Part 2

ENGINE ASSEMBLY

COMPONENTS:

REMOVAL (STEPS 56-110)

56. REMOVE EXHAUST PIPE NO. 1 SUPPORT BRACKET SUB-ASSEMBLY (for Automatic Transmission)
a. Remove the 2 bolts and exhaust pipe No. 1 support bracket sub-assembly.

57. DISCONNECT POWER STEERING LINK WIRE HARNESS (for 2WD)
a. Remove the bolt (A) to disconnect the earth wire from the bracket.
b. Remove the 2 clamps to disconnect the wire harness from the bracket.
c. Disconnect the 2 connectors (C) and (D) from the power steering link assembly.
d. Release the lock of connector (E) and disconnect the connector from the power steering link assembly.
e. Remove the bolt (B) and the power steering earth wire from the power steering link assembly.

58. DISCONNECT POWER STEERING LINK WIRE HARNESS (for 4WD)
a. Remove the bolt (A) and the power steering earth wire from the power steering link assembly.
b. Remove the bolt (B) to disconnect the earth wire from the bracket.
c. Remove the 2 clamps to disconnect the wire harness from the front frame.
d. Disconnect the 2 connectors (C) and (D) from the power steering link assembly.
e. Release the lock of connector (E) and disconnect the connector from the power steering link assembly.
f. Remove the bolt (F) to disconnect the bracket from the front frame.
59. DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for 2WD)
60. DISCONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for 4WD)
61. REMOVE ENGINE AND TRANSMISSION ASSEMBLY (for 2WD)
a. Set the engine lifter.

b. Remove the 4 bolts, then separate the engine rear mounting member.

c. Remove the 12 bolts shown in the illustration.
d. Operate the engine lifter, then slowly remove the engine from the vehicle.

NOTICE: Make sure that the engine is clear of all wiring and hoses.

62. REMOVE ENGINE AND TRANSMISSION ASSEMBLY (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 from the vehicle.

NOTICE: Make sure that the engine is clear of all wiring and hoses.

63. INSTALL ENGINE HANGERS
a. Install the No. 1 and No. 2 or No. 3 engine hangers with the 4 bolts as shown in the illustration.
Torque: 33 Nm (336 kgf-cm, 24 ft. lbs.)

Part No.:

b. Attach an engine sling device and hang the engine with a chain block.
64. REMOVE FRONT PROPELLER SHAFT ASSEMBLY (for 4WD)
65. REMOVE STARTER ASSEMBLY
66. REMOVE MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission)
67. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)
68. REMOVE OIL DIPSTICK GUIDE SUB-ASSEMBLY (for 2WD)

a. Remove the oil level gauge.
b. Remove the bolt, then remove the No. 2 oil dipstick guide.
c. Remove the O-ring from the No. 2 oil dipstick guide.

d. Remove the bolt and clamp, then remove the No. 1 oil dipstick guide.
e. Remove the O-ring from the No. 1 oil dipstick guide.
69. REMOVE OIL DIPSTICK GUIDE SUB-ASSEMBLY (for 4WD)

a. Remove the oil level gauge.
b. Remove the bolt, then remove the No. 2 oil dipstick guide.
c. Remove the O-ring from the No. 2 oil dipstick guide.

d. Remove the bolt, then remove the No. 1 oil dipstick guide.
e. Remove the O-ring from the No. 1 oil dipstick guide.
70. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
a. Disconnect the heated oxygen sensor connector.

b. Remove the 6 nuts, exhaust manifold and gasket.

71. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH
a. Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.
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.

72. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Disconnect the heated oxygen sensor connector.

b. Remove the 6 nuts, exhaust manifold and gasket.

73. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.
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.

74. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH (for 4WD)
75. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD)
76. REMOVE FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)

a. Using SST, hold the crankshaft.
SST 09213-70011 (09213-70020), 09330-00021

b. Remove the 8 bolts and the flywheel.
77. REMOVE DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission)

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.

78. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (for 2WD)
a. Remove the 2 bolts, then separate the front suspension crossmember sub-assembly from the engine.

79. REMOVE FRONT FRAME ASSEMBLY (for 4WD)
a. Remove the 2 bolts, then separate the front frame assembly from the engine.
80. FIX ENGINE ON ENGINE STAND
a. Fix the engine onto a engine stand with the bolts.
81. REMOVE V-RIBBED BELT

82. REMOVE NO. 2 ENGINE COVER
a. Remove the 3 clips and clamp, then remove the No. 2 engine cover.

83. REMOVE NO. 1 ENGINE COVER
a. Remove the 3 clips, then remove the No. 1 engine cover.

84. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY
a. Remove the bolt, plate and idler pulley.
85. REMOVE GENERATOR ASSEMBLY
86. REMOVE COOLER COMPRESSOR ASSEMBLY (for 2WD)
7. MOVE OIL FILTER BRACKET (for 4WD)
88. REMOVE COOLER COMPRESSOR ASSEMBLY (for 4WD)

89. REMOVE ENGINE MOUNTING BRACKET LH
a. Disconnect the 2 clamps.
b. Remove the 4 bolts and mounting bracket.

90. REMOVE ENGINE MOUNTING BRACKET RH
a. Remove the 4 bolts and mounting bracket.

91. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
a. Remove the 5 bolts, then remove the V-ribbed belt tensioner assembly. (2WD)
b. Remove the 4 bolts, then remove the V-ribbed belt tensioner assembly. (4WD)
92. REMOVE FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD)
93. REMOVE WATER PUMP PULLEY
94. REMOVE ENGINE WIRE
a. Remove the engine wire from the engine.

95. REMOVE INJECTOR DRIVER
a. Remove the bolt, 2 nuts and injector driver.
96. REMOVE INTAKE AIR SURGE TANK ASSEMBLY

97. INSPECT INTAKE AIR SURGE TANK ASSEMBLY
a. Using a precision straightedge and feeler gauge, measure the warpage on the contact surface of the cylinder head.
Maximum warpage: 2.5 mm (0.098 inch)
If the warpage is greater than the maximum, replace the surge tank.
98. REMOVE NO. 2 SURGE TANK STAY
a. Remove the bolt and No. 2 surge tank stay.

99. REMOVE WATER HOSE JOINT
a. Remove the bolt, and disconnect 2 hoses and water hose joint.
100. REMOVE INTAKE MANIFOLD

101. 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.
102. REMOVE FUEL PUMP
103. REMOVE FUEL INJECTOR ASSEMBLY
104. REMOVE KNOCK SENSOR

105. REMOVE RADIO SETTING CONDENSER
a. Remove the 2 bolts and 2 radio setting condensers.

106. REMOVE V-BANK COVER BRACKET SUB-ASSEMBLY
a. Remove the bolt and V-bank cover bracket.
107. REMOVE IGNITION COIL ASSEMBLY
a. Remove the 6 bolts and 6 ignition coils.

108. REMOVE ENGINE OIL LEVEL SENSOR
a. Remove the 4 bolts, then remove the oil level sensor and gasket.

109. REMOVE OIL PRESSURE SWITCH ASSEMBLY
a. Using a 24 mm deep socket wrench, remove the oil pressure switch.

110. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
a. Using a 19 mm deep socket wrench, remove the temperature sensor.