REMOVAL AND INSTALLATION


caution *: indicates parts which should be temporarily tightened, and then fully tightened with the engine weight applied on the vehicle body.
Pre-removal Operation
  • Engine Room Under Cover and Side Cover Removal (Refer to GROUP 51 - Under Cover ).
  • Engine Coolant Draining.
  • Clutch Fluid Draining
  • Engine Oil Draining.
  • Transmission Oil Draining (Refer to GROUP 22A - On-vehicle Service, Transmission Oil Replacement ).
  • Transfer Oil Draining (Refer to GROUP 22A - On-vehicle Service, Transfer Oil Replacement ).
  • Battery and Battery Tray Removal (Refer to GROUP 54A - Battery ).
  • Engine-ECU Removal (Refer to GROUP 13E - Engine-ECU ).
  • Suction Hose and Pressure Hose Removal (Refer to GROUP 37 - Power Steering Oil Pump Assembly ).
  • Suction Flexible Hose and Discharge Flexible Hose Removal (Refer to GROUP 55 - Compressor Assembly ).
  • Air Cleaner Assembly Removal (Refer to GROUP 15 - Air Cleaner ).
  • Fuel Filter Removal (Refer to GROUP 13B - Fuel Filter ).
  • Radiator Condenser Tank, Radiator Upper Hose and Radiator Lower Hose Removal (Refer to GROUP 14 - Radiator ).
  • Intercooler Air Hose D, E, F and Air Pipe B, D Removal (Refer to GROUP 15 - Intercooler ).
  • Propeller Shaft Removal (Refer to GROUP 25 - Propeller Shaft .)
  • Drive Shaft Removal (Refer to GROUP 26 - Drive Shaft .)
  • Backbone Brace and DPF assembly Removal (Refer to GROUP 15 - Exhaust Pipe, Main Muffler and Catalytic converter .)
  • Centre Member Removal (Refer to GROUP 32 - Engine Roll Stopper and Centre Member .)
  • Crossmember Removal (Refer to GROUP 32 - Crossmember ).

 Post-installation Operation
  • Crossmember Installation (Refer to GROUP 32 - Crossmember ).
  • Centre Member Installation (Refer to GROUP 32 - Engine Roll Stopper and Centre Member .)
  • Backbone Brace and DPF assembly Installation (Refer to GROUP 15 - Exhaust Pipe, Main Muffler and Catalytic converter .)
  • Drive Shaft Installation (Refer to GROUP 26 - Drive Shaft .)
  • Suction Flexible Hose and Discharge Flexible Hose Installation (Refer to GROUP 55 - Compressor Assembly ).
  • Fuel Filter Installation (Refer to GROUP 13B - Fuel Filter ).
  • Intercooler Air Hose D, E, F and Air Pipe B, D Installation (Refer to GROUP 15 - Intercooler ).
  • Radiator Condenser Tank,Radiator Upper Hose and Radiator Lower Hose Installation (Refer to GROUP 14 - Radiator ).
  • Propeller Shaft Installation (Refer to GROUP 25 - Propeller Shaft .)
  • Suction Hose and Pressure Hose Installation (Refer to GROUP 37 - Power Steering Oil Pump Assembly ).
  • Air Cleaner Assembly Installation (Refer to GROUP 15 - Air Cleaner ).
  • Battery and Battery Tray Installation (Refer to GROUP 54A - Battery ).
  • Engine-ECU Installation (Refer to GROUP 13E - Engine-ECU ).
  • Transfer Oil Refilling (Refer to GROUP 22A - On-vehicle Service, Transfer Oil Replacement ).
  • Transmission Oil Refilling (Refer to GROUP 22A - On-vehicle Service, Transmission Oil Replacement ).
  • Engine Coolant Refilling (Refer to GROUP 14 - On-vehicle Service, Engine Coolant Replacement ).
  • Engine Oil Refilling.
  • Clutch Line Bleeding (GROUP 21A- On-vehicle Service, Clutch Bleeding ).
  • Fuel Leak Check
  • Engine Room Under Cover and Side Cover Installation (Refer to GROUP 51 - Under Cover ).




Removal steps


1.
 Engine cover


2.
 Engine wiring harness


3.
 Battery wiring harness


4.
 Brake booster vacuum hose connection


5.
 Heater water hoses connection


6.
 Heater water hoses connection


7.
 Fuel return line hose connection


8.
 Fuel line hose connection




Removal steps
<<A>>
 >>C<
 9.
 Clutch tube assembly B connection


10.
 Cable bracket and transmission control cable assembly (Transmission side)


11.
 Transmission assembly lower part coupling bolts


12.
 Back-up lamp switch connector connection
<<B>>
13.
 Engine mounting bracket
<<B>>
14.
 Transmission mounting bracket

>>B<<
 15.
 Engine and transmission assembly


·
 Transfer assembly (Refer to GROUP 22A - Transfer Assembly ).


16.
 Transmission assembly

>>A<<
 17.
 Engine assembly

REMOVAL SERVICE POINTS

<<A>> CLUTCH TUBE ASSEMBLY B CONNECTION REMOVAL



caution
  • Do not remove the O-rings and the clips from the clutch tube assembly.
  • If the O-rings or the clips of the clutch tube assembly is damaged, replace the assembly.

<<B>>ENGINE MOUNTING BRACKET/ TRANSMISSION MOUNTING BRACKET REMOVAL


1.Set the special tool in the position shown in the figure.
2.Adjust the height of the special tool so that no load is applied to the engine mounting bracket and transmission mounting bracket.
3.Remove each coupling bolt and nut of the transmission mounting insulator and stopper.
4.Remove the Engine mounting bracket and transmission mounting bracket.

INSTALLATION SERVICE POINTS

>>A<< ENGINE ASSEMBLY INSTALLATION


Set the special tool in the position shown in the figure.

>>B<< ENGINE AND TRANSMISSION ASSEMBLY INSTALLATION
Install the engine assembly, being careful not to pinch the cables, hoses, or wiring harness connectors.

>>C<< CLUTCH TUBE ASSEMBLY B CONNECTION INSTALLATION

caution
  • Check that the O-rings and the clips are not damaged before installing the clutch tube assembly.
  • If the O-rings of the clutch tube assembly and their installation positions are contaminated, clean with the clutch fluid before installation.
After installing the clip to the clutch tube, install the other clutch tube.