Partial Engine Assembly Replacement
REPLACEMENT1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
2. REMOVE FRONT WHEEL
3. REMOVE ENGINE UNDER COVER NO. 1
4. REMOVE FRONT FENDER SPLASH SHIELD FRONT RH
5. REMOVE FRONT FENDER SPLASH SHIELD FRONT LH
6. REMOVE FRONT FENDER APRON SEAL RH
7. DRAIN ENGINE OIL
8. DRAIN COOLANT
9. DRAIN AUTOMATIC TRANSAXLE FLUID
10. DRAIN TRANSFER OIL (4WD DRIVE TYPE)
11. REMOVE BATTERY
12. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1
13. REMOVE VANE PUMP V BELT
14. REMOVE CRUISE CONTROL ACTUATOR ASSY
15. REMOVE ENGINE MOVING CONTROL ROD
a. Remove the 4 bolts, engine moving control rod and engine mounting bracket CTR.
16. REMOVE ENGINE MOUNTING STAY NO. 2 RH
a. Remove the bolt, engine mounting stay No. 2 and engine mounting bracket No. 2 RH.
17. REMOVE UNION TO CHECK VALVE HOSE
a. Remove the vacuum hose for the brake booster.
18. REMOVE V-BANK COVER
a. Using a 5 mm hexagon wrench, remove the 3 nuts.
b. Turn the V-bank cover fastener counterclockwise, and remove the V-bank cover fastener and V-bank cover.
19. REMOVE AIR CLEANER ASSEMBLY WITH HOSE
20. SEPARATE ACCELERATOR CONTROL CABLE ASSY
21. SEPARATE 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 bee.
22. REMOVE RADIATOR HOSE INLET
23. REMOVE RADIATOR HOSE OUTLET
24. SEPARATE OIL COOLER INLET HOSE
25. SEPARATE OIL COOLER OUTLET HOSE
26. SEPARATE HEATER INLET WATER HOSE
27. SEPARATE HEATER OUTLET WATER HOSE
28. REMOVE GLOVE COMPARTMENT DOOR ASSY
29. SEPARATE ENGINE WIRE
a. Separate the engine wire from engine ECU and junction block.
b. Separate 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 upward.
3. Separate the connector.
c. Pull out the engine wire.
d. Remove the body ground.
30. SEPARATE FLOOR SHIFT TRANSMISSION CONTROL CABLE ASSY
31. SEPARATE OIL RESERVOIR TO PUMP HOSE NO. 1
32. SEPARATE STEERING GEAR OUTLET RETURN TUBE
33. REMOVE EXHAUST PIPE ASSY FRONT
34. REMOVE EXHAUST FRONT PIPE ASSY NO. 2
35. REMOVE PROPELLER W/ CENTER BEARING SHAFT ASSY (4WD DRIVE TYPE)
a. Place the matchmarks on both of the flanges.
b. Remove the 4 nuts, bolts and washers.
c. Insert SST after removing propeller shaft assembly.
SST 09325-20010
36. 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.
37. SEPARATE FRONT STABILIZER LINK ASSY RH
HINT: Perform the same procedure on the opposite side.
38. 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.
39. REMOVE FRONT AXLE HUB RH NUT
SST 09930-00010
HINT: Perform the same procedure on the opposite side.
40. 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.
41. SEPARATE SPEED SENSOR FRONT RH
HINT: Perform the same procedure on the opposite side.
42. 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.
43. SEPARATE TIE ROD ASSY RH
SST 09628-62011
HINT: Perform the same procedure on the opposite side.
44. 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.
45. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO. 1 RH
HINT: Perform the same procedure on the opposite side.
46. REMOVE STARTER ASSY
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 matchmarks 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 6 bolts, frame side rail plate sub-assembly RH and LH.
c. Remove the 6 bolts, 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 STABILIZER BAR FRONT (4WD DRIVE TYPE)
56. REMOVE RACK & PINION POWER STEERING GEAR ASSY (4WD DRIVE TYPE)
57. 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.
c. Remove the 2 bolts, and separate engine mounting insulator RR.
58. REMOVE FRONT DRIVE SHAFT ASSY RH (4WD DRIVE TYPE)
59. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (4WD DRIVE TYPE)
a. Remove the 6 bolts and engine mounting bracket RR.
60. REMOVE TRANSFER ASSY (4WD DRIVE TYPE)
61. REMOVE FRONT DRIVE SHAFT ASSY LH
SST 09520-01010, 09520-24010 (09520-32040)
62. REMOVE FRONT DRIVE SHAFT ASSY RH (2WD DRIVE TYPE)
63. REMOVE MANIFOLD STAY
64. REMOVE MANIFOLD STAY NO. 2
65. REMOVE ENGINE WIRE
66. REMOVE AUTOMATIC TRANSAXLE ASSY
67. REMOVE DRIVE PLATE & RING GEAR SUB-ASSY
SST 09213-54015 (91651-60855), 09330-00021
68. INSTALL ENGINE STAND
69. REMOVE ENGINE HANGER NO. 1
70. REMOVE THROTTLE BODY BRACKET
71. REMOVE INTAKE AIR SURGE TANK
72. REMOVE IGNITION COIL ASSY
73. REMOVE INTAKE MANIFOLD
74. REMOVE WATER OUTLET
75. REMOVE EXHAUST MANIFOLD SUB-ASSY RH
76. REMOVE EXHAUST MANIFOLD SUB-ASSY LH
77. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (2WD DRIVE TYPE)
78. REMOVE PUMP BRACKET
a. Remove the 3 bolts and pump bracket.
79. REMOVE GENERATOR BRACKET NO. 1
80. REMOVE COMPRESSOR MOUNTING BRACKET NO. 1
81. REMOVE WATER INLET PIPE
82. REMOVE WATER INLET
83. REMOVE THERMOSTAT
84. REMOVE CYLINDER HEAD PLATE REAR
85. REMOVE ENGINE OIL PRESSURE SWITCH ASSY
a. Remove the oil pressure switch.
86. REMOVE KNOCK CONTROL SENSOR
a. Using SST, remove the 2 knock control sensors.
SST 09816-30010
87. REPLACE PARTIAL ENGINE ASSY
88. 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.)
89. 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.)
90. INSTALL CYLINDER HEAD PLATE REAR
91. INSTALL THERMOSTAT
92. INSTALL WATER INLET
93. INSTALL WATER INLET PIPE
94. INSTALL COMPRESSOR MOUNTING BRACKET NO. 1
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
95. INSTALL GENERATOR BRACKET NO. 1
Torque: 58 Nm (591 kgf-cm, 43 ft. lbs.)
96. INSTALL PUMP BRACKET
Torque: 32 Nm (326 kgf-cm, 24 ft. lbs.)
97. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (2WD DRIVE TYPE)
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
98. INSTALL EXHAUST MANIFOLD SUB-ASSY LH
a. Install a new gasket and the exhaust manifold LH.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
99. INSTALL EXHAUST MANIFOLD SUB-ASSY RH
a. Install a new gasket and the exhaust manifold RH.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
100. INSTALL WATER OUTLET
101. INSTALL INTAKE MANIFOLD
102. INSTALL IGNITION COIL ASSY
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
103. INSTALL INTAKE AIR SURGE TANK
104. INSTALL THROTTLE BODY BRACKET
Torque: 20 Nm (199 kgf-cm, 14 ft. lbs.)
105. INSTALL ENGINE HANGER NO. 1
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
106. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY
SST 09213-54015 (91651-60855), 09330-00021
107. INSTALL AUTOMATIC TRANSAXLE ASSY
108. INSTALL MANIFOLD STAY NO. 2
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
109. INSTALL MANIFOLD STAY
Torque: 34 Nm (347 kgf-cm, 25 ft. lbs.)
110. INSTALL FRONT DRIVE SHAFT ASSY RH (2WD DRIVE TYPE)
111. INSTALL FRONT DRIVE SHAFT ASSY LH
112. INSTALL TRANSFER ASSY (4WD DRIVE TYPE)
113. INSTALL TRANSVERSE ENGINE MOUNTING BRACKET (4WD DRIVE TYPE)
a. Install the engine mounting bracket RR with the 6 bolts.
Torque:
Bolt A 34 Nm (347 kgf-cm, 25 ft. lbs.)
Bolt B 64 Nm (653 kgf-cm, 47 ft. lbs.)
114. INSTALL FRONT DRIVE SHAFT ASSY RH (4WD DRIVE TYPE)
115. 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.)
c. Install the engine mounting insulator with the 2 bolts.
Torque: 75 Nm (765 kgf-cm, 55 ft. lbs.)
116. INSTALL RACK & PINION POWER STEERING GEAR ASSY (4WD DRIVE TYPE)
Torque: 70 Nm (714 kgf-cm, 52 ft. lbs.)
117. INSTALL STABILIZER BAR FRONT (4WD DRIVE TYPE)
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
118. 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.
119. 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 6 bolts.
Torque:
Bolt A 85 Nm (867 kgf-cm, 63 ft. lbs.)
Bolt B 32 Nm (326 kgf-cm, 24 ft. lbs.)
d. Install the front suspension member brace rear RH and LH with the 6 bolts.
Torque:
Bolt C 85 Nm (867 kgf-cm, 63 ft. lbs.)
Bolt D 32 Nm (326 kgf-cm, 24 ft. lbs.)
120. 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.)
121. 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.)
122. INSTALL GENERATOR BRACKET NO. 2
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
123. INSTALL GENERATOR ASSY
124. INSTALL STEERING INTERMEDIATE SHAFT SUB-ASSY
a. Align the matchmarks 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.)
125. 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.)
126. INSTALL STARTER ASSY
127. 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.)
128. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO. 1 RH
HINT: Perform the same procedure on the opposite side.
129. 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.
130. INSTALL TIE ROD ASSY RH
HINT: Perform the same procedure on the opposite side.
131. INSTALL SPEED SENSOR FRONT LH
132. INSTALL SPEED SENSOR FRONT RH
HINT: Perform the same procedure on the opposite side.
133. 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.
134. INSTALL FRONT AXLE HUB RH NUT
HINT: Perform the same procedure on the opposite side
135. 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.)
136. INSTALL FRONT STABILIZER LINK ASSY RH
HINT: Perform the same procedure on the opposite side.
137. INSTALL PROPELLER W/ CENTER BEARING SHAFT ASSY (4WD DRIVE TYPE)
a. Align the matchmarks on both the flanges of the front propeller shaft and intermediate shaft, then install and tighten the 4 bolts, washers and nuts.
Torque: 74 Nm (755 kgf-cm, 55 ft. lbs.)
138. INSTALL EXHAUST FRONT PIPE ASSY NO. 2
139. INSTALL EXHAUST PIPE ASSY FRONT
140. 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.
b. Install the fuel pipe clamp.
141. INSTALL AIR CLEANER ASSEMBLY WITH HOSE
142. CONNECT VACUUM HOSE
143. INSTALL V-BANK COVER
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.)
b. Push in the V-bank cover fastener with hand.
144. INSTALL ENGINE MOUNTING STAY NO. 2 RH
a. Install the engine mounting stay No. 2 and engine mounting bracket No. 2 RH with the bolt.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
145. INSTALL ENGINE MOVING CONTROL ROD
a. Install the engine moving control rod and engine mounting bracket CTR 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.)
146. INSTALL CRUISE CONTROL ACTUATOR ASSY
147. INSTALL VANE PUMP V BELT
148. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1
149. INSPECT DRIVE BELT DEFLECTION AND TENSION
150. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
151. ADD TRANSFER OIL (4WD DRIVE TYPE)
152. ADD AUTOMATIC TRANSAXLE FLUID
153. ADD ENGINE OIL
154. ADD COOLANT
155. ADD POWER STEERING FLUID
156. BLEED POWER STEERING FLUID
157. INSPECT OIL LEAK
158. INSPECT CHECK ENGINE COOLANT LEAK
159. INSPECT FUEL LEAK
160. CHECK EXHAUST GAS LEAK
161. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
162. INSPECT IGNITION TIMING
SST 09843-18040, 09843-18020
163. INSPECT ENGINE IDLE SPEED
SST 09843-18040
164. INSPECT CO/HC
165. CHECK ABS SPEED SENSOR SIGNAL