Section 154 (Partial Engine): Replacement
- DISCHARGE FUEL SYSTEM PRESSURE, see PRECAUTION .
- 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 REPLACEMENT .
- DRAIN ENGINE OIL
- DRAIN AUTOMATIC TRANSAXLE FLUID, see REPLACEMENT .
- 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-ASSEMBLY, see WINDSHIELD WIPER MOTOR ASSY .
- REMOVE WIPER LINK ASSEMBLY, see WINDSHIELD WIPER MOTOR ASSY .
- REMOVE COWL TOP TO COWL BRACE INNER NO. 1, see REPLACEMENT .
- REMOVE COWL TOP PANEL SUB-ASSEMBLY OUTER FRONT, see REPLACEMENT .
- REMOVE V-BANK COVER SUB-ASSEMBLY, see ADJUSTMENT .
- REMOVE BATTERY
- REMOVE AIR CLEANER CAP SUB-ASSEMBLY, see REPLACEMENT .
- REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
- 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 REPLACEMENT .
- REMOVE GENERATOR ASSEMBLY, 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 ASSEMBLY, see REPLACEMENT .
- DISCONNECT UNION TO CHECK VALVE HOSE
- DISCONNECT FUEL VAPOR FEED HOSE NO. 1
- DISCONNECT FUEL PIPE SUB-ASSEMBLY NO. 1, see PRECAUTION .
- 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 ASSEMBLY
- 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 ASSEMBLY CENTER (4WD DRIVE TYPE), see REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY .
- REMOVE EXHAUST PIPE ASSEMBLY FRONT (2WD DRIVE TYPE), see REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY .
- REMOVE EXHAUST PIPE ASSEMBLY FRONT (4WD DRIVE TYPE), see REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY .
- SEPARATE FRONT STABILIZER LINK ASSEMBLY LH, see REMOVAL & INSTALLATION .
- SEPARATE FRONT STABILIZER LINK ASSEMBLY RH
HINT:
Perform the same procedure as above on the opposite side.
- REMOVE FRONT AXLE HUB LH NUT, see REMOVAL & INSTALLATION
.
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 REMOVAL & INSTALLATION .
- SEPARATE SPEED SENSOR FRONT RH
HINT:
Perform the same procedure as above on the opposite side.
- SEPARATE TIE ROD ASSEMBLY LH, see REMOVAL & INSTALLATION
.
SST 09628-6201 1
- SEPARATE TIE ROD ASSEMBLY RH
SST 09628-6201 1
HINT:
Perform the same procedure as above on the opposite side.
- SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 LH, see REMOVAL & INSTALLATION .
- SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 RH
HINT:
Perform the same procedure as above on the opposite side.
- SEPARATE FRONT AXLE ASSEMBLY LH, see REMOVAL & INSTALLATION .
- SEPARATE FRONT AXLE ASSEMBLY RH
HINT:
Perform the same procedure as above on the opposite side.
- SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY, 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 the illustration).
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-ASSEMBLY RH (2WD DRIVE TYPE), see REPLACEMENT .
- REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (4WD DRIVE TYPE), see REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY .
- REMOVE VANE PUMP V BELT, see REPLACEMENT .
- REMOVE VANE PUMP ASSEMBLY
- 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 ASSEMBLY (4WD DRIVE TYPE)
- REMOVE FRONT FRAME ASSEMBLY
- Remove the 2 nuts and separate engine mounting insulator RH and LH.
- Remove the nut and separate the engine mounting insulator FR.
- (c) 4WD:
Remove the 2 bolts and separate the engine mounting insulator RR.
- REMOVE FRONT DRIVE SHAFT ASSEMBLY LH, see REMOVAL & INSTALLATION
.
SST 09520-01010, 09520-24010 (09520-32040)
- REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (2WD DRIVE TYPE), see REMOVAL & INSTALLATION .
- REMOVE FRONT DRIVE SHAFT ASSEMBLY RH (4WD DRIVE TYPE), see REMOVAL & INSTALLATION .
- REMOVE STARTER ASSEMBLY, see REPLACEMENT .
- REMOVE ENGINE MOUNTING BRACKET FR, see REPLACEMENT .
- REMOVE AUTOMATIC TRANSAXLE ASSEMBLY (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-ASSEMBLY, see REPLACEMENT
.
SST 09213-54015 (91651-60855), 09330-00021
- INSTALL ENGINE STAND
- REMOVE ENGINE HANGER NO. 2
- REMOVE EMISSION CONTROL VALVE SET, see ADJUSTMENT .
- REMOVE INTAKE AIR SURGE TANK, see ADJUSTMENT .
- REMOVE INTAKE MANIFOLD, see REPLACEMENT .
- REMOVE WATER OUTLET, see REPLACEMENT .
- REMOVE IGNITION COIL ASSEMBLY
- REMOVE MANIFOLD CONVERTER INSULATOR NO. 3
- REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 2
- REMOVE MANIFOLD STAY NO. 2
- REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY 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 ASSEMBLY
- Using a 27 mm deep socket wrench, remove the oil pressure switch.
- REMOVE KNOCK SENSOR, see REPLACEMENT .
- REPLACE PARTIAL ENGINE ASSEMBLY
- INSTALL KNOCK SENSOR, see REPLACEMENT .
- INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
- 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 REPLACEMENT .
- INSTALL WATER INLET, see REPLACEMENT .
- 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-ASSEMBLY 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 ASSEMBLY, see ADJUSTMENT .
- INSTALL WATER OUTLET, see REPLACEMENT .
- INSTALL INTAKE MANIFOLD, see REPLACEMENT .
- INSTALL INTAKE AIR SURGE TANK, see ADJUSTMENT .
- INSTALL EMISSION CONTROL VALVE SET, see ADJUSTMENT .
- INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY, see REPLACEMENT
.
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 COMPONENTS .
- INSTALL TRANSFER STIFFENER PLATE RH (4WD DRIVE TYPE), see COMPONENTS .
- INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (2WD DRIVE TYPE), see COMPONENTS .
- INSTALL ENGINE MOUNTING BRACKET FR, see COMPONENTS .
- INSTALL STARTER ASSEMBLY, see REPLACEMENT .
- INSTALL FRONT DRIVE SHAFT ASSEMBLY LH, see REMOVAL & INSTALLATION .
- INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (2WD DRIVE TYPE), see REMOVAL & INSTALLATION .
- INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (4WD DRIVE TYPE), see REMOVAL & INSTALLATION .
- INSTALL FRONT FRAME ASSEMBLY
- 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)
- (c) 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 ASSEMBLY (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 ASSEMBLY
- 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 REPLACEMENT .
- INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH (2WD DRIVE TYPE), see REPLACEMENT .
- INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (4WD DRIVE TYPE), see REPLACEMENT .
- INSTALL MANIFOLD STAY, see REPLACEMENT .
- INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 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 32N.m (329 kgf.cm, 24 ft.lbf)
Nut C 32N.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 32N.m (329 kgf.cm, 24 ft.lbf)
Nut C 32N.m (329 kgf.cm, 24 ft.lbf)
- INSTALL STEERING INTERMEDIATE SHAFT ASSEMBLY, see OVERHAUL .
- INSTALL FRONT AXLE ASSEMBLY LH, see REMOVAL & INSTALLATION .
- INSTALL FRONT AXLE ASSEMBLY RH
HINT:
Perform the same procedure as above on the opposite side.
- INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 LH, see REMOVAL & INSTALLATION .
- INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 RH
HINT:
Perform the same procedure as above on the opposite side.
- INSTALL TIE ROD ASSEMBLY LH, see REMOVAL & INSTALLATION .
- INSTALL TIE ROD ASSEMBLY RH
HINT:
Perform the same procedure as above on the opposite side.
- INSTALL SPEED SENSOR FRONT LH, see REMOVAL & INSTALLATION .
- INSTALL SPEED SENSOR FRONT RH
HINT:
Perform the same procedure as above on the opposite side.
- INSTALL FRONT AXLE HUB LH NUT, see REMOVAL & INSTALLATION .
- INSTALL FRONT AXLE HUB RH NUT
HINT:
Perform the same procedure as above on the opposite side.
- INSTALL FRONT STABILIZER LINK ASSEMBLY LH, see REMOVAL & INSTALLATION .
- INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT:
Perform the same procedure as above on the opposite side.
- INSTALL EXHAUST PIPE ASSEMBLY FRONT (2WD DRIVE TYPE), see REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY .
- INSTALL EXHAUST PIPE ASSEMBLY FRONT (4WD DRIVE TYPE), see REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY .
- INSTALL EXHAUST PIPE ASSEMBLY CENTER (4WD DRIVE TYPE), see REMOVAL & INSTALLATION AND DISASSEMBLY & REASSEMBLY .
- INSTALL PROPELLER SHAFT (4WD DRIVE TYPE), see OVERHAUL .
- CONNECT FUEL PIPE SUB-ASSEMBLY NO. 1, see PRECAUTION .
- INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY, see REPLACEMENT .
- 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 x REPLACEMENT .
- INSTALL ENGINE MOVING CONTROL ROD, see REPLACEMENT .
- INSTALL GENERATOR ASSEMBLY, see REPLACEMENT .
- INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1, see REPLACEMENT .
- INSPECT DRIVE BELT DEFLECTION AND TENSION (REFERENCE), see INSPECTION .
- 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-ASSEMBLY, see REPLACEMENT .
- CONNECT VACUUM HOSE
- INSTALL V-BANK COVER SUB-ASSEMBLY, see ADJUSTMENT .
- INSTALL COWL TOP PANEL SUB-ASSEMBLY OUTER FRONT, see REPLACEMENT .
- INSTALL COWL TOP TO COWL BRACE INNER NO. 1, see REPLACEMENT .
- INSTALL WIPER LINK ASSEMBLY, 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 REPLACEMENT .
- ADD TRANSFER OIL (4WD DRIVE TYPE), see ADJUSTMENT .
- INSPECT TRANSFER OIL (4WD DRIVE TYPE), see ADJUSTMENT .
- ADD AUTOMATIC TRANSAXLE FLUID
- ADD ENGINE OIL, see REPLACEMENT .
- ADD COOLANT, see REPLACEMENT .
- ADD POWER STEERING FLUID
- BLEED POWER STEERING FLUID
- INSPECT AUTOMATIC TRANSAXLE FLUID, see ON-VEHICLE INSPECTION .
- CHECK FOR ENGINE OIL LEAKS
- CHECK FOR ENGINE COOLANT LEAKS, see REPLACEMENT .
- CHECK POWER STEERING FLUID LEAKAGE
- INSPECT FOR FUEL LEAKS
- CHECK FOR EXHAUST GAS LEAKS
- INSPECT AND ADJUST FRONT WHEEL ALIGNMENT, see ADJUSTMENT .
- INSPECT STEERING WHEEL CENTER POINT
- INSPECT IGNITION TIMING, see INSPECTION
.
SST 09843-18040
- INSPECT ENGINE IDLE SPEED, see INSPECTION
.
SST 09843-18040
- INSPECT CO/HC, see INSPECTION .
- CHECK ABS SPEED SENSOR SIGNAL, see PRE-CHECK .