Chock the rear wheels front and rear.
If the engine does not have lifting eyes, select them and bolts from the PARTS LIST.
Attention:
- Always carry out work in a safe environment, avoid performing unforeseen operations.
- Do not start work until the exhaust systems and engine coolant have cooled sufficiently.
- If the required components or operations are not covered in the Engine Mechanical chapter, refer to relevant chapters.
- Always lift the engine at the indicated points.
- Use either a 2-post lift or other self-contained lift at your disposal. If, for some reason, you have to use a stand under the side, before starting work, in order to avoid a shift in the center of gravity in the rear
- direction, support the vehicle at the point of support on the rear axle with a telescopic strut or similar device.
- For the stop points for the lift and jack on the rear axle, see chapter «Garage Jack, Safety Beds and 2 Post Lift».
Removing
Description of works
Remove the engine and transmission from the vehicle and separate the engine and transmission.
Preparatory work
1. If the engine can be hung on a winch, remove the hood. See chapter Body.
2. If the engine can be hoisted, remove the hood grille cover and hood grille extension assembly. See chapter Body.
3. Relieve fuel pressure. See chapter Engine management system.
4. Drain the engine coolant from the radiator. See chapter Lubrication system and engine cooling system.
Caution: Perform this operation when the engine is cold.
5. Remove the following components:
- engine protection from the bottom;
- headlights; see chapter electrical equipment;
- hood grille; see chapter Body;
- protective pad from the front right and left fenders; see chapter Body;
- front wheels;
- battery, battery shelf;
- drive belts; see section «Drive belts»;
- air duct and air cleaner housing assembly; see section «Air cleaner and air duct»;
- upper and lower radiator hoses, automatic transmission fluid cooler and cooling fan assembly; see chapter Lubrication system and engine cooling system;
- front exhaust pipe; see chapter Accelerator, fuel system and exhaust system.
In the engine compartment on the left
1. Disconnect all engine wiring connectors near left engine mount insulator and temporarily secure wiring harness to engine.
Caution: Place plastic bags over the connectors during operation to prevent foreign matter from getting on the connectors.
2. Disconnect the fuel hose from the engine side. See section «Fuel injectors and fuel pipe».
3. Disconnect the heater hoses. Seal the hoses with plugs to prevent engine coolant from escaping. See chapter Lubrication system and engine cooling system.
4. Disconnect the control linkage from the gearbox. See chapter Manual Transmission.
5. Disconnect the ground wire from the transmission side.
In the engine compartment on the right
1. Disconnect the ground wire between the front cover and the vehicle.
2. Remove generator and generator bracket. See chapter electrical equipment.
3. Remove the air conditioning compressor from the engine (on models with air conditioning) with the tubes connected and temporarily secure it to the vehicle with a rope so as not to stretch the tubes. See chapter Air conditioning automatic.
Under the bottom of the car
1. Remove the front wheel ABS sensors (left and right) from the swivel. See chapter Brake system.
2. Remove the brake caliper assembly with connected pipes from the steering knuckle. Temporarily secure it to the side of the car with a rope so as not to stretch the brake hose. See chapter Brake system.
3. Take out the drive shafts (left and right) from the swivel. See chapter Front axle and suspension.
4. Remove rear torque rod (1).
5. In preparation for separating the gearbox, remove the gearbox mounting bolts that go through the bottom rear of the oil pan (top). See chapters Manual Transmission and Automatic transmission.
Withdrawal operations
1. If the engine can be hung on a winch, remove the top of the intake manifold so that it is not touched by a hanging chain. See section «upper intake manifold».
2. If the engine can be hoisted from the winch, attach the engine lifting eyes to the left front (A) and back right (IN) cylinder heads and hang the engine on the winch.
Lifting eye bolts: 25.5 Nm (2.6 kg m)
3. Lift the engine with a winch and hang it in the required position.
4. Support the bottom of the engine and gearbox securely with a lift table trolley (suitable special tool) or an equivalent rigid fixture, e.g. telescopic pole and at the same time adjust the tension of the winch.
Caution: Place a piece of board or similar object as a support surface for stability.
5. Remove the steak of the right engine mount (1), right engine mount insulator (2) and right engine mount (3).
4. Insulator left engine mount
A. From the front of the engine
B. From the side of the gearbox.
6. Loosen the nut (WITH), that secures the through bolt of the engine mount.
7. Remove the engine and transmission assembly from the vehicle through the bottom, carefully manipulating the lifting devices.
Attention:
- During work, make sure that no part of the engine touches the body.
- Before and during lifting, check that all electrical wiring is disconnected.
- During removal, do not allow the vehicle to fall off the lifting device due to a shift in the center of gravity.
- If necessary, support the vehicle with a jack or equivalent at the rear.
Branch Operations
Caution: During this operation, securely support the engine by placing a block of wood under the engine oil pan and transmission oil pan, and hang it from the lifting eyes with a winch.
1. If lifting the engine with a winch is not performed at the same time, attach the engine lifting eyes at the front left and rear right of the cylinder head. See above «Withdrawal».
2. Remove the generator. See chapter electrical equipment.
3. Lift with a winch and position above the engine.
4. Separate the engine and transmission. See chapters Manual Transmission and Automatic transmission.
Installation
Installation is carried out in the reverse order of removal, taking into account the following:
Be careful not to damage the engine mount insulator or expose it to oil.
If installation direction is specified, refer to the component drawing above and install according to the direction marks.
Make sure all leg insulators are seated correctly and tighten the mounting nuts and bolts.
Tighten the bolts of the insulator of the right engine mount in the order indicated by the numbers in the figure.
Check after installation
Leak Check
The following are procedures for checking fluid, engine oil, and exhaust leaks.
Before starting the engine, check the oil/fluid levels, including engine coolant and engine oil. If the level is below normal, add and bring to the required level. See chapter General information and maintenance.
Check for fuel leaks as follows:
- Turn the ignition key to position «ON» (without starting the engine). After pressurizing the fuel lines, check for fuel leaks at the joints.
- Start the engine. While increasing the engine speed, check again for fuel leaks at the fuel line joints.
Let the engine run and check for unusual noise or vibration.
Warm up the engine well and check for fuel, exhaust, or oil/fluid leaks, including engine coolant and engine oil.
Bleed the pipes and hoses of the relevant systems, such as the cooling system.
After the engine has cooled down, check the oil/fluid levels again, including engine coolant and engine oil. Top up if necessary and bring to the required level.
Check table
Component | Before starting the engine | Engine running | After stopping the engine |
Engine coolant | Level | A leak | Level |
Engine oil | Level | A leak | Level |
Other oils and fluids** | Level | A leak | Level |
Fuel | A leak | A leak | A leak |
Traffic fumes | - | A leak | - |
*: Fluid for manual transmission, automatic transmission, brake fluid, etc