Engine room (Left)
3. Remove air duct and air cleaner case.
4. Disconnect vacuum hose to the vehicle on the engine.
5. Disconnect harness connectors from alternator and air com-pressor.
6. Remove alternator.
7. After removing refrigerant, remove pipes of air compressor and inlet/outlet.
8. Disconnect heating hose, install blank cap to hose to prevent coolant from leaking.
9. Remove heating pipe.
10. Remove heat insulator.
11. Remove catalytic converter.
Engine room (Right)
12. Remove power steering reservoir tank from bracket, and fix it to the vehicle with a rope.
CAUTION:
Keep the reservoir tank level when fixing to prevent oil leak.
13. Remove fuel feed and return hoses.
CAUTION:
Install blank caps immediately to avoid fuel leakage.
14. Remove all harness connectors on the engine, and move har- nesses to the side of the vehicle.
Vehicle underfloor
15. Remove starter motor.
16. Detach A/T oil cooler pipes from oil pan. (A/T model)
17. Remove rear propeller shaft.
18. Remove mounting bolts to secure the engine to transmission.
1) Remove torque converter installation bolt. (A/T model)
2) Lift transmission bottom with transmission jack, and removerear mount members from the vehicle.
3) Lower transmission with the jack, and remove upper mounting bolts securing the engine to transmission.
4) Lift transmission with the jack, and reinstall rear mount mem- bers to the vehicle.
5) Position the jack to the front side of transmission.
6) Remove remaining mounting bolts securing the engine to trans- mission.
Removal operation
19. Remove air conditioner high pressure pipes at the rear of theengine room.
I This is due to some inconvenience in the rear slinger installa-
tion.
20. Install the engine slingers (standard service part) to front-left and rear-right.
:25-28N ×m (2.5 - 2.9 kg-m, 18 - 20 ft-lb)
WARNING:
For engines without engine slingers, attach proper slingers
and bolts described in the PARTS CATALOG.
FEM082
ENGINE REMOVALZD
Removal (Cont'd)
EM-64
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6. Remove fuel pump with fuel tank chamber assy as follows:
a. Push the locking clip upwards and slide the pump chamberassy towards the rear of the vehicle.
b. Lift the pump chamber assy from the bracket.
c. Carefully remove the pump chamber assy and top plate from the tank.
7. Take off the fuel pump chamber lid by opening out the 4 clips. Remove the fuel pump from the fuel pump chamber.
INSTALLATION
Installation is reverse procedure of removal.
CAUTION:
IAlways use a new top plate seal.
I Tighten to specified torque.
Diesel engine
1. Remove inspection hole cover located under the luggage com-
partment carpet.
2. Disconnect fuel feed and return tubes and connector.
3. Remove the screws by which the fuel gauge is mounted to the fuel tank.
NFE015
NFE016
EFE016
NFE031
FUEL SYSTEMTD27Ti
Fuel Pump and Gauge (Cont'd)
FE-8
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Bulb Replacement
The headlamp is a semi-sealed beam type which uses a replacable
halogen bulb. The bulb can be replaced from the engine compart-
ment side without removing the headlamp body.
IGrasp only the plastic base when handling the bulb. Never
touch the glass envelope.
1. Disconnect the battery cable.
2. Disconnect the harness connector from the back side of the bulb.
3. Pull off the rubber cap.
4. Press end of the retaining pin together to release bulb.
5. Remove the headlamp bulb. Do not shake or rotate the bulb when removing it.
6. Install the new bulb in reverse order of removal.
CAUTION:
I Do not leave headlamp reflector without bulb for a long
period of time as dust, moisture, smoke, etc. may enter the
headlamp body and affect the performance of the head-
lamp. Thus, the headlamp bulb should not be removed
from the headlamp reflector until just before a replacement
bulb is to be installed.
Aiming Adjustment
When performing headlamp aiming adjustment, use an aiming
machine, aiming wall screen or headlamp tester. For operating
instructions, of any aimer, it should be in good repair, calibrated and
used according to respective operation manuals supplied with the
unit.
For details, refer to the regulations in your own country.
Before performing aiming adjustment, check the following:
a. Keep all tires inflated to correct pressures.
b. Place vehicle and tester on one and same flat surface.
c. See that there is noload in vehicle other than coolant,
engine oil filled up to correct level, full fuel tank and the
driver (or equivalent weight placed in driver's position).
CAUTION:
Be sure aiming switch is set to ª0º when performing aiming
adjustment on vehicles equipped with headlamp aiming con-
trol.
NEL623
SEL984W
HEADLAMP
EL-47
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F
Fan switch ......................................................HA-60
F/FOG - Wiring diagram .................................EL-55
Final drive disassembly............................PD-15, 37
Final drive pre-inspection .........................PD-15, 37
Final drive removal and installation ...............PD-15
Finisher, interior - See Trim ............................BT-18
Finisher, rear panel .........................................BT-18
Floor trim .........................................................BT-18
Fluid temperature sensor (A/T) .....................AT-146
Fluids .............................................MA-5, 17, 20, 36
Flywheel (clutch) .......................................CL-11, 12
Flywheel runout..............................................EM-94
Fog lamp, front .........................................EL-55, 57
Fog lamp, rear ................................................EL-58
Fork rod (M/T) ................................................MT-13
Forward clutch...............................................AT-162
Front axle ....................................................FA-4, 13
Front bumper ....................................................BT-6
Front case (Transfer) ..................................TF-9, 23
Front combination lamp removal andinstallation .....................................................BT-6
Front disc brake .............................................BR-27
Front door .......................................................BT-10
Front Door Trim...............................................BT-19
Front drive shaft (Transfer) .........................TF-9, 19
Front final drive disassembly (4WD) ..............PD-14
Front final drive removal and installa- tion (4WD) ............................................PD-12, 13
Front fog lamp ..........................................EL-55, 57
Front passenger air bag .................................RS-19
Front seat ........................................................BT-34
Front seat belt ..................................................RS-4
Front seat belt pre-tensioner ..........................RS-14
Front side air bag ...........................................RS-20
Front suspension ........................................FA-4, 29
Fuel cut control (at no load & high engine speed).....................................EC-22, 334
Fuel cut solenoid valve ................................EC-399
Fuel cut system ............................................EC-237
Fuel filler lid.......................................................BT-8
Fuel filter replacement...................MA-5, 20, 23, 33
Fuel gauge..................................FE-3, 6, EL-86, 98
Fuel injection system .............................EC-20, 329
Fuel injection timing feed back (Elec- tronic Fuel Injection Pump) ......................EC-197
Fuel precautions ................................................GI-6
Fuel pump and gauge ..............................FE-3, 6, 7
Fuel system ..................................................FE-3, 6
Fuel tank .......................................................FE-3, 6
Fuel temperature sensor ......................EC-123, 395
Fuse ................................................................EL-19
Fuse and fusible link box .............................Foldout
Fuse block ....................................................Foldout
Fusible link ......................................................EL-19 GGarage jack and safety stand .........................GI-31
Gauges .....................................................EL-82, 85
Gear components (M/T) ........MT-11, 14, 16, 21, 23
Generator - See Alternator .............................SC-27
GLOW - Wiring diagram...............................EC-246
Glow control system ....................EC-244, 334, 412
Glow plug .............................................EC-244, 413
Glow relay ............................................EC-246, 419
Grease .........................................MA-17, 39, 40, 44
Ground distribution..........................................EL-20
H
Harness connector ............................................EL-5
Harness connector inspection .........................GI-19
Harness layout ....EL-280, 281, 282, 298, 310, 312,320, 321, 322, 323, 324
Hazard warning lamp................................EL-61, 62
Headlamp ......EL-28, 32, 33, 34, 41, 42, 43, 46, 47
Headlamp aiming control .............EL-41, 42, 43, 46
Headlamp washer .........................................EL-118
Headlining - See Roof trim .............................BT-20
Heat up switch..............................................EC-265
Heated seat .......................................BT-36, EL-151
HEATER - Wiring diagram .............................HA-41
HEATUP - Wiring diagram ...........................EC-266
Height (Dimensions) ........................................GI-10
HFC134a (R134a) system precaution .............HA-3
HFC134a (R134a) system service procedure....................................................HA-15
HFC134a (R134a) system service tools ........HA-11
High clutch ....................................................AT-160
H/LAMP - Wiring diagram ............EL-28, 34, 43, 62
Hood..................................................................BT-6
Hood lock system .............................................BT-6
Horn ..............................................................EL-122
HORN - Wiring diagram................................EL-122
How to erase DTC for OBD system ......EC-33, 344
HSEAT - Wiring diagram...............................EL-151
I
Identification .....................................................HA-2
Identification plate .....................................GI-28, 29
Idle speed...............................................EC-50, 361
Idle speed inspection ...............................MA-20, 26
ILL - Wiring diagram .......................................EL-68
Illumination ................................................EL-67, 68
Injection nozzle ......................................EC-24, 336
Injection nozzle inspection ..................MA-5, 20, 25
Injection timing control valve ........................EC-403
INJPMP - Wiring diagram ...EC-126, 169, 176, 183, 190, 200, 240
Instrument panel .............................................BT-16
INT/L - Wiring diagram....................................EL-74
ALPHABETICAL INDEX
IDX-4
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