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
QUICK REFERENCE CHART: QX42001
Engine model VQ35DE
Firing order 1-2-3-4-5-6
Idle speed rpmA/T
(in ªNº position)750 50
Ignition timing (degree BTDC at idle speed) 15É 2É
CO% at idleIdle mixture screw is preset and
sealed at factory.
Drive belt deflection (Cold) mm (in) Used belt
Deflection of
new belt
LimitDeflection
after
adjustment
Alternator
Power steering oil pump
Fan7 (0.28)4-5
(0.16 - 0.20)3.5 - 4.5
(0.138 - 0.177)
Air conditioner compressor 12 (0.472)9-10
(0.354 - 0.394)8-9
(0.31 - 0.35)
Applied pressed force
N (kg, lb)98 (10, 22)
Drive belt tension adjustment (Cold)
N (kg, lb)Used belt
New belt
LimitAfter
adjustment
Alternator
Power steering pump
Fan294 (30, 66)730 - 818
(74.4 - 83.5,
164 - 184)838 - 926
(85.4 - 94.5,
188 - 208)
Air conditioner compressor 196 (20, 44)348 - 436
(35.5 - 44.5,
78 - 98)470 - 559
(47.9 - 57.0,
106 - 126)
Radiator cap relief pressure
kPa (kg/cm
2, psi)78 - 98 (0.8 - 1.0, 11 - 14)
Cooling system leakage testing pressure
kPa (kg/cm
2, psi)157 (1.6, 23)
Compression pressure
kPa (kg/cm
2, psi)/rpmStandard 1,275 (13.0, 185)/300
Minimum 981 (10.0, 142)/300
Spark plugStandard PLFR5A-11
Cold PLFR6A-11
Hot PLFR4A-11
Applied model 245/70 R16 tire
Camber
Degree minute
(Decimal degree)Minimum þ0É35¢(þ0.58É)
Nominal 0É10¢(0.17É)
Maximum 0É55¢(0.92É)
Left and right
difference45¢(0.75É) or less
Caster
Degree minute
(Decimal degree)Minimum 2É15¢(2.25É)
Nominal 3É00¢(3.00É)
Maximum 3É45¢(3.75É)
Left and right
difference45¢(0.75É) or less
Total toe-in Minimum 1 (0.04)
Distance (A þ B)
mm (in)Nominal 2 (0.08)
Maximum 3 (0.12)
Angle (left plus right)
Degree minute
(Decimal degree)Minimum 5¢(0.08É)
Nominal 10¢(0.17É)
Maximum 15¢(0.25É)
Wheel turning angle
(Full turn)Minimum 30É00¢(30.00É)
Inside
Degree minute
(Decimal degree)Nominal 33É00¢(33.00É)
Maximum 34É00¢(34.00É)
Outside
Degree minute
(Decimal degree)Minimum 28É00¢(28.00É)
Nominal 31É00¢(31.00É)
Maximum 32É00¢(32.00É)
* Fuel, radiator coolant and engine oil full.
Spare tire, jack, hand tools and mats in designated positions.
Unit: mm (in)Front brake
Pad wear limit 2.0 (0.079)
Rotor repair limit 26.0 (1.024)
Rear brake
Lining wear limit 1.5 (0.059)
Drum repair limit 296.5 (11.67)
Pedal free height 175 - 185 (6.89 - 7.28)
Pedal depressed height*1 70 (2.76)
Parking brake
Number of notches*2 6 - 8
*1 Under force of 490 N (50 kg, 110 lb) with engine running
*2 At pulling force: 196 N (20 kg, 44 lb)
Unit Liter US measure
Coolant with reservoir 9.2 9-3/4 qt
Engine*With oil filter 5.0 5-1/4 qt
Without oil filter 4.8 5-1/8 qt
Dry engine (engine overhaul) 6.8 7-1/4 qt
Transmis-
sionA/T2WD
8.5 9 qt
4WD
All-mode 4WD transfer 3.0 2-5/8 qt
Differential carrierFront 1.85 3-7/8 pt
Rear 2.8 5-7/8 pt
Power steering system 0.9 1 qt
Air conditioning systemRefrigerant 0.60 - 0.70 kg 1.32 - 1.54 lb
Compressor
oil0.20 6.8 fl oz
* For further details, see ªChanging Engine Oilº in MA section.
Preload
(At hub bolt)
N (kg, lb)Wheel bearing lock nut
78-98(8-10,58-72)
Tightening torque
N×m (kg-m, ft-lb)
Retightening torque after loosen-
ing wheel bearing lock nut
N×m (kg-m, in-lb)0.5 - 1.5 (0.05 - 0.15, 4.3 - 13.0)
Axial end play
mm (in)0 (0)
Starting force at wheel hub bolt
N (kg, lb)A
Turning angle
degree15É - 30É
Starting force at wheel hub bolt
N (kg, lb)B
Wheel bearing preload at wheel hub
bolt
B þ A N (kg, lb)7.06 - 20.99 (0.72 - 2.14, 1.59 - 4.72)
SGI285
GENERAL PRECAUTIONSNBGI0001S02IDo not operate the engine for an extended period of time
without proper exhaust ventilation.
Keep the work area well ventilated and free of any inflammable
materials. Special care should be taken when handling any
inflammable or poisonous materials, such as gasoline, refrig-
erant gas, etc. When working in a pit or other enclosed area,
be sure to properly ventilate the area before working with haz-
ardous materials.
Do not smoke while working on the vehicle.
SGI231
IBefore jacking up the vehicle, apply wheel chocks or other tire
blocks to the wheels to prevent the vehicle from moving. After
jacking up the vehicle, support the vehicle weight with safety
stands at the points designated for proper lifting before work-
ing on the vehicle.
These operations should be done on a level surface.
IWhen removing a heavy component such as the engine or
transaxle/transmission, be careful not to lose your balance and
drop it. Also, do not allow it to strike adjacent parts, especially
the brake tubes and master cylinder.
SEF289H
IBefore starting repairs which do not require battery power:
Turn off ignition switch.
Disconnect the negative battery terminal.
SGI233
ITo prevent serious burns:
Avoid contact with hot metal parts.
Do not remove the radiator cap when the engine is hot.
SGI234
IBefore servicing the vehicle:
Protect fenders, upholstery and carpeting with appropriate cov-
ers.
Take caution that keys, buckles or buttons do not scratch paint.
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PRECAUTIONS
Precautions (Cont'd)
GI-5
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
ENGINE LUBRICATION &
COOLING SYSTEMS
SECTION
LC
CONTENTS
ENGINE LUBRICATION SYSTEM..................................2
Precautions ..................................................................2
LIQUID GASKET APPLICATION PROCEDURE............2
Preparation ..................................................................2
SPECIAL SERVICE TOOLS........................................2
COMMERCIAL SERVICE TOOL..................................3
Lubrication Circuit ........................................................3
Oil Pressure Check......................................................4
Oil Pump ......................................................................5
REMOVAL AND INSTALLATION.................................5
DISASSEMBLY AND ASSEMBLY................................5
OIL PUMP INSPECTION............................................6
REGULATOR VALVE INSPECTION............................6
OIL FILTER...............................................................7
Oil Cooler .....................................................................7
REMOVAL AND INSTALLATION.................................7
INSPECTION.............................................................8
Service Data and Specifications (SDS).......................8
OIL PRESSURE........................................................8
REGULATOR VALVE.................................................8
OIL PUMP.................................................................8
ENGINE COOLING SYSTEM..........................................9
Precautions ..................................................................9
LIQUID GASKET APPLICATION PROCEDURE............9
Preparation ..................................................................9
SPECIAL SERVICE TOOLS........................................9
Cooling Circuit ...........................................................10
System Check............................................................ 11
CHECKING COOLING SYSTEM HOSES................... 11
CHECKING RADIATOR............................................ 11
CHECKING RADIATOR CAP.................................... 11
CHECKING COOLING SYSTEM FOR LEAKS............12
Water Pump ...............................................................12
REMOVAL AND INSTALLATION...............................12
REMOVAL...............................................................12
INSPECTION...........................................................14
INSTALLATION........................................................14
Thermostat .................................................................16
REMOVAL AND INSTALLATION...............................16
INSPECTION...........................................................16
Water Control Valve ...................................................17
REMOVAL AND INSTALLATION...............................17
INSPECTION...........................................................18
Radiator .....................................................................19
REMOVAL AND INSTALLATION...............................19
Cooling Fan (Crankshaft driven) ...............................20
REMOVAL AND INSTALLATION...............................20
INSPECTION...........................................................20
Refilling Engine Coolant ............................................20
Radiator (Aluminum type) ..........................................21
PREPARATION.......................................................21
DISASSEMBLY........................................................21
ASSEMBLY.............................................................22
INSPECTION...........................................................23
Overheating Cause Analysis .....................................24
Service Data and Specifications (SDS).....................25
THERMOSTAT........................................................25
WATER CONTROL VALVE.......................................25
RADIATOR..............................................................25
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SEM164F
AEM080
Precautions
LIQUID GASKET APPLICATION PROCEDURENBLC00131. Use a scraper to remove all traces of old liquid gasket from
mating surfaces and grooves. Also, completely clean any oil
from these areas.
2. Apply a continuous bead of liquid gasket to mating surfaces.
(Use Genuine RTV silicone sealant Part No. 999MP-A7007
or equivalent.)
IFor oil pan, be sure liquid gasket diameter is 4.0 to 5.0 mm
(0.157 to 0.197 in).
IFor areas except oil pan, be sure liquid gasket diameter is 2.0
to 3.0 mm (0.079 to 0.118 in).
3. Apply liquid gasket around the inner side of bolt holes (unless
otherwise specified).
4. Assembly should be done within 5 minutes after coating.
5. Wait at least 30 minutes before refilling engine oil and engine
coolant.
Preparation
SPECIAL SERVICE TOOLSNBLC0014The actual shapes of Kent-Moore tools may differ from those of special service tools illustrated here.
Tool number
(Kent-Moore No.)
Tool nameDescription
WS39930000
(Ð)
Tube pressure
NT052
Pressing the tube of liquid gasket
EG17650301
(J33984-A)
Radiator cap tester
adapter
NT564
Adapting radiator cap tester to radiator filler neck
a: 28 (1.10) dia.
b: 31.4 (1.236) dia.
c: 41.3 (1.626) dia.
Unit: mm (in)
KV99103510
(Ð)
Radiator plate pliers A
NT224
Installing radiator upper and lower tanks
KV99103520
(Ð)
Radiator plate pliers B
NT225
Removing radiator upper and lower tanks
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ENGINE COOLING SYSTEM
Precautions
LC-9
System CheckNBLC0016WARNING:
Never remove the radiator cap when the engine is hot; serious
burns could be caused by high pressure fluid escaping from
the radiator.
Wrap a thick cloth around the cap and carefully remove it by
turning it a quarter turn to allow built-up pressure to escape
and then turn the cap all the way off.
CHECKING COOLING SYSTEM HOSESNBLC0016S01Check hoses for improper attachment, leaks, cracks, damage,
loose connections, chafing and deterioration.
CHECKING RADIATORNBLC0016S02Check radiator for mud or clogging. If necessary, clean radiator as
follows.
IBe careful not to bend or damage the radiator fins.
IWhen radiator is cleaned without removal, remove all sur-
rounding parts such as cooling fan, radiator shroud and horns.
Then tape the harness and connectors to prevent water from
entering.
1. Apply water by hose to the back side of the radiator core ver-
tically downward.
2. Apply water again to all radiator core surfaces once per
minute.
3. Stop washing if any stains no longer flow out from the radia-
tor.
4. Blow air into the back side of radiator core vertically downward.
IUse compressed air lower than 490 kPa (5 kg/cm
2, 71 psi) and
keep distance more than 30 cm (11.8 in).
5. Blow air again into all the radiator core surfaces once per
minute until no water sprays out.
SLC755A
CHECKING RADIATOR CAPNBLC0016S03To check radiator cap, apply pressure to cap with a tester.
Radiator cap relief pressure:
Standard
78-98kPa
(0.8 - 1.0 kg/cm
2, 11 - 14 psi)
Limit
59-98kPa
(0.6 - 1.0 kg/cm
2,9-14psi)
SMA967B
Pull the negative pressure valve to open it.
Check that it closes completely when released.
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ENGINE COOLING SYSTEM
System Check
LC-11