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Engine Assembly

REMOVAL & INSTALLATION

2.4L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

    CAUTION
    The fuel injection system remains under pressure after the engine has been

    OFF/B>. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  2. Relieve the fuel system pressure.
  3. Drain the engine oil and coolant.
  4. Drain the cooling system.
  5. Remove or disconnect the following:

    CAUTION
    Wait at least 90 seconds after the negative battery cable is disconnected to prevent possible deployment of the air bag.

  6. Battery
  7. Hood, matchmark for reassembly
  8. Oil dipstick
  9. Engine undercover
  10. Lower radiator hose
  11. Starter
  12. Exhaust pipe from the exhaust manifold
  13. Transfer case from vehicle, if equipped with 4WD
  14. Transmission, if equipped with a manual transmission
  15. If equipped with an automatic transmission and 2WD:
    1. Remove the inspection plate.
    2. Matchmark the flexplate and converter. Remove the torque converter bolts and move the torque converter back as far as it will go.
    3. Remove the lower bell housing bolts.
  16. Remove or disconnect the following:
  17. Attach an engine removal device to the engine support eyes on the engine.
  18. If equipped with an automatic transmission, support the transmission with a floor jack. Remove the remaining bell housing bolts.
  19. Remove the engine mount nuts and remove the engine from the vehicle.

    To install:

  20. Lower the engine into position
  21. Install or connect the following:
  22. Remove the engine removal device and the transmission support.
  23. Install or connect the following:
  24. If equipped with an automatic transmission, align the torque converter and flexplate and install the bolts. Torque the bolts to 25–30 ft. lbs. (34–41 Nm) 1997–98 and 33–38 ft. lbs. (45–52 Nm).
  25. Install or connect the following:
  26. Fill the engine with the specified amount of oil and fill the radiator with coolant.
  27. Inspect the fuel system for leaks.
  28. Check the automatic transmission fluid level, if equipped.
  29. Recheck all engine adjustments.
3.0L and 3.5L Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2. Relieve the fuel system pressure.

    CAUTION
    The fuel injection system remains under pressure after the engine has been

    OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

  3. Drain the engine oil.
  4. Drain the cooling system.
  5. Remove or disconnect the following:
  6. If equipped with an automatic transmission and 2WD:
    1. Remove the inspection plate.
    2. Matchmark the flexplate to the converter; remove the torque converter bolts and move the torque converter back as far as it will go.
    3. Remove the lower bell housing bolts.
  7. Remove or disconnect the following:
  8. Attach an engine removal device to the engine support eyes on the engine.
  9. If equipped with an automatic transmission, support the transmission with a floor jack. Remove the remaining bell housing bolts.
  10. Remove the engine mount nuts and remove the engine from the vehicle.

    To install:

  11. Lower the engine into position and install the engine mount nuts. Tighten the nuts to 20 ft. lbs. (27 Nm), on the Montero, tighten to 33 ft. lbs. (44 Nm).
  12. Install or connect the following:
  13. Remove the engine removal device and the transmission support.
  14. Install or connect the following:
  15. Refill the engine with the specified amount of oil.
  16. Refill the radiator with coolant.
  17. Check fuel system for leaks.
  18. Check the automatic transmission fluid level, if equipped.
  19. Recheck all engine adjustments.

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