Part 3
Part 1 Of 6:
Part 2 Of 6:
Part 3 Of 6:
Part 4 Of 6:
Part 5 Of 6:
Part 6 Of 6:
REPLACEMENT
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 ENGINE MOUNTING BRACKET (4WD DRIVE TYPE)
a. Install the engine mounting bracket RR with the 6 bolts.
Torque:
34 Nm (347 kgf-cm, 25 ft. lbs.) for Bolt A
64 Nm (653 kgf-cm, 47 ft. lbs.) for Bolt B
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 as above 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 by 60° to put into a cotter pin.
b. Insert a new cotter pin.
130. INSTALL TIE ROD ASSY RH
HINT: Perform the same procedure as above on the opposite side.
131. INSTALL SPEED SENSOR FRONT LH
132. INSTALL SPEED SENSOR FRONT RH
HINT: Perform the same procedure as above 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 as above 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 as above 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 (REFERENCE)
150. INSTALL FRONT WHEELS
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 FOR ENGINE COOLANT LEAKS
159. INSPECT FOR FUEL LEAKS
160. CHECK FOR EXHAUST GAS LEAKS
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