Removal
Remove the lower protective covers.
Raise the power unit to release the engine mount from the power unit load and remove the engine mount.
Insert the special tool (a ratchet or a 12.7 mm insert) into the special hole of the automatic tensioner of the drive belt of the auxiliary units in the assembly.
Turn the automatic tensioner counterclockwise to align hole "A" with hole "B".
Caution: If the accessory drive belt is reused, mark an arrow with chalk on the reverse (non-working) side of the belt indicating the direction of rotation.
Insert the special key into the hole for fixing the automatic tensioner and remove the accessory drive belt.
Note: Instead of a special key, it is permissible to use a wire, which must be bent at a right angle.
Remove residual pressure from the high pressure fuel line.
Drain the coolant.
Drain the engine oil.
Drain the transmission and transfer case oil (4WD models).
Remove the hood.
Remove the air filter.
On 4G69 series engines, disconnect the accelerator pedal cable.
Remove the radiator assembly.
Disconnect the exhaust pipe from the exhaust manifold.
Remove the gearbox and transfer case assembly.
Remove the accessory drive belt.
Remove the power steering pump from the engine along with the hoses and bracket attached to it.
Note: Secure the power steering pump and hoses with wire in a location where it will not be damaged or interfere with removal and installation of the engine assembly.
Disconnect the compressor wire connector and the air conditioner electromagnetic clutch assembly.
Remove the compressor from its bracket with the hoses attached.
Note: Secure the air conditioning compressor pump assembly with hoses to the body in a location where it will not be damaged or interfere with removal and installation of the engine assembly.
On 4G69 series engines, disconnect the high pressure fuel hose.
Removal the gearbox assembly
Temporarily install 2 bolts into the upper radiator supports for installing special tools as shown in the figure.
Remove the gearbox assembly.
Place a hydraulic wheel jack under the engine.
Remove the special tools used to remove the gearbox.
Mount the engine on the crossbar and hang it on a hoist or similar device as shown in the figure.
Place a block of wood between the jack base and the engine oil pan.
Raise the engine slightly to relieve the support from the weight of the engine.
Loosen the bracket mounting nuts and bolts and remove the engine mount assembly with the bracket.
Check that all cables, wires, hoses and other connections are disconnected from the engine.
Install special devices (engine lift and crossbar) on the engine.
Using these tools, lift the engine assembly up out of the engine compartment.
Note: Make sure it does not move to the side or swing.
Installation
Installation is carried out in the reverse order of removal.
Using special tools (engine lift and crossbar), lower and install the engine assembly into the engine compartment.
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Remove the special tools (engine lift and crossmember) from the engine.
When installing the engine, check that the wires, tubes, hoses and wire connectors are connected correctly. Make sure that they are not twisted or damaged.
Check that the clamps and clips are installed correctly.
Place a hydraulic wheel jack under the engine.
Insert a wooden block between the jack support foot and the engine oil pan. Install the engine support, adjusting its position with the jack.
Support the engine with a jack and disconnect the hoist.
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When installing the self-locking nut, do not tighten it on a warm engine.
Tightening torque of the self-locking nut: 45+5 Nm.
Install the gearbox assembly.
Remove 2 bolts from the upper radiator support.
On 4G69 series engines, connect the high pressure fuel hose.
Install the gearbox and transfer case assembly.
Connect the exhaust pipe to the exhaust manifold.
Install the radiator assembly.
On 4G69 series engines, connect the accelerator pedal cable.
Install the air filter.
Install the hood.
Fill the transmission and transfer case (4WD models) with oil.
Fill with coolant and engine oil.
Install the lower guards.