Partial Engine Assembly
REPLACEMENT1. PREVENT GASOLINE FROM SPILLING OUT
2. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY
3. REMOVE HOOD SUB-ASSEMBLY
a. Disconnect the windshield washer hose.
b. Disconnect the hood dampers.
c. Remove the 4 bolts and hood sub-assembly.
4. REMOVE V-BANK COVER SUB-ASSEMBLY
a. Remove the 2 nuts and V-bank cover sub-assembly.
5. REMOVE ENGINE ROOM COVER SIDE
6. REMOVE ENGINE ROOM SIDE COVER LH
7. REMOVE AIR CLEANER HOSE ASSEMBLY
a. Disconnect the vacuum hoses (for P/S idle up and for fuel pressure regulator) and ventilation hose.
8. REMOVE AIR CLEANER ASSEMBLY
a. Disconnect the intake air flow meter connector.
b. Disconnect the ground cable from the body.
c. Remove the air cleaner cap and air cleaner element.
d. Remove the 3 bolts and air cleaner assembly.
9. REMOVE ENGINE UNDER COVER SUB-ASSEMBLY NO.1
10. REMOVE ENGINE UNDER COVER ASSEMBLY REAR
11. DRAIN ENGINE COOLANT
12. DRAIN ENGINE OIL
a. Remove the oil pan drain plug and drain the engine oil.
b. Clean the oil pan drain plug and install a new gasket and the drain plug.
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
13. REMOVE RADIATOR ASSEMBLY
14. REMOVE FAN SHROUD
a. Disconnect the fasteners of the clamp and oil cooler hoses from the fan shroud in sequence.
b. Remove the fan shroud with fan.
15. DISCONNECT FUEL HOSE NO.2
a. Observe the following precautions when disconnecting the fuel tube connector:
1 Remove the fuel pipe clamp No.2.
2 Check if there is any dirt on the pipe and around the connector before disconnecting them. Clean the dirt away if necessary.
3 Disconnect the connector from the hose while pinching part A with fingers as shown in the illustration.
4 When the connector and the pipe are stuck, pinch the fuel pipe with fingers and push the fuel tube connector to the fuel pipe by pressing the release buttons, then pull the connector out from the pipe. Do not use any tool at this time.
5 Check if there is any dirt or other foreign objects on the seal surface of the disconnected pipe and clean it away.
6 Do not damage the disconnected pipe and connector, and prevent intrusion of foreign objects by covering them with a plastic bag.
16. DISCONNECT FUEL HOSE
a. Observe the following precautions when disconnecting the fuel tube connector:
1 Remove the fuel pipe clamp No.1.
2 Check if there is any dirt on the pipe and around the connector before disconnecting them. Clean the dirt away if necessary.
3 Disconnect the connector from the hose while pinching part A with fingers as shown in the illustration.
4 When the connector and the pipe are stuck, pinch the fuel pipe with fingers and push the fuel tube connector to the fuel pipe by pressing the release buttons, then pull the connector out from the pipe. Do not use any tool at this time.
5 Check if there is any dirt or other foreign objects on the seal surface of the disconnected pipe and clean it away.
6 Do not damage the disconnected pipe and connector, and prevent intrusion of foreign objects by covering them with a plastic bag.
17. DISCONNECT FUEL VAPOR FEED HOSE ASSEMBLY
18. REMOVE FAN AND GENERATOR V BELT
19. SEPARATE VANE PUMP ASSEMBLY
a. Disconnect the vacuum hose.
b. Remove the nut, 2 bolts and vane pump assembly.
HINT: Hang up the hose instead of detaching.
20. SEPARATE COMPRESSOR
a. Disconnect the compressor connector.
b. Remove the nut, 3 bolts, compressor stay and compressor.
HINT: Hang up the hoses instead of detaching.
21. REMOVE FAN W/ FLUID COUPLING
a. Remove the 4 nuts and fan w/ fluid coupling.
b. Remove the fan pulley.
22. REMOVE TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY
a. Remove the bolt and transmission oil filler tube.
23. REMOVE OIL LEVEL GAUGE GUIDE
a. Remove the bolt and oil level gauge guide.
b. Remove the O-ring.
24. DISCONNECT HEATER HOSE
25. SEPARATE ENGINE WIRE
a. Remove the front door scuff plate RH.
b. Remove the cowl side trim board RH.
c. Remove the glove compartment door.
d. Disconnect each connector for the ECM, four-wheel-drive-control ECU and instrument panel wire before pull out the engine wire into the engine room.
e. Disconnect the 3 ground cables from the body. Disconnect the engine wire No.2 from the battery terminals (positive and negative) and engine room relay block.
26. REMOVE ENGINE ASSEMBLY
a. Attach the engine chain hoist to the engine hangers.
b. Remove the 4 nuts and 4 bolts.
c. Lift the engine out of the vehicle slowly and carefully.
HINT: Make sure the engine is kept clear of all wiring hoses and cables.
27. REMOVE ENGINE WIRE
a. Disconnect the VSV connector.
b. Disconnect the solenoid connector.
28. REMOVE INTAKE MANIFOLD ASSEMBLY
29. REMOVE WIRING HARNESS HEAT INSULATOR NO.2
a. Remove the 2 bolts and wiring harness heat insulator No.2.
30. REMOVE ENGINE WIRE NO.2
a. Remove the bolt and separate the ground cable wire.
b. Remove the nut, 2 bolts and engine wire No.2.
31. REMOVE ENGINE MOUNTING BRACKET FRONT NO.1 RH
a. Remove the 4 bolts and the engine-mounting bracket together with the engine-mounting insulator front.
32. REMOVE ENGINE MOUNTING BRACKET FRONT NO.1 LH
a. Remove the 4 bolts and the engine-mounting bracket together with the engine-mounting insulator front.
33. REMOVE GENERATOR ASSEMBLY
34. REMOVE HEATER HOSE
35. REMOVE DRIVE PLATE & RING GEAR SUB-ASSEMBLY
36. REMOVE OIL COOLER PIPE
a. Disconnect the 3 hoses.
b. Remove the bolt, nut and oil cooler pipe.
37. REMOVE PUMP BRACKET
a. Remove the 4 bolts and pump bracket.
38. REMOVE TIMING BELT COVER SUB-ASSEMBLY NO.3 LH
a. Remove the grommet and separate the cam position sensor connector from the timing belt cover sub-assembly No.3 LH.
b. Remove the 4 bolts and timing belt cover sub-assembly No.3 LH.
39. REMOVE TIMING CHAIN OR BELT COVER NO.2
a. Remove the nut, 3 bolts and timing belt cover No.2.
40. REMOVE TIMING BELT COVER SUB-ASSEMBLY NO.2
a. Remove the 2 bolts and timing belt cover sub-assembly No.2.
41. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
a. Remove the bolt, 2 nuts and V-ribbed belt tensioner.
42. REMOVE FAN BRACKET SUB-ASSEMBLY
a. Remove the 2 nuts, 2 bolts and fan bracket sub-assembly.
43. REMOVE IGNITION COIL ASSEMBLY
a. Remove the 8 bolts and 8 ignition coils.
44. REMOVE CAMSHAFT POSITION SENSOR
a. Remove the bolt, stud bolt and camshaft position sensor.
45. REMOVE CRANKSHAFT POSITION SENSOR
a. Remove the bolt and crankshaft position sensor.
46. REMOVE VVT SENSOR
a. Remove the 2 bolts and VVT sensors.
47. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY
a. Remove the wire clamp.
b. Remove the bolt and water by-pass.
c. Remove the O-ring from the water by-pass pipe sub-assembly.
48. REMOVE AIR SWITCHING VALVE NO.2
49. REMOVE WATER BY-PASS JOINT RR
a. Remove the 4 nuts and water by-pass joint.
b. Remove the 2 gaskets from the water by-pass joint.
50. REMOVE AIR PUMP ASSEMBLY W/ BRACKET
51. REMOVE STARTER ASSEMBLY
a. Disconnect the engine wire No.2.
b. Remove the 2 bolts and starter assembly.
52. REMOVE KNOCK SENSOR
SST 09816-30010
53. REMOVE WATER INLET HOUSING
54. REMOVE WATER BY-PASS JOINT FR
a. Remove the 4 nuts, water by-pass joint and 2 gaskets.
55. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Remove the 4 bolts and exhaust manifold heat insulator No.1.
b. Disconnect the oxygen sensor connector.
c. Remove the 8 nuts and exhaust manifold sub-assembly.
56. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
a. Remove the 4 bolts and exhaust manifold heat insulator No.2.
b. Disconnect the oxygen sensor connector.
c. Remove the 8 nuts and exhaust manifold sub-assembly.
57. REMOVE OIL COOLER ASSEMBLY
a. Remove the 2 bolts and nut.
b. Remove the oil cooler assembly w/ bracket and gasket.
58. REMOVE VENTILATION VALVE SUB-ASSEMBLY
a. Remove the ventilation valve cover.
b. Remove the ventilation valve sub-assembly.
59. REPLACE PARTIAL ENGINE ASSEMBLY
60. INSTALL VENTILATION VALVE SUB-ASSEMBLY
a. Apply adhesive to 2 or 3 threads.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
b. INSTALL the ventilation valve.
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)
HINT: After tightening the valve to the specified torque, turn the ventilation valve clockwise with the port facing in the direction indicated in the illustration.
c. Install the ventilation valve cover to the ventilation valve.
d. Connect the ventilation hose to the ventilation valve.
61. INSTALL OIL COOLER ASSEMBLY
a. Place a new gasket into the groove of the oil cooler.
b. Apply a light coat of engine oil to the gasket.
c. Install the oil cooler assembly with the 2 bolts and nut.
Torque: 18 Nm (185 kgf-cm 13 ft. lbs.)
62. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
a. Place a new gasket on the cylinder head.
NOTICE: Be careful of the installation direction.
b. Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in diagonally.
Torque: 44 Nm (450 kgf-cm, 33 ft. lbs)
c. Install the heat insulator with the 4 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
63. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Place a new gasket on the cylinder head.
NOTICE: Be careful of the installation direction.
b. Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts diagonally.
Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.)
c. Install the heat insulator with the 4 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
64. INSTALL WATER BY-PASS JOINT FR
a. With the flat-bottom of each new gasket facing downward as shown in the illustration, install the 2 gaskets to the engine front side.
b. Install the water by-pass joint with the 4 nuts. Alternately tighten the nuts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
65. INSTALL WATER INLET HOUSING
66. INSTALL KNOCK SENSOR
SST 09816-30010
67. INSTALL STARTER ASSEMBLY
a. Install the starter assembly with the 2 bolts.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
b. Connect the engine wire No.2.
Torque: 9.8 Nm (100 kgf-cm, 7.2 ft. lbs.)
68. INSTALL AIR PUMP ASSEMBLY W/ BRACKET
69. INSTALL WATER BY-PASS JOINT RR
a. With the flat-bottom of each new gasket facing downward as shown in the illustration, install the 2 gaskets to the engine rear side.
b. Install the water by-pass joint with the 4 nuts. Alternately tighten the nuts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
70. INSTALL AIR SWITCHING VALVE NO.2
71. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
a. Install a new O-ring to the water by-pass pipe.
b. Apply soapy water to the O-ring.
c. Push in the water by-pass pipe end into the pipe hole of the water pump.
d. Install the water by-pass pipe with the bolt.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
72. INSTALL WT SENSOR
a. Install the WT sensors with the 2 bolts.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
73. INSTALL CRANKSHAFT POSITION SENSOR
a. Install the crankshaft position sensor with the bolt.
Torque: 6.5 Nm (65 kgf-cm, 58 inch lbs.)
74. INSTALL CAMSHAFT POSITION SENSOR
a. Install the camshaft position sensor with the bolt and the stud bolt.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
75. INSTALL IGNITION COIL ASSEMBLY
a. Install the 8 ignition coils with the 8 bolts.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
76. INSTALL FAN BRACKET SUB-ASSEMBLY
a. Install the fan bracket with the 2 bolts and 2 nuts.
Torque:
12 mm head: 16 Nm (160 kgf-cm, 12 ft. lbs.)
14 mm head: 32 Nm (326 kgf-cm, 24 ft. lbs.)
77. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
a. Install the V-ribbed belt tensioner with the bolt and 2 nuts.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
78. INSTALL TIMING BELT COVER SUB-ASSEMBLY NO.2
a. Install the timing belt cover sub-assembly No.2 with the 2 bolts.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
79. INSTALL TIMING CHAIN OR BELT COVER NO.2
a. Install the timing chain or belt cover with the nut and 3 bolts.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
80. INSTALL TIMING BELT COVER SUB-ASSEMBLY NO.3 LH
a. Install the timing belt cover sub-assembly with the 4 bolts.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
b. Install the camshaft position sensor connector and grommet to the timing belt cover.
81. INSTALL PUMP BRACKET
a. Install the pump bracket with the 4 bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
82. INSTALL OIL COOLER PIPE
a. Install the oil cooler pipe with the bolt and nut.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
b. Connect the 3 hoses.
83. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY
84. INSTALL HEATER HOSE
85. INSTALL GENERATOR ASSEMBLY
86. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 LH
a. Install the engine-mounting bracket and engine-mounting insulator with the 4 bolts.
Torque: 36 Nm (367 kgf-cm, 27 ft. lbs.)
87. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 RH
a. Install the engine-mounting bracket and engine-mounting insulator with the 4 bolts.
Torque: 36 Nm (367 kgf-cm, 27 ft. lbs.)
88. INSTALL ENGINE WIRE NO.2
a. Install the engine wire protector with the nut and 2 bolts.
b. Connect the ground cable wire clamp with the bolt.
89. INSTALL WIRING HARNESS HEAT INSULATOR NO.2
a. Install the wiring harness heat insulator with the 2 bolts.
Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)
90. INSTALL INTAKE MANIFOLD ASSEMBLY
91. INSTALL ENGINE WIRE
92. INSTALL ENGINE ASSEMBLY
a. Attach the engine chain hoist to the engine hangers.
b. Slowly lower the engine assembly into the engine compartment.
c. Attach the engine mounting brackets to the frame brackets.
d. Install the engine mounting brackets with the 4 nuts and 4 bolts.
Torque: 38 Nm (387 kgf-cm, 28 ft. lbs.)
e. Remove the engine chain hoist.
93. INSTALL ENGINE WIRE
94. CONNECT HEATER HOSE
95. INSTALL OIL LEVEL GAUGE GUIDE
a. Install a new O-ring to the oil level gauge guide.
b. Install the oil level gauge guide with the bolt.
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
96. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY
a. Install a new O-ring to the oil filler tube sub-assembly.
b. Install the transmission oil filler tube sub-assembly with the bolt.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
97. INSTALL FAN W/ FLUID COUPLING
a. Install the fan pulley to the engine.
b. Install the fan w/ fluid coupling with the 4 nuts.
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)
98. INSTALL COMPRESSOR
a. Install the compressor with the stay, nut and 3 bolts.
Torque:
Bolt: 47 Nm (475 kgf-cm, 34 ft. lbs.)
Nut: 25 Nm (255 kgf-cm, 18 ft. lbs.)
b. Connect the compressor connector.
99. INSTALL VANE PUMP ASSEMBLY
a. Install the vane pump assembly with the nut and 2 bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
100. INSTALL FAN AND GENERATOR V BELT
101. CONNECT FUEL VAPOR FEED HOSE ASSEMBLY
102. CONNECT FUEL HOSE
103. CONNECT FUEL HOSE NO.2
104. INSTALL FAN SHROUD
a. Install the fan shroud with the fan into the engine room.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
105. INSTALL RADIATOR ASSEMBLY
106. ADD ENGINE COOLANT
107. ADD ENGINE OIL
108. INSTALL ENGINE UNDER COVER ASSEMBLY REAR
109. INSTALL ENGINE UNDER COVER SUB-ASSEMBLY NO.1
110. INSTALL AIR CLEANER ASSEMBLY
a. Install the air cleaner assembly with the 3 bolts.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
b. Connect the wire harness clamp and the ground cable.
Torque: 8.3 Nm (85 kgf-cm, 73 inch lbs.)
111. INSTALL AIR CLEANER HOSE ASSEMBLY
112. INSTALL ENGINE ROOM SIDE COVER LH
113. INSTALL ENGINE ROOM COVER SIDE
114. INSTALL V-BANK COVER SUB-ASSEMBLY
a. Install the V-bank cover sub-assembly with the 2 nuts.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
115. INSTALL HOOD SUB-ASSEMBLY
a. Install the hood with the 4 bolts.
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
b. Connect the hood damper.
Torque: 18 Nm (180 kgf-cm, 13 ft. lbs.)
c. Connect the windshield washer hose.
116. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
117. CHECK FOR ENGINE COOLANT LEAKS
118. CHECK FOR EXHAUST GAS LEAKS
119. INSPECT CHECK FOR FUEL LEAKS
120. INSPECT AUTOMATIC TRANSMISSION FLUID
121. INSPECT CHECK FOR ENGINE OIL LEAKS