Engine

NOTE: Elevate and safely support the vehicle as needed to gain access to any components. Depending on tools, arm length and agility, each operation may be easier from above or below. All wires and hoses should be labeled at the time of removal. The amount of time saved during reassembly makes the extra effort well worthwhile.

2-Wheel Drive Pick-up (2.0L and 2.6L Engines) and 4-Wheel Drive Pick-up (2.6L Engines)

If the vehicle is equipped with air conditioning, take the vehicle to a trained and certified mechanic to discharge the air conditioning system using a recycling/recovery machine.
Matchmark and remove the hood. Disconnect the negative battery cable at the battery.
Elevate and safely support the truck on jackstands. Remove the undercovers and shields below the engine.
Drain the engine coolant.
CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.
Drain the engine and transmission oil.
Remove the air cleaner assembly.

Fig. 1: Preliminary engine removal components — 2.0L Engines

Fig. 2: Preliminary engine removal components — 2.6L Engines

Fig. 3: Engine and transmission mounting components — 2.0L Engines

Fig. 4: 2-Wheel and 4-wheel drive engine and transmission mounting components — 2.6L Engines

Fig. 5: Removing the 4-wheel drive manual shifter assembly
If the vehicle is equipped with air conditioning, remove the upper and lower fan shrouds from the radiator.
Disconnect the upper and lower hose from the radiator and remove the radiator.
Disconnect the battery ground cable from the left-hand side of the engine block.
Disconnect the coil wire from the distributor cap.
Label and disconnect the water temperature sensor (with automatic transmission), the water temperature gauge sender and the starter motor connector.
Disconnect the positive battery cable from the starter.
Disconnect the transmission harness, the oxygen sensor connection, the wiring to the alternator and the oil pressure sender wire.
Disconnect the accelerator cable.
Carefully disconnect both hoses from the power steering pump. Do not damage the hose and mop up any spilled fluid.
Disconnect both air conditioning hoses from the compressor. Carefully move the hoses out of the way but do not crimp or crease the hoses. Cap the compressor nozzles and the lines.
Disconnect the brake booster vacuum hose.
Disconnect the exhaust pipe from the bottom of the exhaust manifold. Use wire or string to support the pipe to the side. Do not let the pipe hang of its own weight.
Carefully label and disconnect the fuel lines, breather and vacuum lines and the canister lines.
CAUTION
On vehicles equipped with fuel injection systems, relieve the fuel system pressure before loosening or removing any fuel lines.
Inside the vehicle, remove the shifter assembly (manual transmission) or disconnect the automatic shift selector linkage.
NOTE: When removing the manual shifter, remove the mounting bolts from the stopper plate and remove the lever assembly with the stopper plate.
Remove the driveshaft, or both driveshafts if the vehicle is equipped with 4-wheel drive. Before disconnecting the rear flange from the axle, scribe matchmarks on both the shaft and axle flange so that the shaft may be reinstalled in its original position. If the driveshaft is the 3-joint type, disconnect the center carrier from the floor pan of the vehicle. After the flange is free at the rear, slide the shaft out of the transmission housing. Immediately plug or cover the transmission; do not allow dirt or foreign matter to enter the transmission case. Do the same for the front driveshaft.
Install the hoisting equipment and make sure it is securely fastened to the engine. Draw tension on the hoist just enough to support the weight of the motor without elevating it.
CAUTION
The truck is supported on stands. Tension the hoist slowly and do not disturb the position of the truck on the supports.
Position a floor jack under the transmission (No.2) crossmember and adjust it to just touch to crossmember for support.
Remove the outer bolts holding the crossmember to the vehicle. Carefully remove the two center bolts holding the crossmember to the transmission case. Lower the jack slowly to remove the crossmember from the vehicle.
Double check for any remaining cables, hoses, wiring or lines still running to the engine and/or transmission and remove them. Check that any item which was moved out of the way is truly in a safe location.
Place the floor jack with a large block of wood under the transmission case for support. The jack will need to be adjusted and eventually removed during the engine removal.
Double check the security of the lifting apparatus. Make certain the cables are tensioned properly. Remove the nut, lockwasher and spacer from each motor mount.
Elevate the hoist slowly and raise the engine and transmission assembly out of the truck. The transmission will need to be lowered and the assembly lifted out on an angle. Take your time; clearances may be close and the unit is heavy. As soon as the engine is clear, mount it on a stand or support it on wooden blocks. Do not allow it to rest on the oil pan or lie on its side. Never leave an engine hanging from a hoist. The transmission should be disconnected from the engine as soon as convenient.
To install:
After repairs, make certain the engine and transmission are fully reassembled before installation. All components removed with the engine out of the truck should be in place before reinstallation.
Install the engine into the truck and lower it until the bolt holes for the mounts align with the brackets. Use the floor jack and wood block to support and guide the transmission into place as necessary. Install the mount nuts, tightening them to 14 ft. lbs (19 Nm).
Using the floor jack as necessary for support, install the No. 2 crossmember. Tighten the body bolts to 41 ft. lbs. (55 Nm) and the nuts holding the crossmember to the transmission to 17 ft. lbs. (24 Nm). When the mounts and crossmember are securely fastened, the floor jack and the engine lifting apparatus may be removed from the vehicle.
Install one or both driveshafts, depending on whether the vehicle is 2-wheel drive or 4-wheel drive. Remove the plug or cover from the transmission and insert the driveshaft. If the driveshaft is of the 3-joint type, connect the center support and tighten the nuts to 26 ft. lbs. (35 Nm). Turn the differential flange until the mark made during removal aligns with the mark on the shaft flange. Install the retaining bolts and tighten to 41 ft. lbs. (55 Nm).
Reinstall the manual shifter assembly with new gaskets or reconnect the automatic shift linkage.
Connect the fuel, vacuum, breather and canister lines to their correct locations. Make certain lines are not crimped or split. Route the lines clear of any hot surfaces or moving parts.
Use a new gasket with new nuts and connect the exhaust pipe to the manifold.
Connect the brake booster vacuum hose.
Using a new O-ring inside each line, connect the air conditioning lines to the compressor. Tighten the fittings carefully to 18 ft. lbs. (25 Nm).
Connect the power steering hoses to the pump. Tighten the retaining nut.
Connect the accelerator cable.
Connect the wiring to the transmission, the oxygen sensor, the alternator and oil pressure sender.
Connect the positive battery cable to the starter.
Connect the other wiring to the starter. Connect the water temperature sender and gauge wiring.
Connect the coil wire to the distributor.
Install the radiator and connect the hoses. The radiator retaining bolts should be tightened only to 8 ft. lbs. (10 Nm).
Install the fan shrouds.
Connect the negative battery cable to the engine (not to the battery).
Install the air cleaner assembly.
Fill the cooling system with coolant. Make certain the draincocks on the engine and radiator are closed before adding the fluid.
Add the correct amount of oil to the engine and the correct amount to the transmission.
Double check all installation items, paying particular attention to loose hoses or hanging wires, untightened nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.
Connect the negative battery cable.
After making certain that the transmission is in Neutral (manual) or P (automatic), start the engine, allowing it to run at idle. Check carefully for any leaks of oil, fuel, vacuum or coolant.
Shut the engine off. Top up fluids as necessary.
Install the undercovers and splash shields. Lower the truck to the ground.
Install the hood, taking care to align the seams and latch correctly.
Perform final adjustments to the belts, throttle cable, idle speed etc. as necessary.
Take the vehicle back to the air conditioning mechanic and have the system evacuated and recharged.

4-Wheel Drive Pickup (2.3L Diesel Engine)

NOTE: All wires and hoses should be labeled at the time of removal. The amount of time saved during reassembly makes the extra effort well worthwhile.

Disconnect the negative battery cable from the battery terminal.
Raise and support the vehicle on jackstands, so that the vehicle can be accessed from the top and the bottom.
Drain the engine oil, transmission oil and coolant fluid.
CAUTION
Used motor oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle oil on a daily basis, it is wise to thoroughly wash your hands with soap and water immediately after handling used motor oil.
Matchmark around the hinges on the hood. Remove the hinge attaching bolts, and remove the hood from the hinges and body.
Remove the air cleaner duct.
Remove the heater hoses.
Disconnect the accelerator and throttle cable.
Disconnect the fuel lines and disconnect the water level sensor connector.
Remove the fuel filter.
Remove the power steering oil pump, if so equipped. Secure the pump to the side of the inner fender well or frame, disconnecting of the pump hoses is not necessary.
Disconnect the glow plug cable and unplug the gauge unit wiring harness connector.
Disconnect the engine ground strap.
Disconnect the starter motor wiring harness at the starter.
Remove the clutch release (slave) cylinder from the bell housing. Support it out of the way with a piece of stiff wire or strong cord. It is not necessary to remove the fluid hose.

Fig. 6: Removing the air cleaner duct

Fig. 7: Heater hose, fuel hose and fuel filter location and connections

Fig. 8: Glow plug cable and gauge unit harness connectors locations
Disconnect the hoses to the engine oil cooler.
Disconnect the brake booster vacuum hose.
Disconnect the alternator wiring harness from the alternator. Label the wires carefully. Remove the alternator drive belt.
Depending on equipment, remove the wiring to either the oil pressure switch or the oil pressure gauge sending unit.
Disconnect the radiator hoses from the engine and radiator.
Remove the radiator assembly.
Disconnect the exhaust pipe at the first joint under the truck. Support the remainder of the system with wire. Remove the bolts holding the front pipe to the turbocharger and remove the front pipe.
Remove the undercovers. On 4-wheel drive vehicles, remove the protective skid plates under the engine and transfer case.
Disconnect the speedometer cable from the transmission.
Disconnect the reverse light switch at the transmission. If 4-wheel drive, disconnect the 4WD indicator switch harness also.
Matchmark and remove the driveshafts:
1. Make mating marks on the flange yoke and differential companion flange.
  NOTE: For 4-wheel drive models, before proceeding with the removal procedure, set the free-wheeling hubs to the unlocked position, and also set the transfer case gear shift lever to the 2H position.
2. Remove the bolts connecting the flange yoke to the differential companion flange, and for rear-wheel drive models, remove the nuts attaching the center bearing assembly.
3. Remove the propeller (driveshaft) shaft by pulling it out.
  NOTE: When the propeller shaft is pulled out of the transmission extension housing or the transfer case, note that transmission oil or transfer case oil may leak depending upon the vehicle position and angle. When removing the propeller shaft, be careful not to damage the oil seal lip and see that no foreign substance is present in the lip area. Also use care to keep the oil seal clean and free of dust.
Remove the gearshift lever assembly.
Use a floor jack to support the transmission. Remove the rear insulator (mount) from the transmission.
Remove the crossmember.
On 4-wheel drive models, the transfer case must be supported by a second floor jack or adjustable stand. Remove the transfer case mounting bracket and the insulator.
Remove the plate from the side frame. Remove the mounting bracket from the transfer case.
Position and secure a chain or overhead engine hoist. Attach it to the lift points and draw tension on the chain or cable to support the engine without lifting it.
Remove the engine mount nuts from the front engine mounts. Double check completely around the motor (and below it) for any wire, cable, hose, or linkage still running to the body. At this point, the engine should be completely isolated from the vehicle.
Elevate the hoist, raising the engine and transmission as a unit. Push downward on the rear of the transmission; remove the engine/transmission diagonally.
Once clear of the vehicle, the unit should be carefully lowered onto wooden blocks. Once the transmission is removed, the engine should be mounted to a secure stand, allowing it to be worked on.

Fig. 9: Disconnecting the engine ground cable from the engine block

Fig. 10: The starter motor wiring harness connections and location

Fig. 11: Disconnecting the engine oil cooler hoses, the brake booster vacuum hose, and the alternator wiring harness

Fig. 12: Disconnecting the oil pressure switch harness

Fig. 13: Detaching the transfer case mounting bracket

Fig. 14: Rear insulation transmission mounts on both 2-wheel drive and 4-wheel drive models

Fig. 15: Transmission crossmember mounts for both 2-wheel drive and 4-wheel drive vehicles

To install:
Position the engine/transmission unit with the hoist and lower it into the vehicle. The front mounts should engage and the transmission and/or transfer case should rest on the jacks.
Install the front mounts.
On 4-wheel drive vehicles, install the mounting bracket to the transfer case and tighten the bolts and nuts to 27 ft. lbs. (36 Nm).
If 4-wheel drive, install the transfer case mounting bracket and insulator.
Install the rear crossmember and the transmission mount (insulator). Tighten the bolts holding the crossmember to the body to 36 ft. lbs. (48 Nm) The bolts holding the transmission insulator to the crossmember should be tightened to 13.5 ft. lbs. (18 Nm).
When the transmission (and transfer case) is properly attached to the supports, the jacks may be removed. The engine hoist chain may also be removed once the engine and transmission is firmly mounted to the vehicle.
Install the gearshift lever assembly.
Install the driveshaft(s).
Connect the wiring to the transmission. Make certain the connectors are tight and the wiring is correctly routed out of the way of moving parts.
Install the speedometer cable.
Install the skid plates and/or undercovers.
Use new gaskets and install the front exhaust pipe. It will be easier to attach the pipe loosely to the system and then to the turbocharger. Tighten the pipe–to–turbocharger nuts. Tighten the pipe–to–pipe joint under the vehicle.
Install the radiator assembly. Connect the hoses to the engine. Use new clamps as necessary.
Connect the wiring harnesses to the alternator, the oil pressure switch and or the oil pressure gauge sender.
Connect the brake booster vacuum hose.
Connect the engine oil cooler lines.
Install the clutch release cylinder. Adjust the clutch.
Install the starter motor wiring harness; connect the engine ground harness to the engine block.
Install the power steering pump. Tighten the bolts to 14 ft. lbs. (18 Nm).
Connect the fuel lines. Install the fuel filter and connect the water level sensor connector.
Connect the glow system harness and the gauge unit harness.
Connect the throttle cable and adjust it.
Connect the heater hoses. Install the air cleaner ductwork.
Double check all installation items, paying particular attention to loose hoses or hanging wires, untightened nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.
Fill the cooling system with the correct amount of coolant.
Install the proper amount of engine oil. If not already done, replace the oil filter.
Bleed the fuel system.
Connect the negative battery cable.
Start the engine, following the correct starting procedures. The engine may crank longer than usual; this is normal.
Allow the engine to run at idle. While it is warming up, check carefully for any leaks of oil, fuel, vacuum or coolant. Shut the engine off and attend to any leaks immediately. Allow the engine to cool completely before working on the cooling system.
Reinstall the hood and align it with the marks made during removal. Close the hood and check the alignment of the seams.

2-Wheel Drive Pick-up (2.4L Engines)

NOTE: When performing this procedure you will need a new fuel line O-ring, a new exhaust manifold to front exhaust pipe gaskets, new oil, transmission fluid, and antifreeze.

If the vehicle is equipped with air conditioning, first have the A/C system discharged by a trained and certified mechanic using a recovery/recycling machine.
Matchmark and remove the hood.
Elevate and safely support the truck on jackstands. Remove the undercovers and shields below the engine and transmission.
NOTE: The transmission assembly must be removed before the engine can be removed. Please refer to Section 7 — Drive Train for detailed instructions on the removal of these components.
Depressurize the fuel system by adhering to the following steps:
1. Disconnect and label the fuel pump harness wiring plug at the fuel tank rear side.
2. Start the engine and after it stops by itself, turn the ignition switch OFF.
Disconnect the negative battery cable from the battery.
Drain the cooling system.
NOTE: While removing or disconnecting any wires or hoses, make sure to label them. This will make reassembly much easier.
Drain the engine and transmission fluid.
Disconnect the cooling system overflow, upper radiator, and lower radiator hoses.
Remove the upper and lower radiator shrouds.
Disconnect the automatic transmission oil cooler hose from the radiator, if the vehicle is so equipped.
Remove the radiator from the engine compartment.
Disconnect the exhaust pipe from the exhaust manifold.
Remove the transmission assembly — refer to Section 7.
Remove the air cleaner duct hose.
Disengage the accelerator cable connection.

Fig. 16: Component identification — 2.4L Engines non-California models

Fig. 17: Component identification — 2.4L Engines California models
Unfasten the throttle control cable connection, if the vehicle is equipped with an automatic transmission.
Disconnect and label the wiring connector to the compressor.
Loosen the belt tension adjuster, the lockbolt and the pivot bolt. Remove the belt, the lockbolt and the pivot bolt from the compressor. Support the compressor and remove it from the bracket and hook it with wire or rope to the body side. Move the compressor with the high-pressure hose and low-pressure hose still connected.
Loosen the power steering pump and remove the drive belt. Remove the power steering oil pump from the bracket and fasten it to the body side with strong wire or cord. Move the power steering oil pump with the pressure hose and return hose still connected.
Unfasten and label the cruise control vacuum hose connection, if so equipped.
Disconnect and label the high pressure fuel hose and remove the O-ring. Cover the fuel pipe line with rags after relieving the pressure, since fuel pressure may still be present.
Disconnect and label the fuel return hose connection.
Remove the water hose connection.
Remove and label the throttle position sensor, ignition coil, power transistor, EGR temperature sensor, engine coolant temperature gauge unit, engine coolant temperature sensor, thermal switch (if equipped with an automatic transmission), oxygen sensor, alternator, oil pressure gauge unit, and air conditioning engine coolant temperature switch connectors.
Unscrew and label the ground cable connection from the lower left hand side of the engine block.
Disengage and label the emission control vacuum hose connection.
Remove and label the brake booster vacuum hose connection.
Disconnect and label the ground cable from the firewall above the back of the engine.
Disconnect and label the idle speed control motor and the idle speed control motor position sensor wires.
Remove and label the idle air control motor connector.
Disconnect and label the control wiring harness.
Install the hoisting equipment and make sure it is securely fastened to the engine. Draw tension on the hoist just enough to support the weight of the motor without elevating it.
CAUTION
The truck is supported on stands. Tension the hoist slowly and do not disturb the position of the truck on the supports.
Remove the heat shield from the right motor mount.
Double check for any remaining cables, hoses, wiring or lines still running to the engine and remove them. Check that any item which was moved out of the way is truly in a safe location.
Double check the security of the lifting apparatus. Make certain the cables or chains are tensioned properly. Remove the bolts holding the motor mounts to the vehicle frame.
Elevate the hoist slowly and raise the engine assembly out of the truck. Take your time; clearances may be close and the unit is heavy. As soon as the engine is clear, mount it on a stand or support it on wooden blocks. Do not allow it to rest on the oil pan or lie on its side. Never leave an engine hanging from a hoist.
To install:
After repairs, make certain the engine is fully reassembled before installation. All components removed when the engine was out of the truck should be in place before reinstallation.
Install the engine into the truck and lower it until the bolt holes for the mounts align with the frame rails. Install the bolts and tighten them to 22–29 ft. lbs. (30–40 Nm). Install the heat shield on the right mount.
Connect the control wiring harness, the idle air control motor wires, the idle speed control motor position sensor wires, idle speed control motor wires, and the ground cables at the lower left engine block and the firewall above the back of the engine.
Fasten the brake booster vacuum hose connection and the emission control vacuum hose connection.
Fasten the air conditioning engine coolant temperature switch connector, the oil pressure gauge unit connector, the alternator connector, the oxygen sensor connector, the thermal switch connector (if equipped with an automatic transmission), the engine coolant temperature sensor connector, the engine coolant temperature gauge unit connector, the EGR temperature sensor connector, The power transistor connector, the ignition coil connector and the throttle position sensor connector.
Reconnect the water hose, the fuel return hose and the high pressure fuel hose. Check the high pressure fuel hose O-ring for cracks or other damage, replace if any is found. It may be best to replace this O-ring even if no damage is found.
Fasten the cruise control vacuum hose, if so equipped.
Install the power steering pump and the power steering pump drive belt. See Section 1 for adjusting procedures.
Install the A/C compressor and drive belt. Refer to Section 1 for adjusting procedures.
Fasten the throttle control cable connection, if the vehicle is equipped with an automatic transmission.
Fasten the accelerator cable connection.
Install the air cleaner duct hose.
Install the radiator, tightening the mounting bolts to 6–8 ft. lbs. (8–11 Nm). Install the fan shrouds.
Reinstall the transmission adhering to the procedures given in Section 7.
Connect the exhaust pipe to the exhaust manifold using a new exhaust gasket.
Install the correct amounts and types of oil for the engine and transmission.
Fill the cooling system with coolant.
Double check all installation items, paying particular attention to loose hoses or hanging wires, untightened nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.
Lower the vehicle to the ground. Connect the negative battery cable.
After making certain that the transmission is in Neutral (manual) or P (automatic), start the engine, allowing it to run at idle. Check carefully for any oil, fuel, vacuum or coolant leaks.
Shut the engine off. Top off fluids as necessary.
Install the undercovers and splash shields.
Install the hood, taking care to align the seams and latch correctly.
Perform final adjustments to the belts, throttle cable, idle speed etc. as necessary.
Take the vehicle back to the air conditioning mechanic to have the system evacuated and recharged as soon as possible.

Montero (2.6L Engines)

NOTE: The transmission, transfer case and front driveshaft must be removed before the engine can be removed. Please refer to Section 7 for detailed instructions on the removal of these components.

If the vehicle is equipped with air conditioning, first have the A/C system discharged by a trained and certified mechanic using a recovery/recycling machine.
Matchmark and remove the hood. Disconnect the negative battery cable.

Fig. 18: Removal of 4-cylinder engine — Montero
Elevate and safely support the truck on jackstands. Remove the undercovers and shields below the engine and transmission.
Drain the engine coolant.
CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.
Drain the engine oil and the transmission oil. Drain the transfer case and the front axle lubricant.
CAUTION
Used motor oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely unless you handle oil on a daily basis, it is wise to thoroughly wash your hands with soap and water immediately after handling used motor oil.
Remove the air cleaner assembly.
Remove the transmission assembly, following procedures outlined in Section 7.
Remove the upper and lower fan shrouds from the radiator.
Disconnect the upper and lower hose from the radiator and remove the radiator.
Disconnect the accelerator cable.
Disconnect the heater hoses at the engine.
Disconnect the brake booster vacuum hose.
Disconnect the coolant by-pass hose, the small coolant hose and the upper radiator hose from the engine.
Disconnect the large multi-plug for the engine control harness.
Disconnect the engine coolant temperature sensor wire; if the vehicle is air conditioned, disconnect the coolant temperature switch wire.
Disconnect the vacuum hose and the coolant temperature gauge sender.
Disconnect the oxygen sensor (carefully) and the oil pressure sending unit wire.
Loosen the power steering pump and remove the belt.
Remove the power steering pump with the hoses attached and undisturbed; place or hang the pump out of the way. Do not disconnect the hoses.
Loosen the air conditioning compressor and remove the belt.
Remove the air conditioning compressor with the hoses attached and undisturbed; place or hang the unit out of the way. Do not loosen or disconnect the hoses; do not allow the hoses to become crimped or crushed when the unit is placed aside.
WARNING
Do not allow the compressor to hang by the hoses.
Disconnect the fuel hoses (on fuel injected models release the fuel pressure first!). Label or identify them for correct reinstallation.
Disconnect the 3 wiring connectors at the alternator.
Remove the ground cable from the engine block.
Disconnect the exhaust pipe from the bottom of the exhaust manifold. Use wire or string to support the pipe to the side. Do not let the pipe hang of its own weight.
Carefully label and disconnect any breather, vacuum and canister lines running to the firewall or body.
Remove the clamp holding the fuel lines to the block.
Install the hoisting equipment and make sure it is securely fastened to the engine. Draw tension on the hoist just enough to support the weight of the motor without elevating it.
CAUTION
The truck is supported on stands. Tension the hoist slowly and do not disturb the position of the truck on the supports.
Remove the heat shield from the right motor mount.
Double check for any remaining cables, hoses, wiring or lines still running to the engine and remove them. Check that any item which was moved out of the way is truly in a safe location.
Double check the security of the lifting apparatus. Make certain the cables or chains are tensioned properly. Remove the bolts holding the motor mounts to the vehicle frame.
Elevate the hoist slowly and raise the engine and transmission assembly out of the truck. The assembly may need to be lifted out on an angle. Take your time; clearances may be close and the unit is heavy. As soon as the engine is clear, mount it on a stand or support it on wooden blocks. Do not allow it to rest on the oil pan or lie on its side. Never leave an engine hanging from a hoist.
To install:
After repairs, make certain the engine is fully reassembled before installation. All components removed when the engine was out of the truck should be in place before reinstallation.
Install the engine into the truck and lower it until the bolt holes for the mounts align with the frame rails. Install the bolts and tighten them to 26 ft. lbs. (35 Nm). Install the heat shield on the right mount.
Clamp the fuel lines into place.
Connect the various vacuum lines and breather hoses running to the body and firewall.
Use a new gasket and new bolts to connect the exhaust pipe to the manifold.
Connect the ground cable to the engine.
Connect the wiring to the alternator.
Connect the fuel hoses.
Install the air conditioning compressor and install the belt. Tension the belt by hand and tighten the compressor mounting bolts snug.
Install the power steering pump and install the belt. Tension the belt by hand and tighten the mounting bolts snug. Both belts will be final tightened later.
Connect the wiring to the oil pressure sender and the oxygen sensor.
Connect the vacuum hose and the wiring to the coolant temperature gauge sender.
Connect the wiring to the coolant temperature sender and the coolant temperature switch if equipped with air conditioning.
Carefully connect the multi-pin connector for the engine control harness. Make certain each pin is firmly seated.
Connect the upper radiator hose to the engine. Install the coolant by-pass hose and the small coolant hose.
Connect the brake booster vacuum hose.
Connect the two heater hoses.
Install the accelerator cable and adjust it correctly.
Install the radiator, tightening the mounting bolts to 5 ft. lbs. (7 Nm). Install the fan shrouds.
Reinstall the transmission, transfer case and drive shafts following procedures given in Section 7.
Install the air cleaner assembly.
Install the correct amounts and types of oil for the engine, transmission, transfer case and axle assemblies.
Fill the cooling system with coolant.
Double check all installation items, paying particular attention to loose hoses or hanging wires, untightened nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.
Lower the vehicle to the ground. Connect the negative battery cable.
After making certain that the transmission is in Neutral (manual) or P (automatic), start the engine, allowing it to run at idle. Check carefully for any leaks of oil, fuel, vacuum or coolant.
Shut the engine off. Top up fluids as necessary.
Install the undercovers and splash shields.
Install the hood, taking care to align the seams and latch correctly.
Recharge the air conditioning system if so equipped.
Perform final adjustments to the belts, throttle cable, idle speed etc. as necessary.

4-Wheel Drive Pick-up & Montero (3.0L 12 Valve Engines)

NOTE: When performing this procedure you will need a new fuel line O-ring, two (2) new exhaust manifold to front exhaust pipe gaskets, new oil, transmission fluid, and antifreeze.

Matchmark and remove the hood.
Elevate and safely support the truck on jackstands. Remove the undercovers and shields below the engine and transmission.
NOTE: While removing or disconnecting any wires or hoses, make sure to label them. This will make reassembly much easier.
Depressurize the fuel system by adhering to the following steps:
1. Disconnect and label the fuel pump harness wiring plug at the fuel tank rear side.
2. Start the engine and after it stops on its own, turn the ignition switch OFF.
Disconnect the negative battery cable from the engine block.
Drain the cooling system.
Drain the engine and transmission fluid.
Disconnect the cooling system overflow, upper radiator, and lower radiator hoses.
Remove the one piece radiator shroud.
Remove the radiator from the engine compartment.
Disconnect the front exhaust pipe from the exhaust manifolds.
Remove the transmission assembly — refer to Section 7.
Remove the air cleaner duct hose.
Disengage the accelerator cable connection.

Fig. 19: Component identification — 3.0L (12 valve) Engines

Fig. 20: When hoisting the engine, use the supplied engine chain blocks
Disconnect and label the wiring connector to the compressor.
Loosen the belt tension adjuster, the lockbolt and the pivot bolt. Remove the belt, the lockbolt and the pivot bolt from the compressor. Support the compressor and remove it from the bracket and hook it with wire or rope to the body side. Move the compressor with the high-pressure hose and low-pressure hose still connected. DO NOT let the compressor hang by the high-pressure hoses.
Loosen the power steering pump and remove the drive belt. Remove the power steering oil pump from the bracket and fasten it to the body side with strong wire or cord. Move the power steering oil pump with the pressure hose and return hose still connected. DO NOT let the pump hang by the pressure hoses.
Unfasten and label the cruise control vacuum hose connection, if so equipped.
Disconnect and label the high pressure fuel hose and remove the O-ring. Cover the fuel pipe line with rags after relieving the pressure, since fuel pressure may still be present.
Disconnect and label the fuel return and vacuum hoses.
Remove both water hose connections located at the top rear of the engine.
Remove and label the throttle position sensor, ignition coil and ignition power transistor assembly, EGR temperature sensor, engine coolant temperature gauge unit, engine coolant temperature sensor, alternator, oil pressure gauge unit, and air conditioning engine coolant temperature switch connectors.
Unscrew and label the ground cable connections from the left hand side of the intake plenum and the lower left hand side of the engine block.
Disengage and label the emission control vacuum hose connection.
Remove and label the brake booster vacuum hose connection.
Disconnect and label the ground cable from the firewall above the back of the engine.
Remove and label the idle air control motor connector.
Disconnect and label the control wiring harness.
Install the hoisting equipment and make sure it is securely fastened to the engine. Draw tension on the hoist just enough to support the weight of the motor without elevating it.
CAUTION
The truck is supported on stands. Tension the hoist slowly and do not disturb the position of the truck on the supports.
Remove the heat protector from both motor mounts.
Double check for any remaining cables, hoses, wiring or lines still running to the engine and remove them. Check that any item which was moved out of the way is truly in a safe location.
Double check the security of the lifting apparatus. Make certain the cables or chains are tensioned properly. Remove the bolts holding the motor mounts to the vehicle frame.
Elevate the hoist slowly and raise the engine assembly out of the truck. Take your time; clearances may be close and the unit is heavy. As soon as the engine is clear, mount it on a stand or support it on wooden blocks. Do not allow it to rest on the oil pan or lie on its side. Never leave an engine hanging from a hoist.
To install:
After repairs, make certain the engine is fully reassembled before installation. All components removed when the engine was out of the truck should be in place before reinstallation.
Install the engine into the truck and lower it until the bolt holes for the mounts align with the frame rails. Install the bolts and tighten them to 22–29 ft. lbs. (30–40 Nm). Install the heat shields on the motor mounts.
Connect the control wiring harness, the idle air control motor wires and the three engine ground cables.
Fasten the brake booster vacuum hose connection and the emission control vacuum hose connection.
Fasten the air conditioning engine coolant temperature switch connector, the oil pressure gauge unit connector, the alternator connector, the engine coolant temperature sensor connector, the engine coolant temperature gauge unit connector, the EGR temperature sensor connector, the ignition coil and ignition power transistor assembly, and the throttle position sensor connector.
Reconnect both water hoses at the rear of the intake plenum, the fuel return hose and the high pressure fuel hose. Check the high pressure fuel hose O-ring for cracks or other damage, replace if any is found. It may be best to replace this O-ring even if no damage is found.
Reconnect the vacuum hose to the fuel return hose fixture.
Fasten the cruise control vacuum hose, if so equipped.
Install the power steering pump and the power steering pump drive belt. See Section 1 for adjusting procedures.
Install the A/C compressor and drive belt. Refer to Section 1 for adjusting procedures.
Fasten the throttle control cable connection, if the vehicle is equipped with an automatic transmission.
Fasten the accelerator cable connection.
Install the air cleaner duct hose.
Install the radiator, tightening the mounting bolts to 6–8 ft. lbs. (8–11 Nm). Install the fan shroud.
Reinstall the transmission adhering to the procedures given in Section 7.
Connect the front exhaust pipe to the exhaust manifolds using a new gasket.
Install the correct amounts and types of oil for the engine and transmission.
Fill the cooling system with coolant.
Double check all installation items, paying particular attention to loose hoses or hanging wires, untightened nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.
Lower the vehicle to the ground. Reconnect the negative battery cable.
After making certain that the transmission is in Neutral (manual) or P (automatic), start the engine, allowing it to run at idle. Check carefully for any oil, fuel, vacuum or coolant leaks.
Shut the engine off. Top off all fluids as necessary.
Install the undercovers and splash shields.
Install the hood, taking care to align the seams and latch correctly.
Perform final adjustments to the belts, throttle cable, idle speed etc. as necessary.

Montero (3.0L 24 Valve Engines)

NOTE: When performing this procedure you will need a new fuel line O-ring, two (2) new exhaust manifold to front exhaust pipe gaskets, fresh oil, transmission fluid, and antifreeze.

Matchmark and remove the hood.
Remove the battery and battery tray.
Remove the cruise control intermediate link, which is mounted to the firewall of the engine compartment.
1. Remove the retaining bolt on the link protector and withdrawal the protector from the assembly.
2. Disconnect the accelerator cable, the throttle cable, and the cruise control cable from the intermediate link. When loosening the adjusting bolts and nuts on the throttle lever, do not remove the adjusting bolts or nuts (just loosen).
3. Remove the four retaining nuts holding the intermediate link to the link bracket. Withdrawal the intermediate link from the bracket.
4. Remove the link bracket. Make sure to keep all screws and bolts in labeled bags or a similar container to keep from mixing them up.
Elevate and safely support the truck on jackstands. Remove the undercovers and shields below the engine and transmission.
Disconnect the negative battery cable from the engine block and set aside.
Drain the cooling system, refer to Section 1.
Drain the engine and transmission fluid, refer to Section 1.
Disconnect the cooling system overflow, upper radiator, and lower radiator hoses.
Remove the one piece radiator shroud.
Remove the radiator from the engine compartment.
Disconnect the front exhaust pipes from the exhaust manifolds. Tie them up with strong cord or wire, do not let them hang of their own weight.
Remove the transmission and transfer assembly — refer to Section 7.
Remove the air cleaner duct hose.

Fig. 21: Component connection identification — 3.0L (24 valve) engines

Fig. 22: Use two wrenches to disconnect the oil cooler hose
Loosen the power steering pump and remove the drive belt. Remove the power steering oil pump from the bracket and fasten it to the body side with strong wire or cord. Move the power steering oil pump with the pressure hose and return hose still connected. DO NOT let the pump hang by the pressure hoses.
Loosen the alternator bolts and remove the drive belt.
Disconnect and label the wiring connector to the compressor.
Loosen the belt tension adjuster, the lockbolt and the pivot bolt. Remove the belt, the lockbolt and the pivot bolt from the compressor. Support the compressor and remove it from the bracket and hook it with wire or rope to the body side. Move the compressor with the high-pressure hose and low-pressure hose still connected. DO NOT let the compressor hang by the high-pressure hoses.
Remove the cooling fan and water pump pulley from the front of the engine.
Disconnect and label the engine control wiring harness.
Disconnect and label the alternator and starter wiring harness.
Unfasten the engine oil cooler hose connection. To loosen these connectors, use two wrenches, usually open end or flare nut, at the same time.
Remove the brake booster vacuum hose connection.
Remove the two heater hose connections, located at the back of the intake manifold.
Disconnect the fuel hose from the intake plenum. The O-ring inside of this connection must be removed and replaced with a new one.
Disconnect the fuel return hose.
Unfasten the oil pressure switch harness connection.
Install the hoisting equipment and make sure it is securely fastened to the engine. Draw tension on the hoist just enough to support the weight of the motor without elevating it.
CAUTION
The truck is supported on stands. Tension the hoist slowly and do not disturb the position of the truck on the supports.
Remove the heat protector from both motor mounts.
Double check for any remaining cables, hoses, wiring or lines still running to the engine and remove them. Check that any item which was moved out of the way is truly in a safe location.
Double check the security of the lifting apparatus. Make certain the cables or chains are tensioned properly. Remove the bolts holding the motor mounts to the vehicle frame.
Elevate the hoist slowly and raise the engine assembly out of the truck. Take your time; clearances may be close and the unit is heavy. As soon as the engine is clear, mount it on a stand or support it on wooden blocks. Do not allow it to rest on the oil pan or lie on its side. Never leave an engine hanging from a hoist.
To install:
After repairs, make certain the engine is fully reassembled before installation. All components removed when the engine was out of the truck should be in place before reinstallation.
Install the engine into the truck and lower it until the bolt holes for the mounts align with the frame rails. Install the bolts and tighten them to 33 ft. lbs. (44 Nm). Install the heat shields on the motor mounts.
Reconnect the oil pressure switch harness.
Fasten the fuel return hose, the fuel hose, and the two heater hoses. Make sure to replace the O-ring in the fuel hose connection with a new one.
Fasten the brake booster vacuum hose connection.
Reconnect the oil cooler hose.
Reconnect the alternator and starter wiring harness, the engine control harness and the lower, left-hand side engine block ground cable.
Install the cooling fan and water pump pulley. Tighten the cooling fan mounting bolts to 7–9 ft. lbs. (10–12 Nm).
Install the power steering pump and power steering pump cover.
Install the A/C compressor and drive belt. Refer to Section 1 for adjusting procedures.
Install the alternator drive belt. Refer to Section 1 for adjusting procedures.
Install the power steering pump drive belt. See Section 1 for adjusting procedures.
Install the air cleaner duct hose.
Install the radiator, tightening the mounting bolts to 6–8 ft. lbs. (8–11 Nm). Install the fan shroud.
Reattach the upper and lower radiator hoses, and the overflow hose.
Reinstall the transmission and transfer assembly adhering to the procedures given in Section 7.
Reattach the front exhaust pipe, or three-way catalytic converter on California models, to the exhaust manifolds. New gaskets are a necessity for this procedure.
Install the cruise control intermediate link assembly.
1. Reattach the link bracket with the center bolt.
2. Install the intermediate link to the link bracket using the four nuts.
3. Connect the accelerator cable, the throttle cable, and the cruise control cable to the intermediate link.
Adjust the accelerator cable, the throttle cable, and the cruise control cable — refer to Section 5 for this procedure.
Install the intermediate link unit's cover.
Install the battery and battery tray.
Reconnect the negative battery cable to the engine block.
Install the correct amounts and types of oil for the engine and transmission.
Fill the cooling system with coolant.
Double check all installation items, paying particular attention to loose hoses or hanging wires, untightened nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.
Lower the vehicle to the ground.
Reconnect the positive and negative battery cables to the battery.
After making certain that the transmission is in Neutral or Park, start the engine, allowing it to run at idle. Check carefully for any oil, fuel, vacuum or coolant leaks.
Shut the engine off. Top off all fluids as necessary.
Install the undercovers and splash shields.
Install the hood, taking care to align the seams and latch correctly.
Perform final adjustments to the belts, throttle cable, idle speed etc. as necessary.

Montero (3.5L Engines)

NOTE: When performing this procedure you will need two (2) new exhaust manifold to front exhaust pipe gaskets, fresh oil, transmission fluid, and antifreeze.

Matchmark and remove the hood.
Remove the battery and battery tray.
NOTE: While removing or disconnecting any wires or hoses, make sure to label them. This will make reassembly much easier.
Remove the cruise control intermediate link, which is mounted to the firewall of the engine compartment.
1. Remove the retaining bolt on the link protector and withdrawal the protector from the assembly.
2. Disconnect the accelerator cable, the throttle cable, and the cruise control cable from the intermediate link. When loosening the adjusting bolts and nuts on the throttle lever, do not remove the adjusting bolts or nuts (just loosen).
3. Remove the four retaining nuts holding the intermediate link to the link bracket. Withdrawal the intermediate link from the bracket.
4. Remove the link bracket. Make sure to keep all screws and bolts in labeled bags or a similar container to keep from mixing them up.
Elevate and safely support the truck on jackstands. Remove the undercovers and shields below the engine and transmission.
Disconnect the negative battery cable from the engine block and set aside.
Drain the cooling system, refer to Section 1.
Drain the engine and transmission fluid, refer to Section 1.
Disconnect the cooling system overflow, upper radiator, and lower radiator hoses.
Remove the one piece radiator shroud.
Remove the radiator from the engine compartment.
Disconnect the front exhaust pipes, or warm up three-way catalytic converter if California model, from the exhaust manifolds. Tie them up with strong cord or wire, do not let them hang of their own weight.
Remove the transmission and transfer assembly — refer to Section 7.
Remove the air cleaner duct hose.
Remove the intake manifold plenum cover.

Fig. 23: Component connection identification — 3.5L engines
Loosen the power steering pump and remove the drive belt. Remove the power steering oil pump from the bracket and fasten it to the body side with strong wire or cord. Move the power steering oil pump with the pressure hose and return hose still connected. DO NOT let the pump hang by the pressure hoses.
Loosen the alternator bolts and remove the alternator drive belt.
Disconnect and label the wiring connector to the compressor.
Loosen the belt tension adjuster, the lockbolt and the pivot bolt. Remove the belt, the lockbolt and the pivot bolt from the compressor. Support the compressor and remove it from the bracket and hook it with wire or rope to the body side. Move the compressor with the high-pressure hose and low-pressure hose still connected. DO NOT let the compressor hang by the high-pressure hoses.
Remove the cooling fan and water pump pulley from the front of the engine.
Disconnect and label the engine control wiring harness.
Disconnect and label the alternator and starter wiring harness.
Unfasten the engine oil cooler hose connection. To loosen these connectors, use two wrenches, usually open end or flare nut, at the same time.
Remove the brake booster vacuum hose connection.
Remove the two heater hose connections, located at the back of the intake manifold.
Disconnect the fuel hose and fuel return hose from the left-hand side of the intake plenum.
Install the hoisting equipment and make sure it is securely fastened to the engine. Draw tension on the hoist just enough to support the weight of the motor without elevating it.
CAUTION
The truck is supported on stands. Tension the hoist slowly and do not disturb the position of the truck on the supports.
Remove the heat protector from both motor mounts.
Double check for any remaining cables, hoses, wiring or lines still running to the engine, label and remove them. Check that any item which was moved out of the way is truly in a safe location.
Double check the security of the lifting apparatus. Make certain the cables or chains are tensioned properly. Remove the bolts holding the motor mounts to the vehicle frame.
Elevate the hoist slowly and raise the engine assembly out of the truck. Take your time; clearances may be close and the unit is heavy. As soon as the engine is clear, mount it on a stand or support it on wooden blocks. Do not allow it to rest on the oil pan or lie on its side. Never leave an engine hanging from a hoist.
To install:
After repairs, make certain the engine is fully reassembled before installation. All components removed when the engine was out of the truck should be in place before reinstallation.
Install the engine into the truck and lower it until the bolt holes for the mounts align with the frame rails. Install the bolts and tighten them to 33 ft. lbs. (44 Nm). Install the heat shields on the motor mounts.
Fasten the fuel return hose, the fuel hose, and the two heater hoses.
Fasten the brake booster vacuum hose connection.
Reconnect the oil cooler hose.
Reconnect the alternator and starter wiring harness, the engine control harness and the lower, left-hand side engine block ground cable.
Install the cooling fan and water pump pulley. Tighten the cooling fan mounting bolts to 7–9 ft. lbs. (10–12 Nm).
Install the power steering pump and power steering pump cover.
Install the A/C compressor and drive belt. Refer to Section 1 for adjusting procedures.
Install the alternator drive belt. Refer to Section 1 for adjusting procedures.
Install the power steering pump drive belt. See Section 1 for adjusting procedures.
Install the air cleaner duct hose.
Install the radiator, tightening the mounting bolts to 6–8 ft. lbs. (8–11 Nm). Install the fan shroud.
Reattach the upper and lower radiator hoses, and the overflow hose.
Reinstall the transmission and transfer assembly adhering to the procedures given in Section 7.
Reattach the front exhaust pipe, or three-way catalytic converter on California models, to the exhaust manifolds. New gaskets are a necessity for this procedure.
Install the cruise control intermediate link assembly.
1. Reattach the link bracket with the center bolt.
2. Install the intermediate link to the link bracket using the four nuts.
3. Connect the accelerator cable, the throttle cable, and the cruise control cable to the intermediate link.
Adjust the accelerator cable, the throttle cable, and the cruise control cable — refer to Section 5 for this procedure.
Install the intermediate link unit's cover.
Install the battery and battery tray.
Reconnect the negative battery cable to the engine block.
Install the correct amounts and types of oil for the engine and transmission.
Fill the cooling system with coolant.
Reconnect the positive and negative battery cables to the battery.
Double check all installation items, paying particular attention to loose hoses or hanging wires, untightened nuts, poor routing of hoses and wires (too tight or rubbing) and tools left in the engine area.
Lower the vehicle to the ground.
After making certain that the transmission is in Neutral or Park, start the engine, allowing it to run at idle. Check carefully for any oil, fuel, vacuum or coolant leaks.
Shut the engine off. Top off all fluids as necessary.
Install the undercovers and splash shields.
Install the hood, taking care to align the seams and latch correctly.
Perform final adjustments to the belts, throttle cable, idle speed etc. as necessary.