Attention:
- Before disconnecting the fuel supply hose, be sure to relieve the fuel pressure (see chapter Engine power supply system).
- Observe fire safety precautions.
- Do not open the radiator cap when the engine is hot, as the coolant is under pressure and may spill out. After the coolant has cooled, cover the cap with a rag and open it slowly.
- Install the jack, supports and lifting hooks in their designated locations.
- For safety, place the removed wheels behind the sill support.
- Lock the rear wheels with the parking brake and support them with wheel chocks.
- To avoid damaging the paintwork, cover with film.
- To avoid damaging the electrical wiring, disconnect the connectors carefully, holding the connector. Also, make sure that the electrical wiring and hoses do not get pinched or touch surrounding components.
- Be careful not to let coolant come into contact with electrical components or paintwork. If coolant does come into contact with them, wipe them off immediately.
- After changing the oil, dispose of the used oil in the prescribed manner.
1. Disconnect the cables from the battery terminals.
Caution: Disconnect the cable from the negative terminal first.
Before connecting the cables, clean the contact surfaces of the terminals with sandpaper and apply grease to them.
2. Remove the air intake pipe and air cleaner cover assembly.
3. Open the hood and secure it with a stand as shown in the figure.
4. Disconnect the power supply cables from the fuse box.
5. Disconnect the ECU and main electrical wiring connectors, remove the electrical wiring clamps.
6. Remove the rubber bushing and pull out the engine electrical wiring.
7. Pull the left side connector out from the stand and disconnect it.
8. Relieve the fuel pressure (see chapter Engine power supply system).
9. Disconnect the carbon filter hoses, fuel supply and return hoses, remove the power steering pump hose clamps.
10. Disconnect the throttle cable.
Attention:
- Do not bend the cable when disconnecting and connecting.
- If the cable is kinked, replace it with a new one.
- Place a mark on the location of the adjusting nut.
- After connecting the cable, be sure to perform adjustment (see chapter Engine Management System).
11. Disconnect the vacuum hoses and the main vacuum hose.
12. Unscrew the mounting and locking bolts, remove the belt and the steering pump.
- Do not disconnect the power steering pump hoses.
13. Loosen the fastening and locking bolt, lock nut and adjusting bolt, remove the alternator belt.
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14. Disconnect the starter cable, ground cable, remove the electrical wiring clamp.
15. Loosen the front mounting bracket mounting bolts and loosen the mounting bolt.
16. Unscrew the mounting nut and remove the rear stiffener of the mounting bracket.
17. Remove the radiator cap.
18. Raise the front of the vehicle with a jack and place it on a rigid support.
19. Remove the mudguard.
20. Loosen the radiator drain cock and drain the coolant (see below).
21. Drain the fluid from the gearbox (see chapter Automatic transmission).
- Use a 9.5mm (3/8 inch) square socket to remove the drain plug bolt.
- When installing the bolt, be sure to replace the washer.
22. Drain the engine oil (see above).
- When installing the bolt, be sure to replace the washer.
Caution: Do not overtighten the drain bolt.
23. Disconnect the oxygen sensor connector.
24. Remove the exhaust pipe A.
25. Remove the shock absorber forks (see chapter Front and rear suspension).
26. Remove the ball joints of the lower suspension arms (see chapter Front and rear suspension).
27. Remove the drive shafts from the differential and from the intermediate shaft (see chapter Drive shafts and rear differential).
28. Remove the control cable.
2WD models
1) Loosen the control cable stand mounting bolts and remove the control cable cover.
Caution: If you remove the control cable cover without unscrewing the cable stand bolts, the lever may break.
2) Remove the lever from the control shaft and remove the cable.
- Do not kink the cable.
- After installation, adjust (see chapter Automatic transmission).
4WD models
- 1) Remove the cover and control cable stand.
- 2) Remove the shift shaft, remove the control lever from the control shaft and remove the cable.
- Do not kink the cable.
- After installation, adjust (see chapter Automatic transmission).
29. Remove the driveshaft.
- Before removal, mark the connection areas so that installation can be performed according to these marks.
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30. Disconnect the upper and lower radiator hoses, as well as the heater hose.
31. Disconnect the automatic transmission radiator hoses.
- Install plugs on the automatic transmission radiator hoses and pipes.
- During installation see chapter Automatic transmission.
32. Disconnect the air conditioning compressor.
- Do not disconnect the hoses.
33. Remove the power steering pump hose clamps.
34. Install the special tool and hang the engine.
35. Unscrew the longitudinal rod mounting bolts.
36. Remove the front beam.
- Before removing the front beam, mark the connection areas with the rear beam so that installation can be performed according to these marks.
37. Remove the rear mounting bracket.
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38. Remove the stopper, disconnect the ground cable and remove the upper bracket.
39. Remove the gearbox mounting bracket.
40. Make sure that all cables, hoses, and electrical wiring are disconnected from the engine.
41. Gradually lower the engine assembly so that it does not touch the body, rear beam and radiator.
Caution: Do not stand under the vehicle while lowering the engine.
Brackets and tightening forces of bolts and nuts
