ENGINE ASSEMBLY
EM-77
< SERVICE INFORMATION >
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• Start engine. With engine speed increased, check again for fuel leakage at connection points.
• Run engine to check for unusual noise and vibration.
• Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oils/fluids including
engine oil and engine coolant.
• Bleed air from passages in lines and hoses, such as in cooling system.
• After cooling down the engine, again check oil/fluid levels including engine oil and engine coolant. Refill to
specified level if necessary.
• Summary of the inspection items:
*Transmission/transaxle/CVT fluid, power steering fluid, brake fluid, etc.Item Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluids* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gas — Leakage —
CYLINDER BLOCK
EM-79
< SERVICE INFORMATION >
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DISASSEMBLY
NOTE:
Explained here is how to disassemble with engine stand supporting transmission surface. When using differ-
ent type of engine stand, some steps may be different.
1. Remove engine assembly and mount to engine stand. Refer to EM-74, "
Removal and Installation".
CAUTION:
Before removing the hanging chains, make sure engine stand is stable and there is no risk of over-
turning.
2. Drain engine oil. Refer to LU-9, "
Changing Engine Oil".
3. Drain engine coolant by removing the cylinder block drain plugs
“A”, “B”, “C” and “D” as shown.
4. Remove the following components and associated parts (the parts referred to in step 1 are not included
here).
• Oil pan (upper and lower) and oil strainer. Refer to EM-24, "
Removal and Installation".
• Crankshaft pulley, front cover and timing chain. Refer to EM-38, "
Removal and Installation".
• Camshaft. Refer to EM-46, "
Removal and Installation".
• Cylinder head. Refer to EM-65, "
Removal and Installation".
5. Remove knock sensor and sub harness.
CAUTION:
Carefully handle sensor, avoiding shocks.
6. Check connecting rod side clearance. Refer to EM-93, "
Inspection After Disassembly".
7. Remove piston and connecting rod assembly as follows.
a. Position the crankshaft pin corresponding to the connecting rod to be removed onto bottom dead center.
b. Remove connecting rod cap.
22. Drive plate 23. Reinforcement plate 24. Rear oil seal retainer
25. Rear oil seal 26. Transmission 27. O-ring
28. Crankshaft position sensor (POS) 29. Gasket 30. Cylinder block heater
31. Connector cap
WBIA0419E
KBIA2549E
PRECAUTIONS
GI-3
< SERVICE INFORMATION >
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General PrecautionINFOID:0000000003531471
• Do not operate the engine for an extended period of time without
proper exhaust ventilation.
Keep the work area well ventilated and free of any flammable
materials. Special care should be taken when handling any flam-
mable or poisonous materials, such as gasoline, refrigerant gas,
etc. When working in a pit or other enclosed area, be sure to prop-
erly ventilate the area before working with hazardous materials.
Do not smoke while working on the vehicle.
• Before jacking up the vehicle, apply wheel chocks or other tire
blocks to the wheels to prevent the vehicle from moving. After jack-
ing up the vehicle, support the vehicle weight with safety stands at
the points designated for proper lifting before working on the vehi-
cle.
These operations should be done on a level surface.
• When removing a heavy component such as the engine or tran-
saxle/transmission, be careful not to lose your balance and drop
them. Also, do not allow them to strike adjacent parts, especially
the brake tubes and master cylinder.
• Before starting repairs which do not require battery power:
Turn off ignition switch.
Disconnect the negative battery terminal.
• If the battery terminals are disconnected, recorded memory of
radio and each control unit is erased.
• Battery posts, terminals and related accessories contain lead and
lead compounds. Wash hands after handling.
• To prevent serious burns:
Avoid contact with hot metal parts.
Do not remove the radiator cap when the engine is hot.
• Dispose of or recycle drained oil or the solvent used for cleaning
parts in an appropriate manner.
• Do not attempt to top off the fuel tank after the fuel pump nozzle
shuts off automatically.
Continued refueling may cause fuel overflow, resulting in fuel spray
and possibly a fire.
• Clean all disassembled parts in the designated liquid or solvent
prior to inspection or assembly.
• Replace oil seals, gaskets, packings, O-rings, locking washers,
cotter pins, self-locking nuts, etc. with new ones.
• Replace inner and outer races of tapered roller bearings and needle bearings as a set.
• Arrange the disassembled parts in accordance with their assembled locations and sequence.
• Do not touch the terminals of electrical components which use microcomputers (such as ECM).
Static electricity may damage internal electronic components.
• After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection.
• Use only the fluids and lubricants specified in this manual.
• Use approved bonding agent, sealants or their equivalents when required.
SGI285
SGI231
SEF289H
SGI233
GI-4
< SERVICE INFORMATION >
PRECAUTIONS
• Use hand tools, power tools (disassembly only) and recommended
special tools where specified for safe and efficient service repairs.
• When repairing the fuel, oil, water, vacuum or exhaust systems,
check all affected lines for leaks.
• Before servicing the vehicle:
Protect fenders, upholstery and carpeting with appropriate covers.
Take caution that keys, buckles or buttons do not scratch paint.
WARNING:
To prevent ECM from storing the diagnostic trouble codes, do not carelessly disconnect the harness
connectors which are related to the engine control system and TCM (transmission control module)
system. The connectors should be disconnected only when working according to the WORK FLOW of
TROUBLE DIAGNOSES in EC and AT sections.
Precaution for Three Way CatalystINFOID:0000000003531472
If a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. To
prevent this, follow the instructions.
• Use unleaded gasoline only. Leaded gasoline will seriously damage the three way catalyst.
• When checking for ignition spark or measuring engine compression, make tests quickly and only when nec-
essary.
• Do not run engine when the fuel tank level is low, otherwise the engine may misfire, causing damage to the
catalyst.
Do not place the vehicle on flammable material. Keep flammable material off the exhaust pipe and the three
way catalyst.
Precaution for Fuel (Unleaded Premium Gasoline Required)INFOID:0000000003531473
Use unleaded premium gasoline with an octane rating of at least 91 AKI (Anti-Knock Index) number (Research
octane number 96).
If unleaded premium gasoline is not available, unleaded regular gasoline with an octane rating of at least 87
AKI number (Research octane number 91) can be used, but only under the following precautions:
• have the fuel tank filled only partially with unleaded regular gasoline, and fill up with unleaded premium gas-
oline as soon as possible.
• avoid full throttle driving and abrupt acceleration.
However, for maximum vehicle performance, the use of unleaded premium gasoline is recommended.
CAUTION:
Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Do not use E-85
fuel (85% fuel ethanol, 15% unleaded gasoline) unless the vehicle is specifically designed for E-85 fuel
(i.e. Flexible Fuel Vehicle - FFV models). Using a fuel other than that specified could adversely affect
the emission control devices and systems, and could also affect the warranty coverage validity.
PBIC0190E
SGI234
GI-48
< SERVICE INFORMATION >
IDENTIFICATION INFORMATION
ENGINE SERIAL NUMBER
TRANSFER SERIAL NUMBER
AUTOMATIC TRANSMISSION NUMBER
DimensionsINFOID:0000000003531505
Unit: mm (in)
Wheels & TiresINFOID:0000000003531506
LAIA0044E
LAIA0048E
PAIA0054E
Drive type2WD 4WD
Overall length 5255 (206.9) 5255 (206.9)
Overall width 2001 (78.8) 2001 (78.8)
Overall height (with roof rack) 1976.8 (77.0) 1997.7 (77.8)
Front tread width 1725 (67.9) 1725 (67.9)
Rear tread width 1725 (67.9) 1725 (67.9)
Wheelbase 3130 (123.2) 3130 (123.2)
Minimum Running Ground Clearance (at front suspen-
sion)With standard
undercover254.8 (10.03) 273.7 (10.77)
With oil pan skid
plate250.5 (9.86) 269.5 (10.61)
IDX-2
ALPHABETICAL INDEX
Numerics
2-4WD shift solenoid valve ..... TF-93
, TF-154, TF-167
4WD - Wiring diagram ....................................... TF-24
4WD shift switch ................................................ TF-65
4WD solenoid valve ................ TF-89, TF-154, TF-167
4WD system description .................................... TF-15
4WD system diagram ........................................ TF-19
A
A/C air flow ...................................................... ATC-30
A/C compressor clutch removal and installation .. ATC-
180
A/C compressor mounting ............................. ATC-179
A/C compressor precaution ............................. ATC-11
A/C compressor special service tool ................ ATC-14
A/C control operation (auto A/C) ...................... ATC-27
A/C diagnostic work flow (auto A/C) .............. ATC-133
A/C evaporator ............................................... ATC-186
A/C HFC134a (R134a) system identification ..... ATC-6
A/C HFC134a (R134a) system precaution ........ ATC-5
A/C HFC134a (R134a) system service procedure ATC-
175
A/C HFC134a (R134a) system service tools ... ATC-14
A/C HFC134a system service equipment precaution ...
ATC-11
A/C lubricant (R134a) ...................................... ATC-22
A/C lubrication oil ............................................. ATC-22
A/C operational check ....................... ATC-56, ATC-58
A/C self-diagnoses (auto A/C) ........ ATC-54, ATC-133
A/C service data specification ........................ ATC-193
A/C trouble diagnoses (auto A/C) .................... ATC-34
A/C, A - Wiring diagram ................................... ATC-42
A/T fluid checking ...................... AT-12, AT-51, MA-22
A/T fluid cooler cleaning .................................... AT-14
A/T fluid replacement ............................. AT-12, MA-24
A/T fluid temperature sensor ........................... AT-123
A/T IND - Wiring diagram .................................... DI-36
A/T indicator ........................................................ DI-36
A/T shift lock system ........................................ AT-216
A/T trouble diagnoses ........................................ AT-42
ABS - Wiring diagram ..................................... BRC-16
ABS (anti-lock brake system) ........................... BRC-7
Accelerator control system ............................... ACC-3
Accelerator pedal position (APP) sensor . EC-608, EC-
614, EC-628
Accelerator pedal released position learning ..... EC-80
AF1B1-Wiring diagram EC-242, EC-250, EC-258, EC-
267, EC-638
AF1B2-Wiring diagram EC-244, EC-252, EC-260, EC-
269, EC-640
AF1HB1-Wiring diagram .................................. EC-175
AF1HB2-Wiring diagram .................................. EC-177
Aiming adjustment .................................. LT-23, LT-61
Air bag .............................................................. SRS-3
Air bag precautions .............................................. AV-4
Air cleaner and air duct ..................................... EM-15
Air cleaner filter replacement ................ EM-16, MA-16
Air conditioner cut control ................................. EC-29
Air flow meter - See Mass air flow sensor EC-197, EC-
206
Air fuel ratio sensor 1 .. EC-239, EC-248, EC-256, EC-
264, EC-636
Air fuel ratio sensor 1 heater ........................... EC-174
Air mix. door motor .......................................... ATC-69
Ambient sensor ............................. ATC-138, ATC-149
Angular tightening application ............................. EM-4
Antenna .............................................................. AV-58
APPS1 - Wiring diagram ................................. EC-610
APPS2 - Wiring diagram ................................. EC-616
APPS3 - Wiring diagram ................................. EC-630
ASC/BS - Wiring diagram ............................... EC-574
ASC/SW - Wiring diagram .............................. EC-557
ASCBOF - Wiring diagram .............................. EC-648
ASCD ................................................................ EC-30
ASCD (automatic speed control device) ........... ACS-3
ASCD brake switch ........................... EC-572, EC-647
ASCD indicator lamp ....................................... EC-654
ASCD steering switch ..................................... EC-555
ASCIND - Wiring diagram ............................... EC-655
ATP switch ............................ TF-106, TF-109, TF-114
Audio .................................................................... AV-6
AUDIO - Wiring diagram .................................... AV-11
AUT/DP - Wiring diagram .................................. SE-16
Auto air conditioner - Wiring diagram .............. ATC-42
Auto anti-dazzling inside mirror ........... GW-69, GW-70
Autolamp ............................................................ LT-38
Automatic amplifier ......................................... ATC-59
Automatic drive positioner .................................. SE-11
Automatic transmission number .......................... GI-50
B
Back door ........................................................... BL-88
Back door trim ..................................................... EI-32
Back sonar .......................................................... DI-50
BACK/L - Wiring diagram ................................... LT-87
Back-up lamp ..................................................... LT-87
Ball joint (front) ................................................ FSU-15
Basic inspection ................................................ EC-73
Battery ................................................................. SC-4
Battery current sensor . EC-520, EC-527, EC-534, EC-
541
Battery/Starting/Charging System Tester SC-6, SC-12,
SC-20
BCM (Body control module) ................ BCS-3, AV-106
Block heater ...................................................... EM-78
Blower motor ................................... ATC-93, ATC-153
Body alignment ................................................ BL-164
Body component parts ..................................... BL-151
Body construction ............................................ BL-163
Body exterior paint color .................................. BL-150
Body mounting ................................................. BL-149
Body repair ....................................................... BL-150
Body sealing .................................................... BL-160
Bose speaker amp. .............................................. AV-8
Brake booster .................................................... BR-17
IDX-8
ALPHABETICAL INDEX
Three way catalyst ............................................ EM-21
Three way catalyst function (Bank 1) ............... EC-376
Three way catalyst function (Bank 2) ............... EC-376
Three way catalyst precautions ............................ GI-5
Throttle control motor ....................................... EC-601
Throttle control motor relay .............................. EC-589
Throttle position sensor (TPS) .. EC-224, EC-343, EC-
514, EC-516, EC-621
Throttle valve closed position learning ............... EC-80
Tie-rod ............................................................... PS-15
Timing chain ..................................................... EM-37
Tire rotation ....................................................... MA-28
Tire size .............................................................. GI-51
Torque converter installation AT-239, AT-240, AT-243,
AT-244
Torque convertor clutch solenoid valve ... AT-114, AT-
116
Tow truck towing ................................................. GI-44
Towing point ....................................................... GI-45
TPS1 - Wiring diagram .................................... EC-345
TPS2 - Wiring diagram .................................... EC-226
TPS3 - Wiring diagram .................................... EC-623
Traction control system - Wiring diagram ....... BRC-16
Transfer control device ............. TF-75, TF-79, TF-138
Transfer control unit inspection table ................. TF-35
Transfer dropping resistor .................................. TF-89
Transfer fluid temperature sensor TF-103, TF-154, TF-
167
Transfer motor .................................... TF-101, TF-142
Transfer motor relay ........................................ TF-101
Transfer oil replacement ................................... MA-24
Transfer serial number ........................................ GI-50
Transmission serial number ................................ GI-50
Tread-FR&RR (Dimensions) ............................... GI-51
Trim ..................................................................... EI-35
TRNSCV - Wiring diagram .................. BL-130, BL-146
Trouble diagnoses .............................................. GI-11
Turbine revolution sensor ................................ AT-105
TURN - Wiring diagram ...................................... LT-67
Turn signal lamp ................................................. LT-63
Two trip detection logic ...................................... EC-49
Two-pole lift ........................................................ GI-43
V
Vacuum hose (brake system) ............................ BR-20
Vacuum hose drawing (Engine control) ........... EC-106
Valve clearance ................................................ EM-55
Valve guide ....................................................... EM-69
Vanity mirror lamp ............................................. LT-110
VDC (vehicle dynamics control) ........................ BRC-7
VDC -Wiring diagram ...................................... BRC-16
Vehicle identification number .............................. GI-49
Vehicle recovery (freeing a stuck vehicle) .......... GI-45
Vehicle security (theft warning) system ............. BL-67
Vehicle speed sensor (VSS) ............................ EC-464
VEHSEC - Wiring diagram ................................. BL-71
VENT/V - Wiring diagram .................. EC-412, EC-419
VIN registration .................................................. EC-79
Viscosity number (SAE) .................................... MA-12
VSS A/T - Wiring diagram .................. AT-107, AT-109
W
W/ANT - Wiring diagram .................................... AV-59
Wait detection switch ......................................... TF-68
WARN - Wiring diagram ...................................... DI-29
Warning chime .................................................... DI-38
Warning lamps .................................................... DI-28
Washer, front ..................................................... WW-4
Washer, rear .................................................... WW-29
Water pump ...................................................... CO-19
Water temperature gauge ..................................... DI-5
Wheel alignment (front) ..................................... FSU-6
Wheel alignment (rear) ................................... RSU-25
Wheel bearing (front) ........................................ FAX-5
Wheel bearing (rear) ......................................... RAX-5
Wheel hub (rear) ............................................... RAX-5
Wheel size .......................................................... GI-51
Wheelbase (Dimensions) .................................... GI-51
Width (Dimensions) ............................................. GI-51
WINDOW - Wiring diagram .............................. GW-22
Window, door ...................................... GW-62, GW-65
Windshield ....................................................... GW-11
WIP/R - Wiring diagram ................................... WW-33
WIPER - Wiring diagram .................................... WW-8
Wiper, front ........................................................ WW-4
Wiper, rear ....................................................... WW-29
Wiring Diagram (Cell code) list ......................... PG-62
Wiring diagrams .................................................. GI-15
WT-T/WARN - Wiring diagram .......................... WT-11
MA-1
MAINTENANCE
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SECTION MA
A
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CONTENTS
MAINTENANCE
SERVICE INFORMATION ............................2
PRECAUTIONS ...................................................2
Precaution for Supplemental Restraint System
(SRS) "AIR BAG" and "SEAT BELT PRE-TEN-
SIONER" ...................................................................
2
PREPARATION ...................................................3
Special Service Tool .................................................3
Commercial Service Tool ..........................................3
GENERAL MAINTENANCE ................................4
General Maintenance ................................................4
PERIODIC MAINTENANCE ................................6
Introduction of Periodic Maintenance ........................6
Maintenance for Off-road Driving (4WD only) ...........6
Schedule 1 ................................................................6
Schedule 2 ................................................................8
RECOMMENDED FLUIDS AND LUBRI-
CANTS ................................................................
10
Fluids and Lubricants ..............................................10
SAE Viscosity Number ............................................10
ENGINE MAINTENANCE ...................................12
Checking Drive Belts ...............................................12
Changing Engine Coolant .......................................12
Checking Fuel Line .................................................15
Changing Fuel Filter ................................................15
Changing Engine Air Cleaner Filter .........................15
Changing Engine Oil ................................................16
Changing Oil Filter ...................................................16
Changing Spark Plugs .............................................18
Checking EVAP Vapor Line .....................................19
CHASSIS AND BODY MAINTENANCE ...........20
Changing In-cabin Microfilter ...................................20
Checking Exhaust System .......................................21
Checking Automatic Transmission Fluid (ATF) .......21
Changing Automatic Transmission Fluid (ATF) .......23
Changing Transfer Fluid ..........................................23
Checking Transfer Fluid ..........................................24
Checking Propeller Shaft .........................................24
Checking Final Drive Oil ..........................................24
Changing Final Drive Oil ..........................................25
Balancing Wheels ....................................................25
Tire Rotation ............................................................27
Checking Brake Fluid Level and Leaks ...................27
CheckingBrake Line and Cables .............................27
Checking Disc Brake ...............................................27
Checking Steering Gear and Linkage ......................28
Checking Power Steering Fluid and Line ................28
Checking Axle and Suspension Parts .....................29
Lubricating Locks, Hinges and Hood Latches .........30
Checking Seat Belts, Buckles, Retractors, An-
chors and Adjusters .................................................
30