1. Component views
Power steering oil pump (RZ4E-TC engine models)
Part name
- Bolt
- Power steering oil pump pulley
- Bolt
- Generator bracket
- Power steering oil pump
- Washer
- Nut
- Flexible hose
- Suction hose
Tightening torque
1: 29 N・m { 3.0 kgf・m / 21 lb・ft }
3: 25 N・m { 2.5 kgf・m / 18 lb・ft }
7: 20 N・m { 2.0 kgf・m / 15 lb・ft }
2. Power steering oil pump installation
1) Install the power steering oil pump to the generator bracket.
Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft }
2) Install the bolt and nut to the power steering oil pump shaft.
Tightening torque: 40 N・m { 4.1 kgf・m / 30 lb・ft } M10 x 1.5 nut
Caution
- Do not tighten the bolt to the hole edge of the power steering oil pump shaft, but create a clearance.
Legend
- M10 x 1.5 bolt
- M10 x 1.5 nut
- Power steering oil pump shaft
- Power steering oil pump pulley
Legend
a. Gap
3) Install the power steering oil pump pulley to the power steering oil pump.
Note
- Secure the M10 x 1.5 bolt with a tool, and tighten the pulley mounting bolt.
Tightening torque: 29 N・m { 3.0 kgf・m / 21 lb・ft }
4) Remove the bolt and nut from the power steering oil pump shaft.
3. Cooling fan belt installation
4. Air intake hose installation
1) Install the air intake hose to the intake air duct and intercooler.
Caution
- Align the marks on the pipe side and hose side.
Tightening torque: 5.0 N・m { 0.5 kgf・m / 44 lb・in }
Legend
- Intercooler
- Air intake hose
- Intake air duct
- Clamp
5. Radiator upper hose installation
1) Install the radiator upper hose and clamp to the water outlet pipe and radiator.
Note
- Align the painted arrow on the upper hose with the pipe boss section to install.
- Insert the upper hose until it makes full contact with the pipe.
- Soapy water can be applied when installing the upper hose.
Legend
- Radiator upper hose
- Boss section
- Clamp
- Arrow mark
Note
- Align the clamp with the upper hose arrow mark end to install.
Legend
- Clamp
- Arrow mark
Note
- Install the clamp in the direction shown in the following diagram.
- The diagram about the clamp direction shows the state viewed from the vehicle front.
6. Engine cover installation
1) Install the engine cover to the engine.
Legend
- Engine cover
7. Preliminary and post procedures
1. Post procedures
1) Lower the vehicle.
2) Connect the battery cable to the battery negative terminal.
3) Referring to the following, perform the setting of the front door power window switch with AUTO UP/AUTO DOWN function.
8. Coolant filling
1) Fill with engine coolant up to the radiator filler neck.
Note
- Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.
Caution
- Fill slowly to prevent air from entering the system.
2) While pressing the radiator upper hose manually several times to bleed the air from the hose, fill the radiator with engine coolant.
Note
- Fill with engine coolant up to the brim of the radiator cap inlet with the amount the engine coolant lowers.
Caution
- Repeat the operation until the coolant level no longer drops.
3) Add engine coolant up to the MAX line of the radiator reserve tank.
Legend
- Radiator reserve tank
- MAX line
- MIN line
4) Install the radiator cap to the radiator.
5) Start and idle the engine.
Caution
- Idle the engine for 5 minutes or more.
6) Stop the engine.
7) Remove the radiator cap from the radiator.
Warning
- Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in burns caused by the release of steam or hot water.
- When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled and slowly turn to release pressure.
8) Fill with engine coolant up to the radiator filler neck.
Note
- If the engine coolant is excessively low, inspect for engine coolant leakage from the cooling system.
9) Install the radiator cap to the radiator.
10) Start the engine.
11) Increase the engine speed to around 2000 rpm and run the engine for 10 minutes once the engine coolant temperature gauge reaches the center.
12) With the engine running, check that the thermostat valve is open.
Note
- Touch the radiator upper hose, and confirm that it has become warm.
- If it has not become warm, go back to Step 11.
Caution
- Do not try determining it by using only an engine coolant temperature gauge.
13) Idle the engine for 5 minutes.
14) Stop the engine.
15) Remove the radiator cap from the radiator.
Warning
- Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in burns caused by the release of steam or hot water.
- When opening the radiator cap, cover the cap with a thick cloth once the engine coolant has cooled and slowly turn to release pressure.
16) Fill with engine coolant up to the radiator filler neck.
Note
- Fill with engine coolant of the specified concentration to the brim of the radiator cap inlet.
17) Add engine coolant up to the MAX line of the radiator reserve tank.
18) Install the radiator cap to the radiator.
19) Repeat steps 10 to 18 until the coolant level no longer lowers.
Caution
- If the level of the radiator reserve tank has fallen the next morning, add up to the MAX line.
9. Power steering fluid filling
Caution
- Do not turn the steering wheel during the filling process unless instructed to do so.
1) Connect the flexible hose to the outlet port of the power steering oil pump.
Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft } RZ4E-TC engine models
Note
- If the flexible hose has a detent, install so that the detent makes full contact with the power steering oil pump.
Legend
- Flexible hose
- Detent
2) Connect the suction hose to the suction pipe.
RZ4E-TC engine models
Legend
- Suction hose
- Flexible hose
3) Fill the reservoir tank with power steering fluid.
Note
- Leave for at least 2 minutes after filling the power steering fluid.
- Fill with power steering fluid between "MAX" and "MIN" lines written on the reservoir tank.
Refer to the following for the brand to be used.
Refer to "201.General Information 14B.Vehicle Information recommended fluids, lubricants and diesel fuels".
4) Start the engine and leave for 2 seconds.
5) Stop the engine.
6) Fill with the power steering fluid as necessary.
Caution
- Repeat the above process until the amount of the power steering fluid is stable when the engine is started.
7) Jack up the front wheels.
Note
- Raise the front of the vehicle until the font tires are off the ground.
8) Start the engine.
9) Turn the steering wheel to the rightmost and leftmost several times.
10) Fill with the power steering fluid as necessary.
11) Turn the steering wheel to the rightmost and leftmost several times.
12) Return the steering wheel to the center position with the front wheels directed straight ahead.
13) Lower the vehicle.
14) Stop the engine.
15) Refill the power steering fluid as necessary.
Caution
- If the power steering fluid bubbles, leave the vehicle for several minutes and then repeat the above process.
10. Underguard installation
1. Models with front and rear underguards (long type)
1) Install the front underguard to the frame.
Tightening torque: 42 N・m { 4.3 kgf・m / 31 lb・ft }
2) Install the rear underguard (long type) to the frame.
Tightening torque: 42 N・m { 4.3 kgf・m / 31 lb・ft }
Legend
- Front underguard
- Rear underguard (long type)
- Bolt
- Clip
2. Models with front and rear underguards (short type)
1) Install the front underguard to the frame.
Tightening torque: 42 N・m { 4.3 kgf・m / 31 lb・ft }
2) Install the rear underguard (short type) to the frame.
Tightening torque: 42 N・m { 4.3 kgf・m / 31 lb・ft }
Legend
- Front underguard
- Rear underguard (short type)
- Bolt
- Clip
3. Models with front and rear underguards and oil pan guard.
1) Install the front underguard to the frame.
Tightening torque: 42 N・m { 4.3 kgf・m / 31 lb・ft }
2) Install the rear underguard to the frame.
Tightening torque: 42 N・m { 4.3 kgf・m / 31 lb・ft }
3) Install the oil pan guard to the frame.
Tightening torque: 42 N・m { 4.3 kgf・m / 31 lb・ft }
Models with hydraulic power steering
Legend
- Front underguard
- Rear underguard
- Oil pan guard
- Bolt
- Clip