Page 1505 of 2870

ME(H4DOTC)-47
MECHANICAL
Engine Assembly
6) Remove the garage jack.
7) Install the pitching stopper.
Tightening torque:
T1: 50 N
⋅m (5.1 kgf-m, 37 ft-lb)
T2: 58 N
⋅m (5.9 kgf-m, 43 ft-lb)
8) Remove the ST from torque converter clutch
case. (AT model)
NOTE:
Be careful not to drop the ST into torque converter
clutch case when removing ST.
ST 498277200 STOPPER SET
9) Install the starter.
STALLATION, Starter.>
10) Install the torque converter clutch onto drive
plate. (AT model)
(1) Tighten the bolts which hold the torque con-
verter clutch to drive plate.
(2) Tighten other bolts while rotating the engine
by using ST.
CAUTION:
Be careful not to drop bolts into the torque con-
verter clutch housing.
ST 499977300 CRANK PULLEY WRENCHTightening torque:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
(3) Clog the service hole with plug.
11) Install the fuel filter and bracket.
12) Install the power steering pump on bracket.
(1) Install the reservoir tank on bracket.
(2) Install the power steering pump.
Tightening torque:
20.1 N
⋅m (2.05 kgf-m, 14.8 ft-lb)
ME-00047
T1
T2
MT-00085ME-00044
ME-00046
ME-00038
ME-00037
Page 1506 of 2870

ME(H4DOTC)-48
MECHANICAL
Engine Assembly
(3) Install the power steering pipe bracket on in-
take manifold RH.
(4) Connect the power steering switch connec-
tor.
(5) Install the front side V-belt, and adjust it.
INSTALLATION, V-belt.>
13) Lift-up the vehicle.
14) Tighten the nuts which hold the lower side of
transmission to engine.
Tightening torque:
50 N
⋅m (5.1 kgf-m, 36.9 ft-lb)
15) Tighten the nuts which install the front cushion
rubber onto crossmember.
Tightening torque:
85 N
⋅m (8.7 kgf-m, 62.7 ft-lb)NOTE:
Make sure the front cushion rubber mounting bolts
(A) and locator (B) are securely installed.
16) Install the ATF cooler pipe to frame. (AT model)
17) Install the center exhaust pipe.
Exhaust Pipe.>
18) Lower the vehicle.
19) Connect the following hoses:
(1) Fuel delivery hose, return hose and evapo-
ration hose
(2) Heater inlet and outlet hoses
(3) Brake booster vacuum hose
20) Connect the following connectors and termi-
nals:
(1) Engine ground terminal
(2) Engine harness connectors
(3) Generator connector and terminal
(4) A/C compressor connectors
21) Connect the following cables:
(1) Accelerator cable
(2) Clutch release spring
22) After connecting each cable, adjust them.
23) Install the air intake system.
(1) Install the intercooler.
11, INSTALLATION, Intercooler.>
(2) Install the air cleaner element and air clean-
er upper cover.
(3) Install the engine harness connector brack-
et.
(4) Install the filler hose to air cleaner case.
ME-00036
ME-00035
ME-00040
ME-00056
(A)
(A)(B)
(B)
Page 1507 of 2870
ME(H4DOTC)-49
MECHANICAL
Engine Assembly
24) Install the A/C pressure hoses.
NOTE:
Use new O-rings.
Tightening torque:
15 N
⋅m (1.5 kgf-m, 10.8 ft-lb)
25) Install the radiator.
STALLATION, Radiator.>
26) Install the coolant filler tank.
CO(H4SO)-42, INSTALLATION, Coolant Filler
Tank.>
27) Install the window washer tank.
28) Install the battery in the vehicle, and then con-
nect the cables.
29) Fill coolant.
COOLANT, REPLACEMENT, Engine Coolant.>
30) Charge the A/C system with refrigerant.
ing Procedure.>
31) Remove the front hood stay, and close the front
hood.
32) Take off the vehicle from lift arms.
ME-00026
Page 1508 of 2870
ME(H4DOTC)-50
MECHANICAL
Engine Mounting
10.Engine Mounting
A: REMOVAL
1) Remove the engine assembly.
ME(H4DOTC)-41, REMOVAL, Engine Assembly.>
2) Remove the engine mounting from engine as-
sembly.
B: INSTALLATION
Install in the reverse order of removal.
Tightening torque:
ENGINE MOUNTING;
35 N
⋅m (3.6 kgf-m, 25.8 ft-lb)
C: INSPECTION
Make sure there are no cracks or other damage.
Page 1509 of 2870
ME(H4DOTC)-51
MECHANICAL
Preparation for Overhaul
11.Preparation for Overhaul
A: PROCEDURE
1) After removing the engine from body, secure it in
the ST shown below.
ST1 498457000 ENGINE STAND ADAPTER
RH
ST2 498457100 ENGINE STAND ADAPTER
LH
ST3 499817000 ENGINE STAND
2) In this section the procedures described under
each index are all connected and stated in order. It
will be the complete procedure for overhauling of
the engine itself when you go through all steps in
the process.
Therefore, in this section, to conduct the particular
procedure within the flow of a section, you need to
go back and conduct the procedure described pre-
viously in order to do that particular procedure.
ME-00057ST3
ST2
ST1
Page 1510 of 2870
ME(H4DOTC)-52
MECHANICAL
V-belt
12.V-belt
A: REMOVAL
1. FRONT SIDE BELT
1) Remove the V-belt cover.
2) Loosen the lock bolt (A).
3) Loosen the slider bolt (B).
4) Remove the front side belt (C).
2. REAR SIDE BELT
1) Loosen the lock nut (A).
2) Loosen the slider bolt (B).
3) Remove the A/C belt.4) Remove the A/C belt tensioner.
B: INSTALLATION
1. FRONT SIDE BELT
CAUTION:
Wipe off any oil or water on the belt and pulley.
1) Install the belt (C), and tighten the slider bolt so
as to obtain the specified belt tension
ME(H4DOTC)-53, INSPECTION, V-belt.>
2) Tighten the lock bolt (A).
3) Tighten the slider bolt (B).
Tightening torque:
Lock bolt through bolt:
25 N
⋅m (2.5 kgf-m, 18.1 ft-lb)
Slider bolt:
8 N
⋅m (0.8 kgf-m, 5.5 ft-lb)
SC-00096
(A)
(C) (B)
ME-00059
(A)
(B)
ME-00060
ME-00061
(A)
(C) (B)
ME-00059
Page 1511 of 2870
ME(H4DOTC)-53
MECHANICAL
V-belt
2. REAR SIDE BELT
1) Install the belt, and tighten the slider bolt (B) so
as to obtain the specified belt tension.
ME(H4DOTC)-53, INSPECTION, V-belt.>
2) Tighten the lock nut (A).
Tightening torque:
Lock nut (A);
22.6 N
⋅m (2.3 kgf-m, 16.6 ft-lb)
C: INSPECTION
1) Replace the belts, if cracks, fraying or wear is
found.
2) Check the drive belt tension and adjust it if nec-
essary by changing generator installing position
and/or idler pulley installing position.
Belt tension (With using belt tension gauge)
(A)
Replaced: 640 — 780 N (65 — 80 kgf, 144 —
175 lb)
Reused: 490 — 640 N (50 — 65 kgf, 110 — 144
lb)
(B)*
Replaced: 740 — 880 N (76 — 89 kgf, 167 —
197 lb)
Reused: 350 — 450 N (36 — 46 kgf, 78 — 101
lb)
*: With air conditioner
(A)
(B)
ME-00060
(A) Front side belt
(B) Rear side belt
C/P Crank pulley
GEN Generator
P/S Power steering oil pump pulley
A/C A/C compressor pulley
I/P Idler pulley
C/P P/SA/C
GEN
(A)
(B)
I/P
PM-00154
Page 1512 of 2870
ME(H4DOTC)-54
MECHANICAL
V-belt
Belt tension (Without using belt tension gauge)
(A)
Replaced: 7 — 9 mm (0.276 — 0.354 in)
Reused: 9 — 11 mm (0.354 — 0.433 in)
(B)*
Replaced: 7.5 — 8.5 mm (0.295 — 0.335 in)
Reused: 9.0 — 10.0 mm (0.354 — 0.394 in)
*: With air conditioner
(A) Front side belt
(B) Rear side belt
C/P Crank pulley
GEN Generator
P/S Power steering oil pump pulley
A/C Air conditioning compressor pulley
I/P Idler pulley
ME-00062
P/S
C/PGEN
I/P A/C 98 N (10 kgf, 22 lb)
(A)(B)