Part 3
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Part 3 Of 6:
Part 4 Of 6:
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Part 6 Of 6:
REPLACEMENT
100. INSTALL GENERATOR ASSY
101. INSTALL INTAKE MANIFOLD
a. Install a new gasket and the intake manifold with the bolts and 2 nuts.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
102. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY
a. Fix the crankshaft with SST.
SST 09213-54015 (91651-08550), 09330-00021
b. Clean the bolt and the bolt hole.
c. Apply Adhesive to 2 to 3 threads of the bolt end.
Adhesive: Part No. 08833-00070, THREE BOND or equivalent.
d. Install and uniformly tighten the 8 bolts, in several passes, in the sequence shown.
Torque: 98 Nm (1000 kgf-cm, 72 ft. lbs.)
103. INSTALL AUTOMATIC TRANSAXLE ASSY
104. INSTALL STARTER ASSY
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
105. INSTALL FRONT DRIVE SHAFT ASSY RH (2WD DRIVE TYPE)
106. INSTALL FRONT DRIVE SHAFT ASSY LH
107. INSTALL TRANSFER ASSY (4WD DRIVE TYPE)
108. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (4WD DRIVE TYPE)
a. Install the mounting bracket 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
109. INSTALL FRONT DRIVE SHAFT ASSY RH (4WD DRIVE TYPE)
110. INSTALL FRONT FRAME ASSY
a. Install the engine mounting insulator LH with a nut.
Torque: 95 Nm (969 kgf-cm, 70 ft. lbs.)
b. Install the engine mounting insulator RH with a nut.
Torque: 95 Nm (969 kgf-cm, 70 ft. lbs.)
c. Install the engine mounting insulator FR with a nut.
Torque: 87 Nm (888 kgf-cm, 64 ft. lbs.)
d. Install the engine mounting insulator RR with 2 nuts (4WD DRIVE TYPE).
Torque: 75 Nm (765 kgf-cm, 55 ft. lbs.)
111. INSTALL RACK & PINION POWER STEERING GEAR ASSY (4WD DRIVE TYPE)
Torque: 70 Nm (714 kgf-cm, 52 ft. lbs.)
112. INSTALL STABILIZER BAR FRONT (4WD DRIVE TYPE)
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
113. INSTALL VANE PUMP ASSY
a. Connect the vane pump to the engine with the 2 bolts.
Torque: 43 Nm (439 kgf-cm, 31 ft. lbs.)
114. 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 plate LH and RH with 6 bolts.
Torque:
85 Nm (867 kgf-cm, 63 ft. lbs.) for Bolt A
32 Nm (326 kgf-cm, 24 ft. lbs.) for Bolt B
d. Install the front suspension member brace rear RH and LH with 6 bolts.
Torque:
85 Nm (867 kgf-cm, 63 ft. lbs.) for Bolt C
32 Nm (326 kgf-cm, 24 ft. lbs.) for Bolt D
115. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
116. INSTALL STEERING INTERMEDIATE SHAFT SUB-ASSY
a. Align the matchmarks on the intermediate shaft and control valve shaft.
b. Tighten the bolt.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)
117. INSTALL DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT
a. Fix the crankshaft, and install the 6 set bolts.
Torque: 41 Nm (418 kgf-cm, 30 ft. lbs.)
118. 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 the 2 nuts.
Torque: 127 Nm (1296 kgf-cm, 94 ft. lbs.)
119. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH
HINT: Perform the same procedure as above on the opposite side.
120. 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.
121. INSTALL TIE ROD ASSY RH
HINT: Perform the same procedure as above on the opposite side.
122. INSTALL SPEED SENSOR FRONT LH
Torque: 8.0 Nm (82 kgf-cm, 71 ft. lbs.)
123. INSTALL SPEED SENSOR FRONT RH
Torque: 8.0 Nm (82 kgf-cm, 71 ft. lbs.)
124. INSTALL FRONT AXLE HUB LH NUT
a. Using a 30 mm socket wrench, install a new hub nut.
Torque: 294 Nm (3,000 kgf-cm, 217 ft. lbs.)
b. Using a chisel, stake the hub nut.
125. INSTALL FRONT AXLE HUB RH NUT
HINT: Perform the same procedure as above on the opposite side.
126. INSTALL FRONT STABILIZER LINK ASSY LH
a. Install the nut by using a 5 mm socket hexagon wrench to fix the stud bolt.
Torque: 74 Nm (755 kgf-cm, 55 ft. lbs.)
127. INSTALL FRONT STABILIZER LINK ASSY RH
HINT: Perform the same procedure as above on the opposite side.
128. INSTALL PROPELLER SHAFT (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.)
129. INSTALL EXHAUST PIPE ASSY FRONT
130. CONNECT FUEL TUBE SUB-ASSY
131. INSTALL RETURN TUBE SUB-ASSY
a. Install the return tube with 2 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
132. INSTALL FAN AND GENERATOR V BELT
SST 09249-63010
133. INSTALL ENGINE MOUNTING BRACKET NO.2 RH
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
134. INSTALL ENGINE MOVING CONTROL ROD W/BRACKET
a. Install the engine mounting control rod w/bracket with 3 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
135. INSTALL ENGINE MOUNTING STAY NO.2 RH
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
136. INSTALL AIR CLEANER ASSY
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
137. ADD TRANSFER OIL
a. Install a new gasket and the filler plug.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
138. ADD AUTOMATIC TRANSAXLE FLUID
139. ADD ENGINE OIL
140. ADD COOLANT
141. OIL LEAK
142. CHECK FOR ENGINE COOLANT LEAKS
143. INSPECT FOR FUEL LEAKS
144. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
145. ADJUST FRONT WHEEL ALIGNMENT
146. INSPECT CHECK IDLE SPEED AND IGNITION TIMING
147. INSPECT CO/HC
148. CHECK ABS SPEED SENSOR SIGNAL