Part 2
ENGINE ASSEMBLY continued53. REMOVE ENGINE AND TRANSMISSION (for 4WD)
a. Set the engine lifter.
b. Remove the 4 bolts, then separate the engine rear mounting member.
c. Remove the 8 bolts shown in the illustration.
d. Operate the engine lifter, then slowly remove the engine and transmission with crossmember sub assembly from the vehicle.
NOTICE: Make sure the engine is clear of all wiring and hoses.
e. Install the 2 engine hangers with the 4 bolts as shown in the illustration.
Part No.:
Torque: 33 Nm (336 kgf-cm 24 ft. lbs.)
f. Attach an engine sling device and hang the engine with a chain block.
54. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD)
55. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (for 4WD)
56. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for 2WD)
57. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for 4WD)
58. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY
a. Using SST, hold the crankshaft.
SST 09213-70011 (09213-70020), 09330-00021
b. Remove the 8 bolts, front spacer, drive plate and rear spacer.
59. REMOVE FRONT ENGINE MOUNTING INSULATOR
a. Remove the 2 bolts, then remove the front suspension crossmember sub-assembly from the engine.
60. FIX ENGINE ON ENGINE STAND
a. Fix the engine onto a engine stand with the bolts.
61. REMOVE ENGINE WIRE
a. Remove the engine wire from the engine.
62. REMOVE OIL LEVEL GAUGE SUB-ASSEMBLY
a. Remove the oil level gauge.
b. Remove the 2 bolts, then remove the oil level gauge guide No.1 and No.2.
c. Remove the O-ring from the oil level gauge guide.
63. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Disconnect the heated oxygen sensor connector.
b. Remove the 6 nuts, exhaust manifold and gasket.
64. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.
Maximum warpage: 0.7 mm (0.028 inch)
HINT: The maximum allowable warpage of each installation surface is 0.3 mm (0.012 inch). If the warpage is greater than the maximum, replace the manifold.
65. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
a. Disconnect the heated oxygen sensor connector.
b. Remove the 6 nuts, exhaust manifold and gasket.
66. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH
a. Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.
Maximum warpage: 0.7 mm (0.028 inch)
HINT: The maximum allowable warpage of each installation surface is 0.3 mm (0.012 inch). If the warpage is greater than the maximum, replace the manifold.
67. REMOVE GENERATOR ASSEMBLY
68. REMOVE FRONT DIFFERENTIAL ASSEMBLY (for 4WD)
69. REMOVE NO.2 IDLER PULLEY SUB-ASSEMBLY
a. Remove the bolt, plate and idler pulley.
2wd:
70. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (for 2WD)
a. Remove the 5 bolts, then remove the V-ribbed belt tensioner assembly.
4wd:
71. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY (for 4WD)
a. Remove the 4 bolts, then remove the V-ribbed belt tensioner assembly.
72. REMOVE WATER PUMP PULLEY
73. REMOVE INJECTOR DRIVER
a. Remove the bolt, 2 nuts and injector driver.
74. DISCONNECT NO.1 WATER BY-PASS HOSE
75. DISCONNECT NO.2 WATER BY-PASS HOSE
76. REMOVE REAR ENGINE COVER SUB-ASSEMBLY
a. Remove the 3 clips and engine cover.
77. REMOVE NO.3 WATER BY-PASS PIPE
a. Remove the bolt and water by-pass pipe.
78. REMOVE NO.4 WATER BY-PASS PIPE
a. Remove the bolt and water by-pass pipe.
79. REMOVE INTAKE AIR SURGE TANK SUB-ASSEMBLY
a. Remove the 2 bolts and intake manifold stay
b. Remove the 4 bolts and 2 surge tank stays.
c. Using a 5 mm hexagon socket wrench, remove the 7 bolts, 2 nuts and gasket.
HINT: Cover the intake manifold port to prevent foreign matter from entering it.
80. INSPECT INTAKE AIR SURGE TANK SUB-ASSEMBLY
a. Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.
Maximum Warpage:
If the warpage is greater than the maximum, replace the surge tank.
81. REMOVE INTAKE MANIFOLD
a. Remove the 4 bolts, 2 nuts, intake manifold and gasket.
HINT: Cover the cylinder head intake port to prevent foreign matter from entering it.
82. INSPECT INTAKE MANIFOLD
a. Surge tank side:
(1) Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.
Maximum warpage: 0.1 mm (0.003 inch)
If the warpage is greater than the maximum, replace the intake manifold.
b. Cylinder head side:
(1) Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.
Maximum warpage: 0.1 mm (0.003 inch)
If the warpage is greater than the maximum, replace the intake manifold.
83. REMOVE FUEL PRESSURE PULSATION DAMPER ASSEMBLY
84. REMOVE NO.1 FUEL PIPE SUB-ASSEMBLY
85. REMOVE NO.2 FUEL PIPE SUB-ASSEMBLY
86. REMOVE HIGH PRESSURE SIDE FUEL PUMP
87. REMOVE NO.2 FUEL DELIVERY PIPE SUBASSEMBLY
88. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
89. REMOVE FUEL INJECTOR ASSEMBLY
90. REMOVE KNOCK SENSOR
a. Remove the 2 bolts and 2 sensors.
91. REMOVE ENGINE MOUNTING BRACKET RH
a. Remove the 4 bolts and mounting bracket.
92. REMOVE ENGINE MOUNTING BRACKET LH
a. Remove the 4 bolts and mounting bracket.
93. REMOVE OIL FILLER CAP SUB-ASSEMBLY
94. REMOVE IGNITION COIL ASSEMBLY
a. Remove the 6 bolts and 6 ignition coils.
95. REMOVE ENGINE OIL LEVEL SENSOR
a. Remove the 4 bolts, then remove the oil level sensor and gasket.
96. REMOVE OIL PRESSURE SWITCH ASSEMBLY
a. Using a 24 mm deep socket wrench, remove the oil pressure switch.
97. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
a. Using a 19 mm deep socket wrench, remove the temperature sensor.