INSTALL FRONT AXLE ASSY LH (See OVERHAUL )
- INSTALL FRONT AXLE ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
- INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO. 1 LH (See OVERHAUL )
- INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO. 1 RH
HINT:
Perform the same procedure as above on the opposite side.
- INSTALL TIE ROD ASSY LH (See OVERHAUL )
- INSTALL TIE ROD ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
- INSTALL SPEED SENSOR FRONT LH (See OVERHAUL )
- INSTALL SPEED SENSOR FRONT RH
HINT:
Perform the same procedure as above on the opposite side.
- INSTALL FRONT AXLE HUB LH NUT (See OVERHAUL )
- INSTALL FRONT AXLE HUB RH NUT
HINT:
Perform the same procedure as above on the opposite side.
- INSTALL FRONT STABILIZER LINK ASSY LH (See OVERHAUL )
- INSTALL FRONT STABILIZER LINK ASSY RH
HINT:
Perform the same procedure as above on the opposite side.
- INSTALL EXHAUST PIPE ASSY FRONT (2WD DRIVE TYPE) (See REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY )
- INSTALL EXHAUST PIPE ASSY FRONT (4WD DRIVE TYPE) (See REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY )
- INSTALL EXHAUST PIPE ASSY CENTER (4WD DRIVE TYPE) (See REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY )
- INSTALL PROPELLER SHAFT (4WD DRIVE TYPE) (See OVERHAUL )
- CONNECT FUEL PIPE SUB-ASSY NO. 1 (See FUEL SYSTEM )
- INSTALL TRANSMISSION CONTROL CABLE ASSY (See TRANSMISSION CONTROL CABLE ASSY (ATM) )
- INSTALL COMPRESSOR AND MAGNETIC CLUTCH (See REPLACEMENT )
- INSTALL GENERATOR BELT ADJUSTING BAR (See REPLACEMENT )
- INSTALL GENERATOR BRACKET NO. 2 (See REPLACEMENT )
- INSTALL ENGINE MOUNTING STAY NO. 2 RH (See REPLACEMENT )
- INSTALL ENGINE MOVING CONTROL ROD (See REPLACEMENT )
- INSTALL GENERATOR ASSY (See REPLACEMENT )
- INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1 (See DRIVE BELT )
- INSPECT DRIVE BELT DEFLECTION AND TENSION (REFERENCE) (See ENGINE )
- INSTALL AIR CLEANER INLET NO. 1 (See REPLACEMENT )
- INSTALL AIR CLEANER BRACKET (See REPLACEMENT )
- INSTALL AIR CLEANER CASE (See REPLACEMENT )
- INSTALL AIR CLEANER INLET NO. 2 (See REPLACEMENT )
- INSTALL AIR CLEANER CAP SUB-ASSY (See REPLACEMENT )
- CONNECT VACUUM HOSE
- INSTALL V-BANK COVER SUB-ASSY (See VALVE CLEARANCE )
- INSTALL COWL TOP PANEL SUB-ASSY OUTER FRONT (See REPLACEMENT )
- INSTALL COWL TOP TO COWL BRACE INNER NO. 1 (See REPLACEMENT )
- INSTALL WIPER LINK ASSY (See WINDSHIELD WIPER MOTOR ASSY )
- INSTALL FR WIPER ARM LH (See WINDSHIELD WIPER MOTOR ASSY )
- INSTALL FR WIPER ARM RH (See WINDSHIELD WIPER MOTOR ASSY )
- INSTALL FRONT WHEELS (See DRIVE BELT )
- ADD TRANSFER OIL (4WD DRIVE TYPE) (See TRANSFER OIL (4WD) )
- INSPECT TRANSFER OIL (4WD DRIVE TYPE) (See TRANSFER OIL (4WD) )
- ADD AUTOMATIC TRANSAXLE FLUID
- ADD ENGINE OIL (See OIL FILTER SUB-ASSY )
- ADD COOLANT (See ENGINE COOLANT )
- ADD POWER STEERING FLUID
- BLEED POWER STEERING FLUID
- INSPECT AUTOMATIC TRANSAXLE FLUID (See AUTOMATIC TRANSAXLE FLUID (ATM) )
- CHECK FOR ENGINE OIL LEAKS
- CHECK FOR ENGINE COOLANT LEAKS (See ENGINE COOLANT )
- CHECK POWER STEERING FLUID LEAKAGE
- INSPECT FOR FUEL LEAKS
- CHECK FOR EXHAUST GAS LEAKS
- INSPECT AND ADJUST FRONT WHEEL ALIGNMENT (See FRONT WHEEL ALIGNMENT )
- INSPECT STEERING WHEEL CENTER POINT
- INSPECT IGNITION TIMING (See
ENGINE )
SST 09843-18040
- INSPECT ENGINE IDLE SPEED (See
ENGINE )
SST09843-18040
- INSPECT CO/HC (See ENGINE )
- CHECK ABS SPEED SENSOR SIGNAL (See PRE-CHECK )