4wd NISSAN X-TRAIL 2005 Service Repair Manual

GI-1
GENERAL INFORMATION
A GENERAL INFORMATION
CONTENTS
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SECTION GI

GENERAL INFORMATION
PRECAUTIONS .......................................................... 3
Description ............................................................... 3
Precautions for Supplemental Restraint System
(SRS) “AIR BAG” and “SEAT BELT PRE-TEN-
SIONER” .................................................................. 3
Precautions for NATS (NISSAN ANTI-THEFT SYS-
TEM) ........................................................................ 3
General Precautions ................................................ 4
Precautions for All Mode 4 × 4 System .................... 5
Precautions for Three Way Catalyst ......................... 5
Precautions for Fuel ................................................. 5
GASOLINE ENGINE ............................................. 5
DIESEL ENGINE ................................................... 5
Precautions for Multiport Fuel Injection System or
Engine Control System ............................................ 6
Precautions for Turbocharger (If Equipped) ............. 6
Precautions for Hoses .............................................. 6
HOSE REMOVAL AND INSTALLATION ............... 6
HOSE CLAMPING ................................................ 7
Precautions for Engine Oils ...................................... 7
HEALTH PROTECTION PRECAUTIONS ............. 7
ENVIRONMENTAL PROTECTION PRECAU-
TIONS ................................................................... 7
Precautions for Air Conditioning ............................... 7
HOW TO USE THIS MANUAL ................................... 8
Description ............................................................... 8
Terms ....................................................................... 8
Units ......................................................................... 8
Contents ................................................................... 8
Components ............................................................. 9
SYMBOLS ............................................................. 9
How to Follow Trouble Diagnoses .......................... 10
DESCRIPTION .................................................... 10
HOW TO FOLLOW TEST GROUPS IN TROU-
BLE DIAGNOSES ............................................... 10
HARNESS WIRE COLOR AND CONNECTOR
NUMBER INDICATION ........................................ 11
KEY TO SYMBOLS SIGNIFYING MEASURE-
MENTS OR PROCEDURES ............................... 12
How to Read Wiring Diagrams ............................... 14CONNECTOR SYMBOLS ................................... 14
SAMPLE/WIRING DIAGRAM - EXAMPL - .......... 15
DESCRIPTION .................................................... 16
Abbreviations .......................................................... 22
SERVICE INFORMATION FOR ELECTRICAL INCI-
DENT ......................................................................... 23
How to Perform Efficient Diagnosis for an Electrical
Incident ................................................................... 23
WORK FLOW ...................................................... 23
INCIDENT SIMULATION TESTS ........................ 23
CIRCUIT INSPECTION ....................................... 26
Control Units and Electrical Parts ........................... 31
PRECAUTIONS .................................................. 31
CONSULT-II CHECKING SYSTEM .......................... 33
Description .............................................................. 33
Function and System Application ........................... 33
Nickel Metal Hydride Battery Replacement ............ 33
Checking Equipment .............................................. 34
CONSULT-II Start Procedure .................................. 34
CONSULT-II Data Link Connector (DLC) Circuit .... 35
INSPECTION PROCEDURE .............................. 35
LIFTING POINT ......................................................... 36
Special Service Tools ............................................. 36
Garage Jack and Safety Stand ............................... 36
2-Pole Lift ............................................................... 37
Board-On Lift .......................................................... 38
TOW TRUCK TOWING ............................................. 39
Tow Truck Towing ................................................... 39
2WD MODELS .................................................... 39
4WD MODELS .................................................... 40
Vehicle Recovery (Freeing a Stuck Vehicle) ........... 40
TIGHTENING TORQUE OF STANDARD BOLTS .... 41
Description .............................................................. 41
Tightening Torque Table (New Standard Included) ... 41
PREVIOUS STANDARD ..................................... 41
NEW STANDARD BASED ON ISO ..................... 42
DISCRIMINATION OF BOLTS AND NUTS ......... 43
IDENTIFICATION INFORMATION ............................ 44
Model Variation ....................................................... 44
IDENTIFICATION NUMBER ................................ 45

PRECAUTIONS
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Use approved bonding agent, sealants or their equivalents when required.

Use tools and recommended special tools where specified for safe and efficient service repairs.

When repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks.

Before servicing the vehicle:
Protect fenders, upholstery and carpeting with appropriate cov-
ers.
Take caution that keys, buckles or buttons do not scratch paint.
WARNING:
To prevent ECM from storing the diagnostic trouble codes, do not carelessly disconnect the harness
connectors which are related to the engine control system and TCM (transmission control module)
system. The connectors should be disconnected only when working according to the WORK FLOW of
TROUBLE DIAGNOSES in EC and AT sections.
Precautions for All Mode 4 × 4 SystemEAS000GQ
Even if the 2WD mode is selected, the All mode 4 × 4 system occasionally changes from 2WD to 4WD auto-
matically depending on the driving conditions.
When spinning the front wheels by running the engine with the front wheels jacked up or mounted on the free
rollers / or a chassis dynamometer, be careful because the vehicle may suddenly move due to the driving
force from the rear wheels.
To avoid personal injury and vehicle damage, use one of the following methods when working with the front
wheels drive force and spinning freely.

Remove the propeller shaft.

Use free rollers / chassis dynamometer designed for 4WD vehicles.
Precautions for Three Way CatalystEAS000FR
If a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. To
prevent this, follow the instructions.

Use unleaded gasoline only. Leaded gasoline will seriously damage the three way catalyst.

When checking for ignition spark or measuring engine compression, make tests quickly and only when
necessary.

Do not run engine when the fuel tank level is low, otherwise the engine may misfire, causing damage to
the catalyst.
Do not place the vehicle on flammable material. Keep flammable material off the exhaust pipe and the three
way catalyst.
Precautions for FuelEAS000P9
GASOLINE ENGINE
Use unleaded gasoline with an octane rating of at least 95 (RON).
CAUTION:
Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Using a fuel
other than that specified could adversely affect the emission control devices and systems, and could
also affect the warranty coverage validity.
DIESEL ENGINE
Diesel fuel of at least 50 cetane.
If two types of diesel fuel are available, use summer or winter fuel properly according to the following temper-
ature conditions.

Above –7°C (20°F) ... Summer type diesel fuel.

Below –7°C (20°F) ... Winter type diesel fuel.
SGI234

CONSULT-II CHECKING SYSTEM
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CONSULT-II CHECKING SYSTEMPFP:00000
DescriptionEAS000G8

CONSULT-II is a hand-held type tester. When it is connected with a diagnostic connector equipped on the
vehicle side, it will communicate with the control unit equipped in the vehicle and then enable various
kinds of diagnostic tests.

Refer to “CONSULT-II Software Operation Manual” for more information.
Function and System Application EAS000G9
x: Applicable
*1: Nissan Anti-Theft System
*2: Gasoline engine models
*3: This item is indicated, but it is what it does not use.
Nickel Metal Hydride Battery Replacement EAS000GA
CONSULT-II contains a nickel metal hydride battery. When replacing the battery obey the following:
WARNING:
Replace the nickel metal hydride battery with Genuine CONSULT-II battery only. Use of another bat-
tery may present a risk of fire or explosion. The battery may present a fire or chemical burn hazard if
mistreated. Do not recharge, disassemble or dispose of in fire.
Keep the battery out of reach of children and discard used battery conforming to the local regulations.
Diagnostic test
modeFunction
ENGINE
A/T
AIR BAG
ABS
ABS (Including ESP)
ALL MODE AWD/ 4WD
NATS*
1
HEADLAMP LEVELIZER
Work supportThis mode enables a technician to adjust some devices faster and more
accurately by following the indications on CONSULT-II.x*2x- -x- -x
Self-diagnostic
resultsSelf-diagnostic results can be read and erased quickly. x x x x x x x x
Trouble diagnos-
tic recordCurrent self-diagnostic results and all trouble diagnostic records previously
stored can be read.--x-----
Data monitor Input/Output data in the ECU can be read. x x - x x x - x
Active testDiagnostic Test Mode in which CONSULT-II drives some actuators apart
from the ECU and also shifts some parameters in a specified range.x - - xxx -x
CAN diagnosis
support monitorThe communication condition of CAN communication line can be indicated. x x - x x x - -
DTC confirmationThe results of SRT (System Readiness Test) and the self-diagnosis status/
result can be confirmed.x*
2-------
DTC work supportThe operating condition to confirm Diagnosis Trouble Codes can be
selected.- x------
ECU (ECM/TCM)
part numberECU (ECM/TCM) part number can be read. x x - x x x - x
ECU discrimi-
nated No.Classification number of a replacement ECU can be read to prevent an
incorrect ECU from being installed.--x-----
Function testThis mode can show results of self-diagnosis of ECU with either “OK” or
“NG”. For engines, more practical tests regarding sensors/switches and/or
actuators are available.xxxxx---
Control unit initial-
izationAll registered ignition key IDs in NATS components can be initialized and
new IDs can be registered.- -----x-
Configuration*
3— - ------x

GI-40
TOW TRUCK TOWING


When towing two wheel drive automatic transmission model with the rear wheels on the ground (if
you do not use towing dollies): Always release the parking brake.
4WD MODELS
NISSAN recommends that a dolly be used as illustrated when towing 4WD models.
CAUTION:
Never tow automatic transmission 4WD models with any of the wheels on the ground as this may
cause serious and expensive damage to the drive train.
Vehicle Recovery (Freeing a Stuck Vehicle) EAS001JC

Use the recovery hooks only, not other parts of the vehicle. Oth-
erwise, the vehicle body will be damaged.

Use the recovery hook only to free a vehicle stuck in sand,
snow, mud, etc. Never tow the vehicle for a long distance using
only the recovery hook.

The recovery hook is under tremendous force when used to free
a stuck vehicle. Always pull the cable straight out from the front
or rear of the vehicle. Never pull on the hook at an angle.

Stand clear of a stuck vehicle.
WARNING:

Do not spin the tires at high speed. This could cause them
to explode and result in serious injury. Parts of the vehicle
could also overheat and be damaged.
PAIA0275E
PAIA0014E

GI-44
IDENTIFICATION INFORMATION

IDENTIFICATION INFORMATIONPFP:00010
Model Variation EAS000GE
Prefix and suffix designations:
Body Axle Engine Transaxle GradeDestination
RHDSouthern/Central
EuropeNorthern Europe Russia
MPV4WDQR20DERS5F51A
(5 speed M/T)LE TDANRAF-EEA TDANLAF-EGA TDANLAF-ESA TDANLAF-EQA
GX TDANRFF-EEA TDANLFF-EGA TDANLFF-ESA TDANLFF-EQA
RE4F04B
(4 speed A/T)GX TDANRFA-EEA TDANLFA-EGA TDANLFA-ESA TDANLFA-EQA
SLX TDANRJA-EEA TDANLJA-EGA TDANLJA-ESA TDANLJA-EQA
QR25DERS5F51A
(5 speed M/T)GX TDBNRFF-EEA TDBNLFF-EGA TDBNLFF-ESA TDBNLFF-EQA
SLX TDBNRJF-EEA TDBNLJF-EGA TDBNLJF-ESA TDBNLJF-EQA
RE4F04B
(4 speed A/T)GX TDBNRFA-EEA TDBNLFA-EGA TDBNLFA-ESA TDBNLFA-EQA
SLX TDBNRJA-EEA TDBNLJA-EGA TDBNLJA-ESA TDBNLJA-EQA
YD22DDTRS6F51A
(6 speed M/T)LE TVHNRAY-UEA TVHNLAY-UGA TVHNLAY-USA —
GX TVHNRFY-UEA TVHNLFY-UGA TVHNLFY-USA —
SLX TVHNRJY-UEA TVHNLJY-UGA TVHNLJY-USA —
2WDQR20DERS5F51A
(5 speed M/T)LE TDAARAF-EEA TDAALAF-EGA TDAALAF-ESA —
GX TDAARFF-EEA TDAALFF-EGA TDAALFF-ESA —
YD22DDTRS6F51A
(6 speed M/T)LE TVHARAY-UEA TVHALAY-UGA TVHALAY-USA —
GX TVHARFY-UEA TVHALFY-UGA TVHALFY-USA —
SAIA0781E

EM-2 ROCKER COVER ..................................................... 44
Removal and Installation ........................................ 44
REMOVAL ........................................................... 44
INSTALLATION .................................................... 45
TIMING CHAIN .......................................................... 46
Removal and Installation ........................................ 46
REMOVAL ........................................................... 46
INSPECTION AFTER REMOVAL ........................ 50
INSTALLATION .................................................... 51
INSPECTION AFTER INSTALLATION ................ 55
CAMSHAFT ............................................................... 56
Removal and Installation ........................................ 56
REMOVAL ........................................................... 56
INSPECTION AFTER REMOVAL ........................ 58
INSTALLATION .................................................... 61
Valve Clearance ...................................................... 64
INSPECTION ....................................................... 64
ADJUSTMENT .................................................... 65
OIL SEAL .................................................................. 67
Removal and Installation of Valve Oil Seal ............. 67
REMOVAL ........................................................... 67
INSTALLATION .................................................... 67
Removal and Installation of Front Oil Seal ............. 67
REMOVAL ........................................................... 67
INSTALLATION .................................................... 68
Removal and Installation of Rear Oil Seal .............. 68
REMOVAL ........................................................... 68
INSTALLATION .................................................... 68
CYLINDER HEAD ..................................................... 70
On-Vehicle Service ................................................. 70
CHECKING COMPRESSION PRESSURE ......... 70
Removal and Installation ........................................ 71
REMOVAL ........................................................... 71
INSPECTION AFTER REMOVAL ........................ 72
INSTALLATION .................................................... 73
INSPECTION AFTER INSTALLATION ................ 73
Disassembly and Assembly .................................... 74
DISASSEMBLY ................................................... 74
ASSEMBLY ......................................................... 75
Inspection After Disassembly ................................. 77
VALVE DIMENSIONS .......................................... 77
VALVE GUIDE CLEARANCE .............................. 77
VALVE GUIDE REPLACEMENT ......................... 77
VALVE SEAT CONTACT ..................................... 79
VALVE SEAT REPLACEMENT ........................... 79
VALVE SPRING SQUARENESS ......................... 80
VALVE SPRING DIMENSIONS AND VALVE
SPRING PRESSURE LOAD ............................... 80
ENGINE ASSEMBLY ................................................ 81
Removal and Installation (2WD Models) ................ 81
REMOVAL ........................................................... 82
INSTALLATION .................................................... 83
INSPECTION AFTER INSTALLATION ................ 84
Removal and Installation (4WD Models) ................ 85
REMOVAL ........................................................... 85
INSTALLATION .................................................... 88
INSPECTION AFTER INSTALLATION ................ 88CYLINDER BLOCK ................................................... 89
Disassembly and Assembly .................................... 89
DISASSEMBLY .................................................... 90
ASSEMBLY .......................................................... 94
How to Select Piston and Bearing .......................... 99
DESCRIPTION .................................................... 99
HOW TO SELECT PISTON ...............................100
HOW TO SELECT CONNECTING ROD BEAR-
ING .....................................................................100
HOW TO SELECT MAIN BEARING ..................102
Inspection After Disassembly ................................107
CRANKSHAFT END PLAY ................................107
CONNECTING ROD SIDE CLEARANCE .........107
PISTON TO PISTON PIN OIL CLEARANCE .....107
PISTON RING SIDE CLEARANCE ...................108
PISTON RING END GAP ..................................108
CONNECTING ROD BEND AND TORSION .....109
CONNECTING ROD BIG END DIAMETER ......109
CONNECTING ROD BUSHING OIL CLEAR-
ANCE .................................................................109
CYLINDER BLOCK DISTORTION ....................110
MAIN BEARING HOUSING INNER DIAMETER . 111
PISTON TO CYLINDER BORE CLEARANCE .. 111
CRANKSHAFT MAIN JOURNAL DIAMETER ...112
CRANKSHAFT PIN JOURNAL DIAMETER ......113
OUT-OF-ROUND AND TAPER OF CRANK-
SHAFT ...............................................................113
CRANKSHAFT RUNOUT ..................................113
CONNECTING ROD BEARING OIL CLEAR-
ANCE .................................................................113
MAIN BEARING OIL CLEARANCE ...................114
MAIN BEARING CRUSH HEIGHT ....................115
CONNECTING ROD BEARING CRUSH
HEIGHT .............................................................115
LOWER CYLINDER BLOCK MOUNTING BOLT
OUTER DIAMETER ...........................................115
CONNECTING ROD BOLT OUTER DIAMETER .115
FLYWHEEL DEFLECTION (M/T MODELS) ......116
MOVEMENT AMOUNT OF FLYWHEEL (M/T
MODELS) ...........................................................116
SERVICE DATA AND SPECIFICATIONS (SDS) ....117
Standard and Limit ................................................117
GENERAL SPECIFICATIONS ...........................117
DRIVE BELT ......................................................117
INTAKE MANIFOLD AND EXHAUST MANI-
FOLD .................................................................117
SPARK PLUG ....................................................117
CYLINDER HEAD ..............................................117
VALVE ................................................................118
CAMSHAFT AND CAMSHAFT BEARING .........121
CYLINDER BLOCK ............................................122
PISTON, PISTON RING AND PISTON PIN ......123
CONNECTING ROD ..........................................124
CRANKSHAFT ...................................................124
MAIN BEARING .................................................126
CONNECTING ROD BEARING .........................127
Tightening Torque .................................................127

EM-4 INSTALLATION ..................................................191
Removal and Installation of Rear Oil Seal ............192
REMOVAL .........................................................192
INSTALLATION ..................................................192
SECONDARY TIMING CHAIN ................................193
Removal and Installation ......................................193
REMOVAL .........................................................193
INSPECTION AFTER REMOVAL ......................195
INSTALLATION ..................................................195
PRIMARY TIMING CHAIN ......................................198
Removal and Installation ......................................198
REMOVAL .........................................................200
INSPECTION AFTER REMOVAL ......................203
INSTALLATION ..................................................203
CYLINDER HEAD ...................................................209
On-Vehicle Service ...............................................209
CHECKING COMPRESSION PRESSURE .......209
Removal and Installation ......................................210
REMOVAL .........................................................210
INSPECTION AFTER REMOVAL ......................211
INSTALLATION ..................................................212
INSPECTION AFTER INSTALLATION ..............214
Disassembly and Assembly ..................................215
DISASSEMBLY .................................................215
ASSEMBLY .......................................................216
INSPECTION AFTER DISASSEMBLY ..............217
ENGINE ASSEMBLY ..............................................222
Removal and Installation (2WD Models) ..............222
REMOVAL .........................................................223
INSTALLATION ..................................................224
INSPECTION AFTER INSTALLATION ..............225
Removal and Installation (4WD Models) ..............226
REMOVAL .........................................................227
INSTALLATION ..................................................229
INSPECTION AFTER INSTALLATION ..............229
CYLINDER BLOCK .................................................230
Disassembly and Assembly ..................................230
DISASSEMBLY .................................................231
ASSEMBLY .......................................................235
How to Select Piston and Bearing ........................241
DESCRIPTION ..................................................241
HOW TO SELECT PISTON ...............................242
HOW TO SELECT CONNECTING ROD BEAR-
ING ....................................................................242HOW TO SELECT MAIN BEARING ..................244
Inspection After Disassembly ................................245
CRANKSHAFT END PLAY ................................245
CONNECTING ROD SIDE CLEARANCE .........246
PISTON TO PISTON PIN CLEARANCE ...........246
PISTON RING SIDE CLEARANCE ...................247
PISTON RING END GAP ..................................247
CONNECTING ROD BEND AND TORSION .....248
CONNECTING ROD BIG END INNER DIAME-
TER ....................................................................248
CONNECTING ROD BUSHING OIL CLEAR-
ANCE .................................................................248
CYLINDER BLOCK TOP SURFACE DISTOR-
TION ..................................................................249
MAIN BEARING HOUSING INNER DIAMETER .249
PISTON TO CYLINDER BORE CLEARANCE ..250
CRANKSHAFT MAIN JOURNAL DIAMETER ...251
CRANKSHAFT PIN JOURNAL DIAMETER ......251
CRANKSHAFT OUT-OF-ROUND AND TAPER .251
CRANKSHAFT RUNOUT ..................................252
CONNECTING ROD BEARING OIL CLEAR-
ANCE .................................................................252
MAIN BEARING OIL CLEARANCE ...................253
CRUSH HEIGHT OF MAIN BEARING ..............253
CRUSH HEIGHT OF CONNECTING ROD
BEARING ...........................................................253
MAIN BEARING CAP BOLT DEFORMATION ...254
CONNECTING ROD BOLT DEFORMATION ....254
OIL JET ..............................................................254
OIL JET RELIEF VALVE ....................................254
FLYWHEEL DEFLECTION ................................255
MOVEMENT AMOUNT OF FLYWHEEL ...........255
SERVICE DATA AND SPECIFICATIONS (SDS) ....256
Standard and Limit ................................................256
GENERAL SPECIFICATIONS ...........................256
INTAKE MANIFOLD AND EXHAUST MANI-
FOLD .................................................................256
DRIVE BELTS ....................................................256
CAMSHAFT .......................................................257
CYLINDER HEAD ..............................................259
VALVE ................................................................259
CYLINDER BLOCK ............................................262
PISTON, PISTON RING AND PISTON PIN ......263
CONNECTING ROD ..........................................264
CRANKSHAFT ...................................................264
AVAILABLE MAIN BEARING .............................265
AVAILABLE CONNECTING ROD BEARING .....265
Tightening Torque .................................................266

TIMING CHAIN
EM-47
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Hood assembly; Refer to BL-12, "HOOD" .

RH and LH undercovers

PCV hose; Refer to EM-18, "INTAKE MANIFOLD" .

Ignition coil; Refer to EM-31, "IGNITION COIL" .

Rocker cover; Refer to EM-44, "ROCKER COVER" .

Engine coolant reservoir tank; Refer to CO-12, "RADIATOR" .

Drive belt; Refer to EM-13, "REMOVAL" .

Alternator; Refer to SC-13, "CHARGING SYSTEM" .

Drive belt auto-tensioner; Refer to EM-14, "REMOVAL" .

Exhaust front tube; Refer to EX-2, "EXHAUST SYSTEM" .
2. Remove A/C compressor from engine. Temporarily secure A/C compressor to vehicle side with a rope to
avoid putting a load on them.
3. Remove bracket mounting bolts for fixing A/C piping on right strut housing and exhaust manifold cover.
Doing so simplifies moving.
4. Remove power steering oil pump with piping connected, and secure it to vehicle side temporarily. Refer to
PS-37, "
HYDRAULIC LINE" .
5. Remove power steering reservoir tank from bracket to move power steering piping. Refer to PS-37,
"HYDRAULIC LINE" .
CAUTION:
To avoid power steering fluid leakage, temporarily fix power steering reservoir tank vertically.
6. Install engine slingers into front left of cylinder head and rear
right of cylinder head.

Use alternator bracket mounting bolt holes for the front side.
7. Lift with hoist, and support the engine posture.
8. Remove RH engine mounting insulator and bracket. Refer to EM-81, "
ENGINE ASSEMBLY" .
9. Remove engine mounting related parts below. Refer to EM-81, "
Removal and Installation (2WD Models)"
(2WD models) or EM-85, "Removal and Installation (4WD Models)" (4WD models).

RH engine mounting insulator

Center member

Rear engine mounting bracket (2WD models)
10. Drain engine oil. Refer to LU-8, "
Changing Engine Oil" .
11. Remove oil pan (upper and lower), and oil strainer. Refer to EM-27, "
OIL PAN AND OIL STRAINER" .
12. Remove intake valve timing control cover.

Loosen bolts in reverse order as shown in the figure.

U s e a s e a l c u t t e r ( s p e c i a l s e r v i c e t o o l : K V 1 0 1111 0 0 ) o r e q u i v -
alent tool to cut liquid gasket for removal.
CAUTION:
Be careful not to damage mounting surface.
13. Pull chain guide between camshaft sprockets out through front cover.Slinger bolts:
Front
: 57.9 N·m (5.9 kg-m, 43 ft-lb)
Rear
: 28.0 N·m (2.9 kg-m, 21 ft-lb)
SBIA0271E
KBIA0085E

ENGINE ASSEMBLY
EM-85
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Removal and Installation (4WD Models)EBS00KNT
WARNING:

Situate vehicle on a flat and solid surface.

Place chocks at front and back of rear wheels.

For engines not equipped with engine slingers, attach proper slingers and bolts described in
PARTS CATALOG.
CAUTION:

Always be careful to work safely, avoid forceful or uninstructed operations.

Do not start working until exhaust system and engine coolant are cool enough.

If items or work required are not covered by the engine section, refer to the applicable sections.

Always use the support point specified for lifting.

Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for
unavoidable reasons, support at the rear axle jacking point with transmission jack or similar tool
before starting work, in preparation for the backward shift of center of gravity.

For supporting points for lifting and jacking point at rear axle, refer to GI-36, "Garage Jack and
Safety Stand" .
REMOVAL
Outline
Remove engine, transaxle and transfer assembly with front suspension member from vehicle downward. Sep-
arate front suspension member, and then separate engine and transaxle.
Preparation
1. Remove hood assembly. Refer to BL-12, "HOOD" .
1. Rear engine mounting insulator 2. Rear engine mounting bracket 3. RH engine mounting insulator
4. RH engine mounting bracket 5. Front engine mounting bracket 6. Front engine mounting insulator
7. Center member 8. LH engine mounting insulator 9. LH engine mounting bracket
10. Stopper 11. Grommet
PBIC3830E

EM-88
[QR]
ENGINE ASSEMBLY

9. Remove power steering oil pump with piping connected from engine. Move it aside on front suspension
member. Refer to PS-37, "
HYDRAULIC LINE" .
10. Remove front engine mounting and rear engine mounting through-bolts to remove front suspension mem-
ber and center member.
11. Remove starter motor. Refer to SC-23, "
STARTING SYSTEM" .
12. Separate engine and transaxle. Refer to MT-19, "
TRANSAXLE ASSEMBLY" (M/T models) or AT- 4 1 3 ,
"REMOVAL AND INSTALLATION" (A/T models).
INSTALLATION
Note the following, and install in the reverse order of removal.

Do not allow engine oil to get on engine mounting insulator. Be careful not to damage engine mounting
insulator.

When installation directions are specified, install parts according to the direction marks on them referring
to figure of components. Refer to EM-85, "
Removal and Installation (4WD Models)" .

Make sure that each mounting insulator is seated properly, and tighten mounting bolts and nuts.
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.

Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-17, "
RECOMMENDED FLUIDS AND LUBRICANTS" .

Use procedure below to check for fuel leakage.
–Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel
leakage at connection points.
–Start engine. With engine speed increased, check again for fuel leakage at connection points.

Run engine to check for unusual noise and vibration.

Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids
including engine oil and engine coolant.

Bleed air from lines and hoses of applicable lines, such as in cooling system.

After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the
specified level, if necessary.
Summary of the inspection items:
* Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —