SEM439G
SEM440G
17. Install RH and LH rocker covers.
Rocker cover tightening procedure:
ITighten in numerical order as shown in the figure.
a. Tighten bolts 1 to 10 in that order to 6.9 to 8.8 N´m (0.7 to 0.9
kg-m, 61 to 78 in-lb).
b. Then tighten bolts 1 to 10 as indicated in figure to 6.9 to 8.8
N´m (0.7 to 0.9 kg-m, 61 to 78 in-lb).
18. Hang engine using the right and left side engine slingers with
a suitable hoist.
19. Set a suitable transmission jack under the suspension mem-
ber.
20. Remove right and left side engine mounting nuts.
21. Remove right and left side suspension member bolts.
22. Install aluminum oil pan. Refer to EM-18, ªInstallationº.
23. Set ring gear stopper using the mounting bolt hole.
IBe careful not to damage the signal plate teeth.
SEM417G
24. Install crankshaft pulley to crankshaft.
IAlign pointer with TDC mark on crankshaft pulley.
SEM531G
25. Install crankshaft pulley bolt.
ILubricate thread and seat surface of the bolt with new
engine oil.
a. Tighten to 39 to 49 N´m (4.0 to 5.0 kg-m, 29 to 36 ft-lb).
b. Put a paint mark on the crankshaft pulley.
SEM963E
c. Again tighten by turning 60É to 66É, about the angle from one
hexagon bolt head corner to another.
26. Install camshaft position sensor (PHASE), crankshaft position
sensors (REF)/(POS) and CVTC sensors.
27. Reinstall removed parts in the reverse order of removal.
IWhen installing fuel tube and intake manifold collectors, refer
to EM-12, ªTIGHTENING PROCEDURESº.
IAfter starting engine, keep idling for three minutes. Then
rev engine up to 3,000 rpm under no load to purge air from
the high-pressure chamber of the chain tensioners. The
engine may produce a rattling noise. This indicates that
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TIMING CHAIN
Installation (Cont'd)
EM-33
SEM828E
7. Apply engine oil to new valve oil seal and install it with Tool.
SEM715A
OIL SEAL INSTALLATION DIRECTIONNBEM0015S02IInstall new oil seal in the direction shown in the figure.
FRONT OIL SEALNBEM0015S031. Remove the following parts:
IEngine undercover
ISuspension member stay
IDrive belts
ICrankshaft position sensor (REF)
Be careful not to damage sensor edge.
ICrankshaft pulley
IRadiator
ICooling fan
SEM829E
2. Remove front oil seal using a suitable tool.
Be careful not to scratch front cover.
3. Apply engine oil to new oil seal and install it using a suitable
tool.
SEM830E
REAR OIL SEALNBEM0015S041. Remove transmission. Refer to AT-277, ªRemovalº.
2. Remove drive plate.
3. Remove oil pan. Refer to EM-15.
4. Remove rear oil seal retainer.
OIL SEAL
Replacement (Cont'd)
EM-36
Rear Engine MountingNBEM0042S0102
SEM459G
SEM605G
SEM461G
SEM324F
1. Release fuel pressure.
Refer to EC-39, ªFuel pressure releaseº.
2. Remove engine hood and front RH and LH wheels.
3. Remove engine undercover and suspension member stay.
4. Drain coolant from radiator.
5. Remove the following parts.
IRadiator shroud
IRadiator
ICooling fan
IDrive belts
IBattery
IEngine cover
IThrottle wires
6. Air duct with air cleaner case.
7. Disconnect vacuum hoses, fuel hoses, heater hoses, EVAP
canister hoses, harnesses, connectors and so on.
8. Remove air conditioner compressor from bracket, then put it
aside holding with a suitable wire.
9. Remove power steering oil pump and reservoir tank with
bracket, then put it aside holding with a suitable wire.
10. Remove alternator.
11. Remove exhaust front tube heat insulators, then remove rear
heated oxygen sensors.
12. Remove exhaust front and rear tubes.
Refer to FE-8, ªRemoval and Installationº.
13. Remove transmission with transfer.
Refer to AT-277, ªRemovalº.
14. Remove TWC (manifold) heat insulators, then remove TWC
(manifold).
15. Install engine slingers.
16. Hoist engine with engine slingers and remove front engine
mounting nuts.
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ENGINE ASSEMBLY
Removal and Installation (Cont'd)
EM-59
E
ECM input/output signal ...............................EC-127
ECTS - Wiring diagram ........................EC-171, 189
Electric sun roof ............................................EL-173
Electrical diagnoses.........................................GI-24
Electrical ignition system ................................EC-30
Electrical unit ................................................Foldout
Electrical units location .................................EL-436
Engine compartment .......................................BT-58
Engine control circuit diagram........................EC-24
Engine control component parts
location .......................................................EC-20
Engine control module (ECM) ......................EC-444
Engine control system diagram and
chart ............................................................EC-25
Engine coolant temperature sensor
(ECTS) ..............................................EC-169, 187
Engine fail-safe system ................................EC-117
Engine oil filter replacement ..........................MA-18
Engine oil precautions .......................................GI-8
Engine oil replacement ..................................MA-18
Engine outer component parts ......................EM-10
Engine removal ..............................................EM-57
Engine room - See Engine
compartment................................................BT-58
Engine serial number ......................................GI-43
EVAP canister.................................................EC-33
EVAP canister purge volume control
solenoid valve.............................EC-32, 367, 541
EVAP canister vent control
valve .........................................EC-374, 553, 573
EVAP control system (small leak)
diagnosis ..................................EC-352, 394, 526
EVAP control system pressure sensor.........EC-381
EVAP control system purge flow moni-
toring diagnosis.........................................EC-561
EVAP vapor lines inspection ..........................MA-20
Evaporative emission (EVAP) system ............EC-32
Exhaust system ................................................FE-8
Exhaust system inspection ............................MA-21
Exterior ............................................................BT-35
F
4LO indicator lamp........................................TF-104
4WD shift indicator lamp.................................TF-98
4WD shift switch ............................................TF-111
4WD solenoid valve.......................................TF-111
4WD warning lamp .........................................TF-13
Fan control amp. ............................................HA-98
F/FOG - Wiring diagram .................................EL-72
Final drive disassembly ..................................PD-43
Final drive pre-inspection ...............................PD-43
Final drive removal and installation ...............PD-43
Finisher, interior - See Trim ............................BT-28
F/LID - Wiring diagram .................................EL-180
Fluid temperature sensor (A/T) .....................AT-110Fluids ..............................................................MA-11
Flywheel runout..............................................EM-70
FO2H-L - Wiring diagram .............................EC-243
FO2H-R - Wiring diagram ............................EC-242
Fog lamp, front................................................EL-70
Fog lamp, front, removal and
installation ...................................................BT-12
Forward clutch ...............................................AT-320
F/PUMP - Wiring diagram ............................EC-627
Freeze frame data ..........................................EC-60
FRO2LH - Wiring diagram ...........EC-197, 223, 235
FRO2RH - Wiring diagram...........EC-196, 222, 234
Front axle..........................................................AX-2
Front bumper ..................................................BT-12
Front case (Transfer) ....................................TF-133
Front combination lamp removal and
installation ...................................................BT-12
Front disc brake .............................................BR-22
Front door .......................................................BT-18
Front drive shaft (Transfer) ...........................TF-125
Front final drive disassembly (4WD) ..............PD-18
Front final drive pre-inspection (4WD) ...........PD-18
Front final drive removal and installa-
tion (4WD)...................................................PD-18
Front fog lamp.................................................EL-70
Front fog lamp removal and installation .........BT-12
Front heated oxygen sensor (HO2S)
(Left bank) ................EC-192, 202, 210, 218, 231
Front heated oxygen sensor (HO2S)
(Right bank) .............EC-192, 202, 210, 218, 231
Front heated oxygen sensor heater
(Left bank).................................................EC-240
Front heated oxygen sensor heater
(Right bank) ..............................................EC-240
Front revolution sensor (Transfer) ................TF-112
Front seat ........................................................BT-41
Front seat belt ..................................................RS-4
Front suspension ..............................................SU-2
Front washer .................................................EL-136
Front wiper ....................................................EL-136
Fuel cut control (at no load & high
engine speed) .............................................EC-32
Fuel filler lid.....................................................BT-15
Fuel filter replacement ...................................MA-16
Fuel gauge ......................................................EL-94
Fuel injection system (Left bank) .........EC-294, 302
Fuel injection system (Right bank) ......EC-294, 302
Fuel lid opener, electric.................................EL-180
Fuel line inspection ........................................MA-16
Fuel precautions ................................................GI-8
Fuel pressure check .......................................EC-39
Fuel pressure regulator ..................................EC-40
Fuel pressure release ....................................EC-39
Fuel pump ....................................................EC-625
Fuel system ......................................................FE-4
Fuel tank temperature sensor ......................EC-309
Fuel tank vacuum relief valve ........................EC-33
FUELLH - Wiring diagram....................EC-297, 305
FUELRH - Wiring diagram ...................EC-296, 304
Fuse ................................................................EL-16
Fuse block ....................................................Foldout
ALPHABETICAL INDEX
IDX-4
Propeller shaft greasing .................................MA-23
Propeller shaft inspection ..............................MA-23
Propeller shaft on vehicle service ....................PD-6
Propeller shaft vibration ...................................PD-6
PST/SW - Wiring diagram ............................EC-635
R
Rack retainer adjustment ..................................ST-8
Radiator ....................................................LC-19, 21
Radio - See Audio.........................................EL-160
Rear air spoiler ...............................................BT-35
Rear axle ........................................................AX-17
Rear bumper ...................................................BT-15
Rear case (Transfer) .....................................TF-123
Rear combination lamp removal and
installation ...................................................BT-35
Rear cover packing replacement diff. ............PD-16
Rear door ........................................................BT-20
Rear drum brake ............................................BR-26
Rear heated oxygen sensor
(HO2S) .............................EC-247, 257, 267, 277
Rear heated oxygen sensor (HO2S)
heater ........................................................EC-286
Rear seat ........................................................BT-44
Rear seat belt ...................................................RS-5
Rear side window ...........................................BT-55
Rear suspension ............................................SU-15
Rear washer..................................................EL-141
Rear window defogger ..................................EL-151
Rear wiper.....................................................EL-141
REF - Wiring diagram ..................................EC-510
Refregerant pressure sensor ........................HA-111
Refrigerant connection precaution ...................HA-4
Refrigerant discharging evacuating
charging ....................................................HA-144
Refrigerant general precaution.........................HA-3
Refrigerant lines ...........................................HA-154
Refrigerant pressure sensor.........................EC-639
Refrigeration cycle..........................................HA-14
REMOTE - Wiring diagram ...........................EL-168
Removal and installation (A/T) ......................AT-277
Removal and installation (Transfer) ..............TF-119
Reverse clutch...............................................AT-314
Revolution sensor (A/T).................................AT-115
Ring gear diff. inspection .........................PD-23, 47
RO2H-L - Wiring diagram.............................EC-290
RO2H-R - Wiring diagram ............................EC-289
Road wheel size ..............................................GI-44
Roof trim .........................................................BT-32
Room lamp - See Interior lamp ......................EL-88
RRO2LH - Wiring diagram...EC-251, 261, 271, 281
RRO2RH - Wiring diagram ..EC-250, 260, 270, 280
S
SAE J1930 terminology list .............................GI-51
Screw jack .......................................................GI-45Seal - See Exterior .........................................BT-35
SEAT - Wiring diagram .................................EL-181
Seat belt inspection .............................MA-28, RS-7
Seat belt pre-tensioner .....................................RS-3
Seat belt pre-tensioner disposal ....................RS-22
Seat belt, front ..................................................RS-4
Seat belt, rear...................................................RS-5
Seat, front .......................................................BT-41
Seat, rear ........................................................BT-44
Self-diagnosis (Transfer) .................................TF-27
SHIFT - Wiring diagram ................................AT-266
Shift lock system ...........................................AT-265
Shift schedule ................................................AT-356
Shift solenoid valve A (A/T) ..AT-125, 137, 147, 171
Shift solenoid valve B (A/T) ..AT-125, 131, 147, 175
Shock absorber (rear) ....................................SU-18
Side air bag ....................................................RS-21
Side bearing preload (front final drive
4WD) ...........................................................PD-24
Side trim ..........................................................BT-28
Side window - See Rear side window ............BT-55
Smart entrance control unit ..........................EL-319
SMJ (super multiple junction) .......................Foldout
Spare tire size .................................................GI-44
Spark plug replacement .................................MA-19
Speedometer...................................................EL-94
Spiral cable.....................................................RS-17
Spot lamp ........................................................EL-88
Spring (Wheelarch) height ...............................SU-5
SROOF - Wiring diagram .............................EL-174
SRS - See Supplemental Restraint
System ........................................................RS-10
SRS - Wiring diagram ....................................RS-35
S/SIG - Wiring diagram ................................EC-622
Stabilizer bar (front)........................................SU-10
Stabilizer bar (rear) ........................................SU-20
Stall test (A/T) .................................................AT-59
Standardized relay ............................................EL-7
START - Wiring diagram.................................SC-11
Start signal ...................................................EC-621
Starter .............................................................SC-18
Starting system...............................................SC-10
Steering gear, linkage and transfer
gear inspection ...........................................MA-26
Steering linkage ..............................................ST-17
Steering switch................................................EL-30
Steering transfer gear .....................................ST-15
Steering wheel and column.............................ST-11
Steering wheel play ..........................................ST-7
Steering wheel turning force .............................ST-9
Stop lamp ........................................................EL-67
STOP/L - Wiring diagram................................EL-67
Strut (front) .......................................................SU-8
Sub-oil pump (Transfer) ................................TF-131
Sun gear (Transfer).......................................TF-134
Sun roof, electric ...........................................EL-173
Sunload sensor ............................................HA-135
Sunroof............................................................BT-45
Supplemental Restraint System .....................RS-10
Supplemental restraint system - Wiring
diagram .......................................................RS-35
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ALPHABETICAL INDEX
IDX-7
SLC756A
CHECKING COOLING SYSTEM FOR LEAKSNBLC0016S04To check for leakage, apply pressure to the cooling system with a
tester.
Testing pressure:
157 kPa (1.6 kg/cm
2, 23 psi)
CAUTION:
Higher than the specified pressure may cause radiator
damage.
Water Pump
REMOVAL AND INSTALLATIONNBLC0017CAUTION:
IWhen removing water pump assembly, be careful not to
get coolant on drive belt.
IWater pump cannot be disassembled and should be
replaced as a unit.
IAfter installing water pump, connect hose and clamp
securely, then check for leaks using radiator cap tester.
SLC326B
SLC327B
REMOVALNBLC00181. Remove under cover.
2. Remove suspension member stay.
3. Drain coolant from radiator.
4. Remove radiator shrouds.
5. Remove drive belts.
6. Remove cooling fan.
7. Remove water drain plug on water pump side of cylinder block.
8. Remove chain tensioner cover and water pump cover.
ENGINE COOLING SYSTEM
System Check (Cont'd)
LC-12
Thermostat
REMOVAL AND INSTALLATIONNBLC0021
SLC329B
SLC962AA
1. Remove under cover.
2. Remove suspension member stay.
3. Drain coolant from radiator.
4. Remove drive belts.
5. Remove water drain plug on water pump side of cylinder block.
6. Disconnect lower radiator hose.
7. Remove water inlet and thermostat assembly.
IDo not disassemble water inlet and thermostat. Replace
them as a unit, if necessary.
SLC948A
8. Install thermostat with jiggle valve facing upward.
IAfter installation, run engine for a few minutes, and check
for leaks.
IBe careful not to spill coolant over engine compartment.
Use a rag to absorb coolant.
9. Reinstall any removed parts in reverse order of removal.
SLC949A
INSPECTIONNBLC00221. Check valve seating condition at ordinary room temperatures.
It should seat tightly.
2. Check valve opening temperature and maximum valve lift.
Standard
Valve opening temperature 76.5ÉC (170ÉF)
Valve lift More than 8.6 mm/90ÉC
(0.339 in/194ÉF)
ENGINE COOLING SYSTEM
Thermostat
LC-16
3. Then check if valve closes at 5ÉC (9ÉF) below valve opening
temperature.
Water Control Valve
REMOVAL AND INSTALLATIONNBLC0032
SLC330B
1. Water outlet housing
2. Water control valve
3. Water outlet4. Water hose
5. Cylinder block water outlet
6. Thermal transmitter7. Engine coolant temperature sen-
sor
1. Release fuel pressure.
Refer to EC-39, ªFuel Pressure Releaseº.
2. Remove under cover.
3. Remove suspension member stay.
4. Drain coolant from radiator.
5. Remove engine cover.
6. Remove air duct with air cleaner assembly.
7. Disconnect wires, hoses, harness and so on.
8. Remove upper intake manifold corrector.
9. Remove intake manifold corrector support bolts.
10. Remove lower intake manifold corrector.
11. Disconnect injector harness connectors.
12. Remove injector tube.
13. Remove intake manifold.
14. Remove water outlet housing and water control valve.
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ENGINE COOLING SYSTEM
Thermostat (Cont'd)
LC-17