Engine Removal

1. Note AM and FM radio presets before beginning this repair.

2. Remove the engine undercovers and hood.

3. Use compressed air to blow the engine free of dust while wearing proper eye protection and a respirator.

4. Release fuel pressure (see MA section of '94 Truck/Pathfinder Service Manual, page MA-12).

5. Disconnect negative cable from the battery.

6. Drain engine coolant and engine oil.

7. Remove heater hoses at engine and reposition for clearance.











8. Disconnect engine harness electrical connectors and ground strap at the right front of the cylinder head. Remove plastic clips securing harness to the bracket at the rear of the cylinder head.





9. Remove vacuum hoses, and brake booster vacuum hose.





10. Remove air box lid, MAFS and air duct.





11. Remove throttle and ASCD cables from bracket and accelerator drum.

12. Remove P/S pump and A/C compressor. Reposition for clearance.

13. Remove A/T lines from radiator.

14. Remove top and bottom radiator hoses.

15. Remove fan shroud, fan, and radiator.

16. Remove drive belts.





17. Remove two fuel hoses at engine. Use special tool to remove the fuel hoses (MAC # HFL 4790).

NOTE:
Replace the fuel tube if it becomes damaged.

18. Remove front exhaust tube.

Steps 19-21 apply to 4WD models only:





19. Remove the front differential support (three nuts on top, two bolts at the side, two bolts at the front).

20. Remove drive shaft to differential, and half shafts to each wheel.

21. While supporting the differential on a suitable stand, lower the rear part of the differential first; then remove the assembly.

22. Remove the starter.

23. Remove wires from alternator and oil pressure sending unit.

24. Attach engine sling. One lifting hook is installed at the rear of the left cylinder head. Install the other lifting hook at the front of the right cylinder head, at the point where the battery ground strap was removed.

25. Remove bolts attaching engine to transmission.

26. Remove engine mount bolts on both sides.

27. Remove transmission lower support brackets on both sides.

28. The engine may be removed without removing the transmission if the following cautions are observed:

^ Support the front of the transmission so it does not drop.

^ On M/T vehicles, make sure the clutch plate is clear of the input shaft before lifting engine.

^ When removing engine, be sure that other components in engine compartment such as the A/C compressor, throttle cables, and connectors are not damaged by the engine assembly.

29. When lifting the engine with the hoist, make sure the lifting chain does not apply pressure on any fragile components, such as electrical connectors or the air regulator. Re-position for clearance if necessary. Use rags to protect the valve covers from contact with the chain.

30. Lift engine with hoist and secure it to an engine stand.

31. Before disassembling the engine, make notes of engine harness routing, vacuum hose routing, and attachment points to ensure correct re-assembly of these components.