Replacement
REMOVAL AND INSTALLATION1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. REMOVE HOOD SUB-ASSY
4. REMOVE V-BANK COVER
5. REMOVE AIR CLEANER INLET NO.1
6. REMOVE INTAKE AIR CONNECTOR PIPE
7. REMOVE AIR CLEANER ASSY
8. REMOVE ENGINE UNDER COVER
9. REMOVE ENGINE UNDER COVER NO.2
10. DRAIN ENGINE OIL
11. DRAIN COOLANT
12. DRAIN AUTOMATIC TRANSMISSION FLUID
13. REMOVE RADIATOR ASSY
14. DISCONNECT FUEL PIPE SUB-ASSY NO.2
15. REMOVE FAN AND GENERATOR V BELT
16. DISCONNECT ENGINE WIRE
a. Disconnect the engine wire from the ECM box.
b. Remove the nut, and disconnect the generator wire from the generator.
c. Disconnect the wire for generator wire from the wire clamp on generator.
d. Remove the bolt, and disconnect the ground cable from the stay on generator
e. Remove the 2 bolts, and disconnect the PS oil hose from the No. 1 oil pan.
f. Remove the bolt, and disconnect the ground strap from the body.
17. DISCONNECT AIR HOSE NO.5
18. DISCONNECT FUEL VAPOR FEED HOSE NO.2
19. DISCONNECT HEATER WATER INLET HOSE A
20. DISCONNECT HEATER WATER OUTLET HOSE A(FROM HEATER UNIT)
21. DISCONNECT VANE PUMP OIL RESERVOIR ASSY
22. DISCONNECT VANE PUMP ASSY
a. Disconnect the 2 PS air hoses.
b. Remove the 2 screws and RH engine under cover.
c. Disconnect the PS oil pressure switch connector.
d. Remove the 2 bolts and nut, and disconnect the vane pump from the engine.
e. Support the vane pump securely.
23. DISCONNECT COOLER COMPRESSOR ASSY
a. Disconnect the compressor connector.
b. Disconnect the wire clamp from the wire bracket on the compressor.
c. Remove the bolt, nut and stay.
d. Remove the bolt, and disconnect the wire bracket from the compressor.
e. Remove the bolt, and disconnect the compressor from the engine.
f. Support the cooler compressor securely.
24. REMOVE FRONT FLOOR BRACE CENTER
25. REMOVE EXHAUST PIPE ASSY
26. REMOVE FRONT SUSPENSION MEMBER BRACE SUB-ASSY RH
27. REMOVE W/ CATALYST CONVERTER ASSY
28. REMOVE FRONT FLOOR HEAT INSULATOR NO.1
29. REMOVE PARKING BRAKE CABLE HEAT INSULATOR
30. REMOVE PROPELLER W/ CENTER BEARING SHAFT ASSY
SST 09922-10010
31. REMOVE FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSY
32. REMOVE STEERING SLIDING YOKE SUB-ASSY
a. Check the steering wheel at the straight-ahead position.
b. Remove the 2 bolts and sliding yoke from the steering intermediate shaft.
33. DISCONNECT POWER STEERING GEAR HOUSING ASSY
a. Remove the bolt, and disconnect the 2 PS oil tubes from the front frame.
b. Remove the 4 bolts, and disconnect the PS gear housing from the front frame.
c. Suspend the PS gear housing securely.
34. REMOVE ENGINE W/ TRANSMISSION ASSEMBLY
a. Remove the nut and No. 1 V-bank cover bracket from the No. 2 engine hanger.
b. Attach the engine chain hoist to the engine hangers.
c. Remove the 2 hole plugs.
d. Remove the 4 nuts holding the engine mounting insulator to the front suspension crossmember.
e. Remove the 4 bolts, 4 nuts and rear engine mounting member.
f. Lift the engine out of the vehicle slowly and carefully.
HINT: Make sure the engine is clear of all wiring, hose and cable.
g. Place the engine and transmission assembly onto the stand.
35. DISCONNECT ENGINE WIRE
a. Disconnect the engine wire from the transmission.
1. Disconnect the VSV connector.
2. Disconnect the PNP switch connector.
3. Disconnect the solenoid connector.
4. Disconnect the direct clutch speed sensor connector.
5. Disconnect the engine wire from the 3 wire clamps.
6. Disconnect the oil level sensor connector.
36. REMOVE TRANSMISSION OIL FILLER TUBE SUB-ASSY
37. REMOVE OIL COOLER OUTLET TUBE NO.1
38. REMOVE OIL COOLER INLET TUBE NO 1
39. REMOVE AUTOMATIC TRANSMISSION ASSY
a. Remove the torque converter clutch bolts.
1. Remove the 2 bolts and flywheel housing under cover.
2. Turn the crankshaft pulley bolt to gain access to each bolt.
3. Hold the crankshaft pulley bolt with a wrench, and remove the 6 bolts.
a. Remove the 10 bolts and ground strap.
b. Remove the transmission together with the torque converter clutch from the engine.
40. REMOVE DRIVE PLATE & RING GEAR SUB-ASSY
41. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY
HINT:
The mounting bolts are tightened in 2 progressive steps (step (c)and (e))
If any one of the mounting bolts is broken or deformed, replace it.
a. Apply adhesive to 2 or 3 threads of the mounting bolt end.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
b. Install the front spacer, drive plate and rear spacer on the crankshaft.
c. Install and uniformly tighten the 8 mounting bolts in several passes, in the sequence shown.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
If any one of the mounting bolts does not meet the torque specification, replace the mounting bolt.
d. Mark the mounting bolt with paint.
e. Retighten the mounting bolt by 90° in the numerical order shown.
f. Check that the painted mark is now at a 90° angle to (e).
42. INSTALL AUTOMATIC TRANSMISSION ASSY
a. Check the torque converter clutch installation.
b. Attach the transmission to the engine.
c. Install the ground strap and 10 bolts
Torque:
Bolt A: 72 Nm (730 kgf-cm, 53 ft. lbs.) for 17 mm head
Bolt B: 37 Nm (380 kgf-cm, 27 ft. lbs.) for 14 mm head
d. Install the torque converter clutch bolts.
1. Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
2. Hold the crankshaft pulley bolt with a wrench, and install the 6 bolt evenly.
Torque: 48 Nm (490 kgf-cm, 35 ft. lbs.)
HINT: First install the black colored bolt, install the other bolt.
3. Install the flywheel housing under cover with the 2 bolts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
43. INSTALL OIL COOLER INLET TUBE NO.1
44. INSTALL OIL COOLER OUTLET TUBE NO.1
45. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSY
46. CONNECT ENGINE WIRE
a. Connect the engine wire to the transmission.
1. Connect the VSV connector.
2. Connect the PNP switch connector.
3. Connect the solenoid connector.
4. Connect the direct clutch speed sensor connector.
5. Connect the engine wire from the 3 wire clamps.
6. Connect the oil level sensor connector.
47. INSTALL ENGINE W/TRANSMISSION ASSEMBLY
a. Attach the engine chain hoist to the engine hangers.
b. Slowly lower the engine and transmission assembly into the engine compartment.
c. Insert the stud bolts of the front engine mounting brackets into the stud bolt holes of the front suspension crossmember.
d. Keep the engine level.
e. Install the rear engine mounting member with the 4 bolts and 4 nuts.
Torque:
25.5 Nm (260 kgf-cm, 19 ft. lbs.) for bolts
13.5 Nm (135 kgf-cm, 10 ft. lbs.) for nuts
NOTICE: Be careful of installation direction.
f. Install the 4 nuts holding the engine mounting brackets to the front suspension crossmember.
Torque: 68 Nm (700 kgf-cm, 50 ft. lbs.)
g. Install the 2 hole plugs.
h. Remove the engine chain hoist.
i. Install the V-bank cover bracket No.1 to the engine hanger No. 2 with the nut.
48. INSTALL POWER STEERING GEAR HOUSING ASSY
a. Connect the sliding yoke to the PS gear housing and intermediate shaft.
b. Install the PS gear housing with the 4 bolts.
Torque: 65 Nm (660 kgf-cm, 48 ft. lbs.)
c. Install the 2 PS oil tube with the bolt.
49. INSTALL STEERING SLIDING YOKE SUB-ASSY
a. Tighten the 2 bolts for sliding yoke.
Torque: 35 Nm (360 kgf-cm, 26 ft. lbs.)
50. INSTALL FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSY
51. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSY
52. INSTALL PARKING BRAKE CABLE HEAT INSULATOR
53. INSTALL FRONT FLOOR HEAT INSULATOR NO.1
54. INSTALL W/ CATALYST CONVERTER ASSY
55. INSTALL FRONT SUSPENSION MEMBER BRACE SUB-ASSY RH
Torque: 58 Nm (590 kgf-cm, 43 ft. lbs.) for nuts
56. INSTALL EXHAUST PIPE ASSY
57. INSTALL FRONT FLOOR BRACE CENTER
58. INSTALL COOLER COMPRESSOR ASSY
a. Install the cooler compressor, stay and wire bracket with the 3 bolts and nut.
Torque:
49 Nm (500 kgf-cm, 36 ft. lbs.) for bolts
29 Nm (300 kgf-cm, 21 ft. lbs.) for nut
b. Connect the compressor connector.
c. Install the wire clamp.
59. INSTALL VANE PUMP ASSY
a. Install the vane pump with the 2 bolts and nut. Alternately tighten the bolts and nut.
Torque:
39.2 Nm (400 kgf-cm, 29 ft. lbs.) for bolts
43.1 Nm (440 kgf-cm, 32 ft. lbs.) for nut
b. Connect the PS oil pressure switch connector.
c. Install the RH engine under cover with the 2 screws.
d. Connect the 2 PS air hoses to the vane pump.
60. INSTALL VANE PUMP OIL RESERVOIR ASSY
61. CONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
62. CONNECT HEATER WATER INLET HOSE A
63. CONNECT FUEL VAPOR FEED HOSE NO.2
64. CONNECT AIR HOSE NO.5
65. CONNECT ENGINE WIRE
a. Connect the engine wire from the ECM box.
b. Install the nut, and connect the generator wire to the generator.
c. Connect the wire for generator wire to the wire clamp on generator.
d. Install the bolt, and disconnect the ground cable to the stay on generator.
e. Install the 2 bolt, and connect the PS oil hose to the No. 1 oil pan.
f. Install the 2 bolts, and connect the ground strap to the body.
66. INSTALL FAN AND GENERATOR V BELT
67. CONNECT FUEL PIPE SUB-ASSY NO.2
68. INSTALL RADIATOR ASSY
69. INSTALL ENGINE UNDER COVER NO.2
70. INSTALL ENGINE UNDER COVER
71. INSTALL AIR CLEANER ASSY
72. INSTALL INTAKE AIR CONNECTOR PIPE
73. INSTALL AIR CLEANER INLET NO.1
74. INSTALL V-BANK COVER
75. INSTALL HOOD SUB-ASSY
76. INSTALL BATTERY NEGATIVE TERMINAL
77. ADD AUTOMATIC TRANSMISSION FLUID
78. ADD COOLANT
79. ADD ENGINE OIL
80. CHECK FOR ENGINE COOLANT LEAKS
81. INSPECT FUEL LEAK
82. INSPECT AUTOMATIC TRANSMISSION FLUID
83. INSPECT ENGINE OIL LEAKS
84. DRIVING TEST
85. ADJUST ENGINE