Part 2
PARTIAL ENGINE ASSYREPLACEMENT
51. REMOVE GENERATOR BELT ADJUSTING BAR
a. Remove the 2 bolts, 2 nuts and the adjusting bar.
52. DISCONNECT COMPRESSOR AND MAGNETIC CLUTCH
a. Remove the bolt, nut and adjusting bar bracket.
b. Remove the 3 bolts and disconnect the compressor.
HINT: Hang up the hoses instead of detaching them.
53. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
a. Set the engine lifter.
b. Remove the 4 bolts, 2 nuts, and frame side rail plate subassembly RH and LH.
c. Remove the 4 bolts, 2 nuts, and front suspension member brace rear RH and LH.
d. Carefully, remove the engine assembly from the vehicle.
e. Install the engine hanger as shown in the illustration.
No. 2 engine hanger: Part No. 12282-20020
Bolt: Part No. 91621-60822
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
f. Using a chain block and an engine sling device, hang the engine assembly.
54. REMOVE VANE PUMP ASSY
a. Remove the power steering oil pressure sensor harness.
b. Remove the pressure feed tube clamp.
c. Remove the 2 bolts and vane pump.
55. REMOVE FRONT FRAME ASSY
a. Remove the 2 nuts and disconnect the engine mounting insulator RH and LH.
b. Remove the bolt and disconnect the engine mounting insulator FR.
56. REMOVE FRONT DRIVE SHAFT ASSY LH
57. REMOVE FRONT DRIVE SHAFT ASSY RH
58. REMOVE ENGINE WIRE
59. REMOVE AUTOMATIC TRANSAXLE ASSY
60. REMOVE DRIVE PLATE & RING GEAR SUB-ASSY
61. INSTALL ENGINE STAND
62. REMOVE INTAKE AIR SURGE TANK
a. Disconnect the throttle motor connector.
b. Disconnect the water bypass hose No. 3.
c. Disconnect the water bypass hose No. 2.
d. Disconnect the union to check valve hose.
e. Disconnect the ventilation hose.
f. Remove the 3 nuts and separate the pressure feed tube.
g. Remove the 2 bolts and engine hunger No. 1.
h. Remove the 2 bolts and surge tank stay No. 1.
i. Remove the 2 bolts and surge tank stay No. 2.
j. Using a socket hexagon wrench 8, remove the 4 bolts.
k. Remove the 2 nuts, emission control valve bracket and surge tank.
l. Remove the gasket from the surge tank.
63. INSPECT INTAKE AIR SURGE TANK
a. Using a precision straight edge and feeler gauge, mea sure the surface contacting the cylinder head for war page.
Maximum warpage: 0.10 mm (0.0039 inch)
If the warpage is greater than the maximum, replace the manifold.
64. REMOVE IGNITION COIL ASSY
65. REMOVE INTAKE MANIFOLD
a. Remove the nut and disconnect the ground cable.
b. Disconnect the 6 fuel injector connectors.
c. Uniformly, loosen and remove the 9 bolts and 2 nuts in the sequence shown in the illustration. Remove the intake manifold.
66. INSPECT INTAKE MANIFOLD
a. Using a precision straight edge and feeler gauge, mea sure the surface contacting the cylinder head and air in take surge tank for warpage.
Maximum warpage
If warpage is greater than the maximum, replace the manifold.
67. REMOVE WATER OUTLET
68. REMOVE EXHAUST MANIFOLD SUB-ASSY RH
a. Disconnect the A/F sensor connector.
b. Remove the 3 bolts and insulator.
c. Uniformly loosen and remove the 6 nuts in the sequence shown in the illustration.
d. Remove the manifold and gasket.
69. INSPECT EXHAUST MANIFOLD SUB-ASSY RH
a. Using a precision straight edge and feeler gauge, mea sure the surface contacting the cylinder head for war page.
Maximum warpage: 0.50 mm (0.0196 inch)
If the warpage is greater than the maximum, replace the manifold.
70. REMOVE MANIFOLD STAY NO.2
a. Remove the 2 bolts and manifold stay.
71. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2
a. Remove the 2 bolts and insulator.
b. Remove the bolt, nut and insulator.
72. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSY NO.2
a. Uniformly loosen and remove the 7 nuts in the sequence shown in the illustration.
b. Remove the converter and gasket.
73. INSPECT EXHAUST MANIFOLD CONVERTER SUB-ASSY NO.2
a. Using a precision straight edge and feeler gauge, mea sure the surface contacting the cylinder head for war page.
Maximum warpage: 0.50 mm (0.0196 inch)
If the warpage is greater than the maximum, replace the manifold.
74. REMOVE DRIVE SHAFT BEARING BRACKET
75. REMOVE PUMP BRACKET
a. Remove the 3 bolts and pump bracket.
76. REMOVE GENERATOR BRACKET NO.1
77. REMOVE COMPRESSOR MOUNTING BRACKET NO.1
78. REMOVE WATER INLET PIPE
79. REMOVE WATER INLET
80. REMOVE THERMOSTAT
81. REMOVE ENGINE OIL PRESSURE SWITCH ASSY
a. Remove the oil pressure switch.
82. REMOVE KNOCK SENSOR
a. 1MZ-FE: Using SST, remove the 2 sensors.
SST 09816-30010
b. 3MZ-FE: Remove the 2 nuts and 2 sensors.
83. REPLACE PARTIAL ENGINE ASSY
84. INSTALL KNOCK SENSOR
a. 1MZ-FE: Using SST, install the 2 knock control sensors.
SST 09816-30010
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
b. 3MZ-FE: Install the 2 knock sensors with the 2 nuts, as shown in the illustration.
Torque: 20 Nm (199 kgf-cm, 14 ft. lbs.)
85. INSTALL ENGINE OIL PRESSURE SWITCH ASSY
a. Clean the threads of the oil pressure switch. 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.)
86. INSTALL THERMOSTAT
87. INSTALL WATER INLET
88. INSTALL WATER INLET PIPE
89. INSTALL COMPRESSOR MOUNTING BRACKET NO.1
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
90. INSTALL GENERATOR BRACKET NO.1
Torque: 58 Nm (591 kgf-cm, 43 ft. lbs.)
91. INSTALL PUMP BRACKET
Torque: 32 Nm (326 kgf-cm, 24 ft. lbs.)
92. INSTALL DRIVE SHAFT BEARING BRACKET
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
93. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO.2
a. Install a new gasket and the converter sub-assembly No. 2 with the 7 nuts. Uniformly, tighten the 7 nuts in the sequence shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
b. Retighten nuts 1 and 2 as shown in the illustration.
94. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2
Torque: 8.5 Nm (87 kgf-cm, 55 inch lbs.)
95. INSTALL MANIFOLD STAY NO.2
Torque: 34 Nm (347 kgf-cm, 25 ft. lbs.)
96. INSTALL EXHAUST MANIFOLD SUB-ASSY RH
a. Install a new gasket and the exhaust manifold RH. Uniformly tighten the 5 nuts in the sequence shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
b. Retighten nuts 1 and 2 shown in the illustration,
97. INSTALL WATER OUTLET
98. INSTALL INTAKE MANIFOLD
a. Install the intake manifold with the 9 bolts, 2 nuts and 2 washers. Uniformly tighten the bolts and nuts in the sequence shown in the illustration.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
b. Retighten the water outlet mounting bolts and nuts.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
c. Install the ground cable with the nut.
Torque: 8.4 Nm (86 kgf-cm, 74 inch lbs.)
d. Connect the heater inlet water hose.
99. INSTALL IGNITION COIL ASSY
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
100. INSTALL INTAKE AIR SURGE TANK
a. Install a new gasket to the intake air surge tank.
b. Install the intake air surge tank and emission control valve bracket with the 2 nuts.
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
c. Using a socket hexagon wrench 8, tighten the 4 bolts.
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
d. Install the surge tank stay No. 2 with the 2 bolts.
Torque: 20 Nm (199 kgf-cm, 15 ft. lbs.)
e. Install the surge tank stay No. 1 with the 2 bolts.
Torque: 20 Nm (199 kgf-cm, 15 ft. lbs.)
f. Install the engine hunger No. 1 with the 2 bolts.
Torque: 20 Nm (199 kgf-cm, 15 ft. lbs.)
g. Install the pressure feed tube with the 3 nuts.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)
h. Connect the ventilation hose.
i. Connect the union to check valve hose.
j. Connect the water bypass hose No. 2.
k. Connect the water bypass hose No. 3.
l. Connect the throttle motor connector.