18. Disconnect the power steering reservoir tank from the engine and move it aside.
19. Disconnect the power steering oil pump from the engine. Move it aside and secure it using suitable wire or

rope. Refer to

ST-24, "Removal and Installation"

20. Remove the A/C compressor bolts and set the compressor aside. Refer to

HA-40, "Removal and Installa-

tion for Compressor"

21. Disconnect the brake booster vacuum line.

22. Disconnect the EVAP line.
23. Disconnect the fuel hose at the engine side connection. Refer to

EM-180, "Removal and Installation"

24. Disconnect the heater hoses at the cowl, and install plugs to avoid leakage of engine coolant.

25. Remove the A/T oil level indicator and indicator tube upper bolts.
26. Remove the front final drive assembly (4WD models). Refer to

DLN-376, "Removal and Installation"

27. Remove the exhaust manifolds. Refer to

EM-170, "Removal and Installation"

28. Remove the A/T. Refer to

TM-225, "2WD : Removal and Installation"

(2WD models) or

TM-228, "4WD :

Removal and Installation"

(4WD models).

29. Install the engine slingers into the left bank cylinder head (A)

and right bank cylinder head (B).

30. Lift using a hoist and secure the engine in position.

31. Remove engine mounting insulator bolts.

32. Remove the engine assembly from the vehicle, avoid interfer-

ence with the vehicle body.

CAUTION:

• Before and during lifting, always check if any harnesses

are left connected.

33. Remove the parts that may restrict installation of the engine to the engine stand.

NOTE:
This procedure is described assuming that you use an engine stand mounting to the surface to which the
transmission mounts.

Remove the drive plate.
• Holding the crankshaft pulley bolt, lock the crankshaft to remove the drive plate bolts.
• Loosen the bolts diagonally.

CAUTION:

Engine slinger torque:

45.0 N·m (4.6 kg-m, 33 ft-lb)

AWBIA0088ZZ

EM-220

< REMOVAL AND INSTALLATION >

[VK56DE]

ENGINE ASSEMBLY

• Be careful not to damage the drive plate. Especially

avoid deforming and damaging of the signal plate teeth
(circumference position).

• Place the drive plate with the signal plate surface facing

other than downward.

• Keep magnetic materials away from the signal plate.

CAUTION:

Use an engine stand that has a load capacity [approximately 240kg (529 lb) or more] large enough
for supporting the engine weight.
• If the load capacity of the stand is not adequate, remove the following parts beforehand to

reduce the potential risk of overturning the stand.

- Remove the fuel tube and fuel injector assembly. Refer to

EM-180, "Removal and Installation"

- Remove the intake manifold. Refer to

EM-166, "Removal and Installation"

- Remove the ignition coil. Refer to

EM-177, "Removal and Installation"

- Remove the rocker cover. Refer to

EM-178, "Removal and Installation"

- Other removable brackets.

CAUTION:

Before removing the hanging chains, make sure the engine stand is stable and there is no risk of
overturning.

34. Remove the generator. Refer to

CHG-21, "Removal and Installation"

35. Remove the engine mounting insulator and bracket using power tool.

INSTALLATION

Installation is in the reverse order of removal.

CAUTION:

• When replacing an engine or transmission you must make sure the dowels are installed correctly

during re-assembly.

• Improper alignment caused by missing dowels may cause vibration, oil leaks or breakage of driv-

etrain components.

INSPECTION AFTER INSTALLATION

• Before starting the engine, check oil/fluid levels including engine coolant and engine oil. If the levels are

lower than required quantity, fill to the specified level. Refer to

MA-10, "Fluids and Lubricants"

• Use procedure below to check for fuel leakage.
• Turn ignition switch ON (with engine stopped). With fuel pressure applied to the fuel piping, check for fuel

leakage at the 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 gas, or any oils/fluids including

engine oil and engine coolant.

• Bleed air from passages in lines and hoses, such as in cooling system.
• After cooling down the engine, again check oil/fluid levels including engine oil and engine coolant. Refill to

specified level if necessary.

• Summary of the inspection items:

KBIA2491E

Item

Before starting engine

Engine running

After engine stopped

Engine coolant

Level

Leakage

Level

Engine oil

Level

Leakage

Level

Other oils and fluids*

Level

Leakage

Level

Fuel

Leakage

Exhaust gas

—

Leakage

—

ENGINE ASSEMBLY

EM-221

< REMOVAL AND INSTALLATION >

[VK56DE]

*Transmission fluid, power steering fluid, brake fluid, etc.

EM-222

< DISASSEMBLY AND ASSEMBLY >

[VK56DE]

ENGINE UNIT

DISASSEMBLY AND ASSEMBLY

ENGINE UNIT

Disassembly and Assembly

INFOID:0000000001282038

Knock sensor sub-harness

Knock sensor

Cylinder block

Main bearing upper

Top ring

Second ring

Oil ring

Crankshaft key

Piston

10.

Connecting rod

11.

Snap ring

12.

Piston pin

13.

Connecting rod bearing

14.

Connecting rod bearing cap

15.

Main bearing cap

WBIA0471E

ENGINE UNIT

EM-223

< DISASSEMBLY AND ASSEMBLY >

[VK56DE]

DISASSEMBLY

NOTE:
Explained here is how to disassemble with engine stand supporting transmission surface. When using differ-
ent type of engine stand, some steps may be different.
1.

Remove engine assembly from vehicle and mount to engine stand. Refer to

EM-218, "Removal and

Installation"

CAUTION:

Before removing the hanging chains, make sure engine stand is stable and there is no risk of over-
turning.

Drain engine oil. Refer to

LU-25, "Changing Engine Oil"

Drain engine coolant by removing the cylinder block drain plugs
(A)”, (“B)”, (“C) and (“D) as shown.

Remove the following components and associated parts (the parts referred to in step 1 are not included
here).
• Oil pan (upper and lower) and oil strainer. Refer to

EM-173, "Removal and Installation"

• Crankshaft pulley, front cover and timing chain. Refer to

EM-185, "Removal and Installation"

• Camshaft. Refer to

EM-193, "Removal and Installation"

• Cylinder head. Refer to

EM-208, "Removal and Installation"

Remove knock sensor and sub harness.

CAUTION:

Carefully handle sensor, avoiding shocks.

Check connecting rod side clearance. Refer to

EM-230, "Inspection After Disassembly"

Remove piston and connecting rod assembly as follows.

Position the crankshaft pin corresponding to the connecting rod to be removed onto bottom dead center.

Remove connecting rod cap.

16.

Thrust bearing lower

17.

Main bearing lower

18.

Crankshaft

19.

Pilot converter

20.

Thrust bearing upper

21.

Side bolt

22.

Drive plate

23.

Reinforcement plate

24.

Rear oil seal retainer

25.

Rear oil seal

26.

Transmission

27.

O-ring

28.

Crankshaft position sensor (POS)

29.

Gasket

30.

Cylinder block heater

31.

Connector cap

WBIA0419E

KBIA2549E

EM-224

< DISASSEMBLY AND ASSEMBLY >

[VK56DE]

ENGINE UNIT

Push the piston and connecting rod assembly out to the cylinder
head side using suitable tool.

Remove connecting rod bearings.

CAUTION:

When removing them, note the installation position. Keep them in the correct order.

Check piston ring side clearance. Refer to

EM-230, "Inspection After Disassembly"

10. Remove piston rings from piston using suitable tool.

CAUTION:

• Do not damage piston.
• Do not damage piston rings by expanding them exces-

sively.

11. Remove piston from connecting rod as follows.
a.

Remove snap ring using suitable tool.

Heat piston to 60

to 70

C (140

to 158

F) using suitable tool.

PBIC0086E

PBIC0087E

PBIC0260E

PBIC0261E

ENGINE UNIT

EM-225

< DISASSEMBLY AND ASSEMBLY >

[VK56DE]

Push out piston pin using suitable tool.

12. Separate and remove rear oil seal retainer from cylinder block.

CAUTION:

Do not damage mating surface.

13. Remove rear oil seal from rear oil seal retainer.

14. Measure the crankshaft side clearance. Refer to

EM-230, "Inspection After Disassembly"

15. Remove main bearing caps as follows:

• Loosen bolts in reverse order as shown in several different

steps.

Loosen side bolts (M10) starting from 30 to 21 to remove.

Loosen main bearing cap sub bolts (M9) starting from 20 to 11 to
remove.

Loosen main bearing cap bolts (M12) starting from 10 to 1 to
remove.

Remove main bearing cap.
• Insert 2 bolts into bolt holes, and then remove main bearing

cap by lifting up and shaking forward and backward.

16. Remove crankshaft.

17. Remove the main bearings and thrust bearings from the cylinder block and main bearing caps.

• When removing them, note the installation position. Keep them in the correct order.

18. Remove pilot converter using Tool if necessary.

PBIC0262E

PBIC0090E

KBIA2492E

Tool number

: ST16610001 (J-23907)

WBIA0596E

EM-226

< DISASSEMBLY AND ASSEMBLY >

[VK56DE]

ENGINE UNIT

ASSEMBLY

Fully air-blow the coolant and oil passages in the cylinder block, cylinder bore, and crankcase to remove
any foreign material.

CAUTION:

Use goggles to protect your eyes.

Install each plug to the cylinder block (only screw-type plugs are
shown).
• Apply liquid gasket.

Use Genuine Thread Sealant or equivalent. Refer to

GI-26,

• Replace copper washers with new ones.
• Tighten each plug as specified below.

Install main bearings and thrust bearings.

Remove any dust, dirt, and oil on the bearing mating surfaces of
the cylinder block and main bearing caps.

Install thrust bearings to both sides of the No. 3 journal housing
on the cylinder block and main bearing caps
• Install thrust bearings with the oil groove facing the crankshaft

arm (outside).

• Install thrust bearings with a protrusion in the center on the

main bearing caps.

Install main bearings paying attention to the direction.
• Install the one with oil holes onto the cylinder block and the

one without oil holes onto the main bearing cap.

• Before installing bearings, apply engine oil to bearing surface

(inside). Do not apply oil to the back surface, but thoroughly
clean it.

• When installing, align the bearing stopper to the notch.
• Ensure the oil holes on the cylinder block and those on the

corresponding bearing are aligned.

Install pilot converter to the crankshaft using suitable tool.

Install crankshaft to the cylinder block.
• While turning crankshaft by hand, make sure it turns smoothly.

Part

Washer

Tightening torque

Yes

53.9 N·m (5.5 kg-m, 40 ft-lb)

19.6 N·m (2.0 kg-m, 15 ft-lb)

Yes

62.7 N·m (6.4 kg-m, 46 ft-lb)

Yes

62.7 N·m (6.4 kg-m, 46 ft-lb)

WBIA0419E

PBIC0093E

PBIC0094E

EMP0569D

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