REMOVAL AND INSTALLATION


Pre-removal Operation
  • Hood Removal (Refer to GROUP 42 - Hood ).
  • Engine Oil Draining (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Air Cleaner Assembly Removal (Refer to GROUP 15 - Air Cleaner ).
  • Battery Removal
  • Cooling Fan and Fan Clutch Assembly Removal (Refer to GROUP 14 - Cooling Fan ).
  • Radiator Removal (Refer to GROUP 14 - Radiator ).
  • Windshield Wiper Assembly Removal (Refer to GROUP 51 - Windshield Wiper ).
  • Cowl Top Panel Front Removal

 Post-installation Operation
  • Cowl Top Panel Front Installation
  • Windshield Wiper Assembly Installation (Refer to GROUP 51 - Windshield Wiper ).
  • Radiator Installation (Refer to GROUP 14 - Radiator ).
  • Cooling Fan and Fan Clutch Assembly Installation (Refer to GROUP 14 - Cooling Fan ).
  • Battery Installation
  • Air Cleaner Assembly Installation (Refer to GROUP 15 - Air Cleaner ).
  • Engine Oil Refilling (Refer to GROUP 12 - On-vehicle Service, Engine Oil Replacement ).
  • Air Bleeding from Fuel Line (Refer to GROUP 13A - On-vehicle Service, Evacuation of Air from Fuel Line ).
  • Hood Installation (Refer to GROUP 42 - Hood ).




Removal steps


1.
 Engine cover


2.
 Earth cable connection


3.
 Control wiring harness connection


4.
 Battery cable connection
<<A>>
5.
 Power steering oil pump assembly
<<B>>
6.
 A/C compressor assembly


7.
 Brake booster vacuum hose connection


8.
 Boost sensor vacuum hose connection


9.
 Heater piping hose connection


10.
 Free-wheeling hub solenoid valve vacuum hose connection <4WD>


11.
 Fuel hose D connection


12.
 Fuel return hose connection
<<C>>
·
 Transmission assembly <M/T>.


·
 Transmission assembly (Refer to GROUP 23A - Transmission Assembly ) <4A/T>.


·
 Transmission assembly (Refer to GROUP 23A - Transmission Assembly ) <5A/T>.


13.
 Front engine mounting insulator mounting bolt
<<D>>
 >>A<<
 14.
 Engine assembly

REMOVAL SERVICE POINTS

<<A>> POWER STEERING OIL PUMP ASSEMBLY REMOVAL
1.With the hose installed, remove the power steering oil pump assembly from the bracket.
2.After removing the power steering oil pump assembly, secure it with a cord in the location where the removal and installation of the engine assembly cannot be hindered.

<<B>> A/C COMPRESSOR ASSEMBLY REMOVAL
1.With the hose installed, remove the A/C compressor assembly from the bracket.
2.After removing the A/C compressor assembly, secure it with a cord in the location where the removal and installation of the engine assembly cannot be hindered.

<<C>> TRANSMISSION ASSEMBLY REMOVAL <M/T>
caution Do not remove the flywheel bolt. If this bolt is removed, the flywheel assembly will become out of balance and damaged.

Refer to GROUP 22A - Transmission Assembly <2WD>.
Refer to GROUP 22A - Transmission Assembly <4WD>.

<<D>> ENGINE ASSEMBLY REMOVAL
1.Check that all cables, hoses and wiring harness connectors are disconnected from the engine

2.Lift the special tool sling chain set (MB991683) and chain block slowly to remove the engine assembly upwards from the engine compartment.

INSTALLATION SERVICE POINT

>>A<< ENGINE ASSEMBLY INSTALLATION

1.Use special tool sling chain set (MB991683) and chain block to lift the engine assembly in the same manner as removal.
2.Install the engine assembly, being careful not to pinch the cables, hoses or wiring harness connectors.