Removal and Installation
REPLACEMENT1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
2. REMOVE FRONT WHEEL
3. REMOVE ENGINE UNDER COVER NO.1
4. REMOVE ENGINE UNDER COVER NO.2
5. REMOVE FRONT FENDER APRON SEAL RH
6. DRAIN ENGINE OIL
7. DRAIN COOLANT
8. DRAIN AUTOMATIC TRANSAXLE FLUID
9. REMOVE BATTERY
10. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
11. REMOVE VANE PUMP V BELT
12. REMOVE ENGINE MOVING CONTROL ROD
a. Remove the 4 bolts, engine moving control rod and bracket.
13. REMOVE ENGINE MOUNTING STAY NO.2 RH
Remove the bolt, engine mounting stay No. 2 RH and engine mounting bracket No. 2 RH.
14. REMOVE UNION TO CHECK VALVE HOSE
a. Remove the vacuum hose for the brake booster.
15. REMOVE V-BANK COVER SUB-ASSY
a. Using a 5 mm hexagon wrench, remove the 3 nuts.
b. Disconnect the 2 clips, and remove the cover.
16. REMOVE AIR CLEANER INLET ASSY
17. REMOVE AIR CLEANER ASSEMBLY WITH HOSE
18. REMOVE AIR CLEANER BRACKET
19. REMOVE AIR CLEANER INLET NO.1
20. REMOVE INTAKE AIR RESONATOR SUB-ASSY
21. DISCONNECT FUEL PIPE SUB-ASSY NO.1
a. Remove the fuel pipe clamp.
b. Disconnect the connector from the tube while pinching part A with fingers as shown in the illustration.
NOTICE:
- Check if there is any dirt mud on the pipe and around the connector before disconnecting them and clean the dirt away.
- Be sure to disconnect with hands.
- Do not bent, fold and rotate the nylon tube.
- When the connector and the pipe are stuck, push and pull the connector to free the connection and pull it out.
- Prevent the disconnected pipe and connector from damaging and mixing foreign objects by covering them with a vinyl bag.
22. REMOVE RADIATOR HOSE INLET
23. REMOVE RADIATOR HOSE OUTLET
24. DISCONNECT OIL COOLER INLET HOSE
25. DISCONNECT OIL COOLER OUTLET HOSE NO.2
26. DISCONNECT HEATER INLET WATER HOSE
27. DISCONNECT HEATER OUTLET WATER HOSE
28. REMOVE GLOVE COMPARTMENT DOOR ASSY
29. DISCONNECT ENGINE WIRE
a. Disconnect the engine wire from engine ECU and junction block.
b. Disconnect the engine wire from engine room junction block.
1. Remove a nut and separate the wire harness.
2. Using a screwdriver, unlock the engine room junction block. Separate the engine wire by pulling it up ward.
3. Separate the connector.
c. Pull out the engine wire.
d. Remove the body ground.
30. DISCONNECT FLOOR SHIFT TRANSMISSION CONTROL CABLE ASSY
31. DISCONNECT OIL RESERVOIR TO PUMP HOSE NO.1
32. DISCONNECT STEERING GEAR OUTLET RETURN TUBE
33. REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET
34. REMOVE EXHAUST PIPE ASSY FRONT
35. SEPARATE FRONT STABILIZER LINK ASSY LH
a. Using a 6 mm socket hexagon wrench, hold the ball stud
b. Remove the nut, and separate the stabilizer link.
36. SEPARATE FRONT STABILIZER LINK ASSY RH
HINT: Perform the same procedure on the opposite side
37. REMOVE FRONT AXLE HUB LH NUT
a. Using SST and a hammer, unstake the staked part of the lock nut.
SST 09930-00010
NOTICE:
- When removing the nut, unstake the staked part of it completely.
- Do not damage the threads of the drive shaft.
- Be sure not to sharpen the tip of the SST.
- Set the SST to the groove with the flat face upward.
b. Using a 30 mm socket wrench. remove the lock nut.
38. REMOVE FRONT AXLE HUB RH NUT
SST 09930-00010
HINT: Perform the same procedure on the opposite side.
39. SEPARATE SPEED SENSOR FRONT LH
a. Remove the bolt, and separate the speed sensor from the steering knuckle
NOTICE: Do not stick any foreign matter on the sensor tip.
40. SEPARATE SPEED SENSOR FRONT RH
HINT: Perform the same procedure on the opposite side.
41. SEPARATE TIE ROD ASSY LH
a. Remove the cotter pin and a nut.
b. Using SST, separate the tie rod end from the steering knuckle.
SST 09628-62011
NOTICE: Do not damage the dust cover of the ball joint.
42. SEPARATE TIE ROD ASSY RH
SST 09628-62011
HINT: Perform the same procedure on the opposite side.
43. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH
a. Remove the bolt and 2 nuts, and separate the front suspension arm from the lower ball joint.
b. Using a plastic hammer, separate the drive shaft from the axle hub.
44. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH
HINT: Perform the same procedure on the opposite side.
45. REMOVE STARTER ASSY
46. REMOVE EXHAUST PIPE SUPPORT BRACKET NO.1
47. REMOVE DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT
a. Using SST, hold the crankshaft.
SST 09213-54015 (91651-60855), 09330-00021
b. Remove the 2 bolts and flywheel housing under cover.
c. Remove the 6 torque converter set bolts.
48. SEPARATE STEERING INTERMEDIATE SHAFT SUB-ASSY
a. Loosen the sliding yoke bolt.
b. Place match marks on the steering intermediate shaft and control valve shaft.
c. Remove the bolt, and separate the steering intermediate shaft.
d. To prevent from rotating the steering wheel, fix the wheel with the seat belt.
NOTICE: The operation is useful to prevent the damage of the spiral cable.
49. REMOVE GENERATOR ASSY
50. REMOVE GENERATOR BRACKET NO.2
51. REMOVE GENERATOR BELT ADJUSTING BAR
a. Remove the 2 bolts, 2 nuts and the adjusting bar.
52. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH
a. Remove the bolt, nut and adjusting bar bracket.
b. Remove the 3 bolts and compressor.
HINT: Hang up the hoses instead of detaching.
53. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
a. Set the engine lifter.
b. Remove the 4 bolts and 2 nuts, frame side rail plate subassembly RH and LH.
c. Remove the 4 bolts and 2 nuts, front suspension member brace rear RH and LH.
d. Carefully, remove the engine assembly from the vehicle.
e. Install the No. 2 engine hanger in the correct direction.
Part No.:
No. 2 engine hanger 12282-20020
Bolt 91621-60822
Torque: 20 Nm (199 kgf-cm, 14 ft. lbs.)
f. Using the chain block and engine sling device, hang the engine assembly.
54. REMOVE VANE PUMP ASSY
a. Separate the power steering oil pressure sensor harness.
b. Separate the pressure feed tube clamp.
c. Remove the 2 bolts and vane pump assembly.
55. REMOVE FRONT FRAME ASSY
a. Remove the 2 nuts, and separate engine mounting insulator RH and LH.
b. Remove the bolt, and separate engine mounting insulator FR.
56. REMOVE FRONT DRIVE SHAFT ASSY LH
SST 09520-01010, 09520-24010 (09520-32040)
57. REMOVE FRONT DRIVE SHAFT ASSY RH
58. REMOVE ENGINE WIRE
59. REMOVE AUTOMATIC TRANSAXLE ASSY
60. REMOVE DRIVE PLATE & RING GEAR SUB-ASSY
SST 09213-54015 (91651-60855), 09330-00021
61. INSTALL ENGINE STAND
62. REMOVE INTAKE AIR SURGE TANK
63. REMOVE IGNITION COIL ASSY
64. REMOVE INTAKE MANIFOLD
65. REMOVE WATER OUTLET
66. REMOVE EXHAUST MANIFOLD SUB-ASSY RH
67. REMOVE MANIFOLD STAY NO.2
68. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2
69. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSY NO.2
70. REMOVE DRIVE SHAFT BEARING BRACKET
71. REMOVE PUMP BRACKET
a. Remove the 3 bolts and pump bracket
72. REMOVE GENERATOR BRACKET NO.1
73. REMOVE COMPRESSOR MOUNTING BRACKET NO.1
74. REMOVE WATER INLET PIPE
75. REMOVE WATER INLET
76. REMOVE THERMOSTAT
77. REMOVE ENGINE OIL PRESSURE SWITCH ASSY
a. Remove the oil pressure switch.
78. REMOVE KNOCK CONTROL SENSOR
a. Using SST, remove the 2 knock control sensors.
SST 09816-30010
79. REPLACE PARTIAL ENGINE ASSY
80. INSTALL KNOCK CONTROL SENSOR
a. Using SST, install the 2 knock control sensors.
SST 09816-30010
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
81. INSTALL ENGINE OIL PRESSURE SWITCH ASSY
a. Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive: Part No. 08833-00080 THREE BOND 1344, LOCTITE 242 or equivalent.
b. Install the oil pressure switch.
Torque: 15 Nm (152 kgf-cm, 11 ft. lbs.)
82. INSTALL THERMOSTAT
83. INSTALL WATER INLET
84. INSTALL WATER INLET PIPE
85. INSTALL COMPRESSOR MOUNTING BRACKET NO.1
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
86. INSTALL GENERATOR BRACKET NO.1
Torque: 58 Nm (591 kgf-cm, 43 ft. lbs.)
87. INSTALL PUMP BRACKET
Torque: 32 Nm (326 kgf-cm, 24 ft. lbs.)
88. INSTALL DRIVE SHAFT BEARING BRACKET
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
89. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSY NO.2
a. Install a new gasket and the exhaust manifold converter.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
90. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)
91. INSTALL MANIFOLD STAY NO.2
Torque: 34 Nm (347 kgf-cm, 25 ft. lbs.)
92. INSTALL EXHAUST MANIFOLD SUB-ASSY RH
a. Install a new gasket and the exhaust manifold RH. Uniformly tighten the nuts in several passes, in the sequence shown.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
3. INSTALL WATER OUTLET
94. INSTALL INTAKE MANIFOLD
95. INSTALL IGNITION COIL ASSY
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
96. INSTALL INTAKE AIR SURGE TANK
97. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY
SST 09213-54015 (91651-60855), 09330-00021
98. INSTALL AUTOMATIC TRANSAXLE ASSY
99. INSTALL FRONT DRIVE SHAFT ASSY RH
100. INSTALL FRONT DRIVE SHAFT ASSY LH
101. INSTALL FRONT FRAME ASSY
a. Install the engine mounting insulator RH and LH with the 2 nuts.
Torque: 95 Nm (969 kgf-cm, 70 ft. lbs.)
b. Install the engine mounting insulator FR with the bolt.
Torque: 87 Nm (887 kgf-cm, 64 ft. lbs.)
102. INSTALL VANE PUMP ASSY
a. Install the vane pump assembly with the 2 bolts.
Torque: 43 Nm (439 kgf-cm, 32 ft. lbs.)
HINT: After adjusting the V-ribbed belt, tighten the bolt A.
103. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
a. Set the engine assembly with transaxle on the engine lifter.
b. Install the engine assembly to the vehicle.
c. Install the frame side rail plate sub-assembly RH and LH with the 4 bolts and 2 nuts.
Torque:
Bolt A 85 Nm (867 kgf-cm, 63 ft. lbs.)
Bolt B Nut 32 Nm (326 kgf-cm, 24 ft. lbs.)
d. Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts.
Torque:
Bolt C 85 Nm (867 kgf-cm, 63 ft. lbs.)
Bolt D, Nut 32 Nm (326 kgf-cm, 24 ft. lbs.)
104. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
a. Install the compressor with the 3 bolts.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
b. Install the adjusting bar bracket with the bolt and nut.
Torque:
Bolt 25 Nm (250 kgf-cm, 18 ft. lbs.)
Nut 26 Nm (260 kgf-cm, 19 ft. lbs.)
105. INSTALL GENERATOR BELT ADJUSTING BAR
a. Install the adjusting bar with the 2 bolts and 2 nuts.
Torque:
Nut A 43 Nm (438 kgf-cm, 32 ft. lbs.)
Bolt B 18 Nm (184 kgf-cm, 13 ft. lbs.)
Bolt C 8.0 Nm (82 kgf-cm, 71 inch lbs.)
106. INSTALL GENERATOR BRACKET NO.2
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
107. INSTALL GENERATOR ASSY
108. INSTALL STEERING INTERMEDIATE SHAFT SUB-ASSY
a. Align the match marks on the intermediate shaft and control valve shaft, and install the bolt.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)
b. Tighten the sliding yoke bolt.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)
109. INSTALL DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT
a. Using SST, hold the crankshaft.
SST 09213-54015 (91651-60855), 09330-00021
b. Using kerosene or gasoline, clean the bolts thoroughly.
c. Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
d. Install the 6 torque converter set bolts
Torque: 41 Nm (418 kgf-cm, 30 ft. lbs.)
NOTICE: First tighten green colored bolt and then tighten the 5 bolts.
e. Install the flywheel housing under cover with the 2 bolts
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)
110. INSTALL EXHAUST PIPE SUPPORT BRACKET NO.1
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)
111. INSTALL STARTER ASSY
112. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH
a. Install the drive shaft to steering knuckle.
b. Install the suspension lower arm with the bolt and 2 nuts.
Torque: 127 Nm (1,295 kgf-cm, 94 ft. lbs.)
113. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH
HINT: Perform the same procedure on the opposite side.
114. INSTALL TIE ROD ASSY LH
a. Connect the tie rod end to the steering knuckle and install a new castle nut.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
NOTICE: Prevent any lubricant from the thread and the taper portions. After tightening the castle nut, tighten it to the additional direction within 60° to put into a cotter pin.
b. Insert a new cotter pin.
115. INSTALL TIE ROD ASSY RH
HINT: Perform the same procedure on the opposite side
116. INSTALL SPEED SENSOR FRONT LH
117. INSTALL SPEED SENSOR FRONT RH
HINT: Perform the same procedure on the opposite side.
118. INSTALL FRONT AXLE HUB LH NUT
a. Using a 30 mm socket wrench, install a new hub nut.
Torque: 294 Nm (2,998 kgf-cm, 217 ft. lbs.)
b. Using a chisel, stake the hub nut
119. INSTALL FRONT AXLE HUB RH NUT
HINT: Perform the same procedure on the opposite side.
120. INSTALL FRONT STABILIZER LINK ASSY LH
a. Using a 6 mm socket hexagon wrench, hold the ball stud, and install the nut.
Torque: 74 Nm (755 kgf-cm, 55 ft. lbs.)
121. INSTALL FRONT STABILIZER LINK ASSY RH
HINT: Perform the same procedure on the opposite side.
122. INSTALL EXHAUST PIPE ASSY FRONT
123. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET
124. CONNECT FUEL PIPE SUB-ASSY NO.1
a. Push in the fuel tube connector to the fuel pipe until connector makes a "click" sound.
NOTICE: Check if there is any damage or foreign objects on the connected part of the pipe. After connecting, check if the pipe and the connector are securely connected by pulling them. Install the fuel pipe clamp.
125. INSTALL AIR CLEANER ASSEMBLY WITH HOSE
126. CONNECT VACUUM HOSE
127. INSTALL V-BANK COVER SUB-ASSY
a. Using a 5 mm socket hexagon wrench, install the V-bank cover with the 3 nuts.
Torque: 7.9 Nm (81 kgf-cm, 70 inch lbs.)
128. INSTALL ENGINE MOUNTING STAY NO.2 RH
a. Install the engine mounting stay No. 2 RH and engine mounting bracket No. 2 RH with the bolt.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
129. INSTALL ENGINE MOVING CONTROL ROD
a. Install the engine moving control rod and bracket with the 4 bolts.
Torque:
Bolt A 64 Nm (653 kgf-cm, 47 ft. lbs.)
Bolt B 23 Nm (235 kgf-cm, 17 ft. lbs.)
130. INSTALL VANE PUMP V BELT
131. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
132. INSPECT DRIVE BELT DEFLECTION AND TENSION (REFERENCE)
133. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
134. ADD AUTOMATIC TRANSAXLE FLUID
135. ADD ENGINE OIL
136. ADD COOLANT
137. ADD POWER STEERING FLUID
138. BLEED POWER STEERING FLUID
139. INSPECT OIL LEAK
140. CHECK ENGINE COOLANT LEAK
141. INSPECT FUEL LEAK
142. CHECK EXHAUST GAS LEAK
143. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
144. INSPECT IGNITION TIMING
SST 09843-18040, 09843-18020
145. INSPECT ENGINE IDLE SPEED
SST 09843-18040
146. INSPECT CO/HC
147. CHECK ABS SPEED SENSOR SIGNAL