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Engine mechanism - Engine assembly73. Install transmission assembly.(a) Install transmission assembly.
Torque: bolt A: Bolt B: Bolt C: (b) Install 6 bolts.
Torque: 74. nstall starter mounting components.Torque: bolt: Nut: 75. Install sub frame together with side member.Install front mounting assembly and rear mounting
assembly.
Torque: front: Rear: 76. Install power steering pump assembly.Torque: 77. Install engine assembly together with
transmission assembly.(a) Erect engine together with transmission assembly on
engine crane.
(b) Install engine assembly to vehicle.
(c) Temporarily install side member and 6 bolts.
(d) Install left engine mounting assembly.
Torque: (e) Install right engine mounting assembly.
(f) Insert special tool into location hole on right side of sub
frame and vehicle.
(g) Temporarily lock bolt A at first, and then lock bolt B.
(h) Insert special tool into location hole on left side of sub
frame and vehicle.
(i) Temporarily lock bolt A at first, and then lock bolt B.
(j) Insert special tool into location hole on right side of sub
frame and vehicle, and then tighten bolts up to speci-
fied torque.
Torque: bolt A: m
Bolt B: Special
tool
Special tool42
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(k) Insert special tool into location hole on left side of sub
frame and vehicle, and then tighten bolts up to speci-
fied torque.
Torque: bolt A: Bolt B: m
(l) As shown in the diagram, tighten 2 bolts.
Torque: Note: after installing sub frame, check the sub
frame is aligned with location hole on
vehicle.78. Install compressor.Torque: 79. Install lower left control arm assembly.(a) Install drive shaft to steering knucle.
(b) Install lower left control arm.
Torque: Hint: perform the same steps at another side.80. Install front left shaft hub nut.(a) Install fixed nut with socket wrench (39mm).
Torque: (b) Drive the cutout part of hub nut into groove with chisel.
Hint: perform the same steps at another side.81. Install left end front stabilizer link assembly.Fix bolts with hex socket wrench.
Torque: Hint: perform the same steps at another side.82. Install left side transversal lever assembly.(a) Connect transversal lever assembly to steering knucle
and install new nuts.
Torque: Note:Do not coat lubricant on thread and conical surface.After tightening nuts up to specified torque, con-
tinue turning nuts for 60¡ãand insert open pin.
(b) Insert new open pin.83. Connect fuel hose assembly.
84. Install battery tray.Torque: Engine mechanism - Engine assembly 43
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Engine mechanism - Engine assembly85. Install alternator mounting components.Torque: 12mm bolt head A: 14mm bolt head B: 86. Install drive belt.
87. Install engine wire harness and all hoses
not connected.(a) Check and connect all joints of engine wire harness.
(b) Check and connect all hoses.88. Install transmission control pull cable assembly
and valve control pull cable.
89. Install air filter assembly and its hose.
90. Install steering middle shaft assembly.(a) Align alignment mark on steering middle shaft.
(b) Install 2 bolts.
Torque: m
(c) Install steering column cover.91. Install front exhaust pipe assembly.
92. Install front chassis bracket.Torque: 93. Install battery and connect wire.
94. Install engine plastic hood components.
95. Install front wheel and engine bottom shield.
96. Refill transmission lubricant.
97. Refill engine oil.
98. Refill coolant.
99. Check there is oil leakage.
100. Check there is coolant leakage.
101. Check idle speed and ignition timing.
102. Check CO/HC.Alignment
mark
Sliding in
Pulling 44
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Engine mechanism - Timing chain assemblyTiming chain assemblyReplacement1. Remove engine left bottom shield.
2. Remove engine right bottom shield.
3. Discharge coolant.
4. Remove engine plastic hood components.
5. Remove drive belt.
6. Remove power steering pump assembly.
7. Remove alternator assembly.
8. Uncouple engine wire harness.(a) Remove ignition coil joint, PS fuel pressure switch joint,
fuel line control joint and speed sensor joint.
(b) Remove bolts and nuts of fixed earth wire and put aside
engine wire harness.9. Remove ignition coil assembly.
10. Remove cylinder head cover components.(a) Remove fuel pipe retaining clip and 2 PCV hoses from
cylinder head cover.
(b) Remove 9 bolts, 2 seal washers, cylinder head cover
components and gasket.11. Remove right engine mounting assembly.(a) Remove PS oil pump reservoir and put it aside.
(b) Place wooden block between jack and engine, prop-
erly place the jack, and then remove right engine mount-
ing assembly.12. Turn crankshaft to cylinder 1 compression top
dead center position.
13. Remove damping pulley components
[4G18-1005110].Remove pulley bolts with special tool.
Remove damping pulley components with special tool.Special
tool
Special
tool45
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Front suspension - front suspension systemFront suspensionFront suspension systemTable on trouble occurrenceThis table could help you find out failure causes, and each figure in the table indicates the possible
sequence of failure causes, please check every part as the sequence, and replace if necessary.Trouble occurrence Possible trouble part Pages to refer to
1. Tire (abrasion or improper tire pressure) 109
2. Wheel alignment (incorrect) 87
Deflection/single side 3. Steering linkage (looseness or abrasion) -
4. Shaft hub bearing (abrasion) 123
5. Suspension parts (abrasion) -
6. Steering gear (poor adjustment or breakage) -
1. Vehicle (overload) -
Bottoming 2. Spring (elastic fatigue) 90
3. Absorber (abrasion) 90
1. Tire (abrasion or improper tire pressure) 109
Swaying left and right/ 2. Stabilizer bar (bending or breakage) 96shaking forward and backward3. Absorber (abrasion) 90
1. Tire (abrasion or improper tire pressure) 109
2. Wheel (poor balance) 109
3. Absorber (abrasion) 90
Front wheel shimmy 4. Wheel alignment (incorrect) 87
5. Ball joint (abrasion) 99
6. Shaft hub bearing (looseness or abrasion) 123
7. Steering linkage (looseness or abrasion) -
8. Steering gear (poor adjustment or breakage) -
1. Tire (abrasion or improper tire pressure) 109
Abnormal tire abrasion 2. Wheel alignment (incorrect) 87
3. Absorber(abrasion) 90
4. Suspension parts (abrasion) -86
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Front suspension - Front wheel alignmentFrontRearIf toe-in is not within specification, please adjust left and
right levers of steering gear.4. Adjustment of toe-in(a) Remove dust cover fixing clip.FrontRearToe-in(Total)Front wheel alignmentAdjustment1. Inspection(a) Check tire is worn and inflation pressure is proper.
Tire inflation pressure under normal temperature:Tire size Front and rear kPa*1 It is used under the condition of speed below 160 km/h.
*2 It is used under the condition of speed above 160 km/h.
(b) Check tire run-out with dial indicator.
Tire run-out: 3.0mm.2. Measurement of vehicle heightVehicle height:
(General road)
(Coarse road)
Measuring point:
A. Height for ground and front wheel center
B. Height for ground and bolt center in front of lower
control arm
C. Height for ground and fixed bolt center of rear axle beam
D. Height for ground and rear wheel center
Note: adjust vehicle height to standard value before checking front wheel alignment.
If vehicle height does not conform to regulations, please shake upward and downward or lift vehicle
body to adjust vehicle height.3. Inspection of toe-inToe-in:Front87
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Inside wheel38o452oOutside wheel: reference32o50Front suspension - Front wheel alignment(Coarse road)
Inside wheel39o052oOutside wheel: reference33o10Camber-031’45’Left-right error45’Caster242’45’Left-right error45’Steering shaft inclination18’45’Left-right error45’Camber-
018’45’Left-right error45’Caster230’45’Left-right error45’Steering shaft inclination1052’45’Left-right error45’A: inside
B: outsideFrontGauge If caster and steering axis inclination are not within specification, please adjust the caster and
then check parts of lower control arm is damaged or worn.(b) Loosen lock nuts at the end of transversal lever .
(c) Evenly rotate end levers of left and right rack to
adjust toe-in.
Hint: try adjusting toe-in to medium value.
(d) Ensure that the end lever length of left rack equals that
of right rack.
(e) Tighten lock nuts at the end of transversal lever.
Torque: 745 N.m
(f) Install dust cover fixing clip.
Hint: ensure that the dust cover does not distort.5. Inspection of turning angle(a) Completely rotate steering wheel to the bottom and then
measure turning angle.
Turning angle:
(General road)
(Coarse road)Wheel
alignment
tester88If left and right inside wheels are not within specification, please check the end lever length of left rack
and right rack.6. Inspection of camber, caster and steering shaft inclination(a) Install camber-caster-kingpin gauge or erect wheel alignment tester.
(b) Check camber, caster and steering-axis inclination.
Camber, caster and steering shaft inclination:
(General road)
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Front suspension - Front wheel alignment7. Adjustment of camberNote: after adjusting the camber, please check toe-in.
(a) Remove front wheels.
(b) Remove 2 nuts under absorber.
If it is necessary to repeat using bolts or nuts, please coat
oil to thread of nuts.
(c) Clean nut absorber and attachment face of steering knucle.
(d) Temporarily install 2 nuts.
(e) Push or pull lower end of absorber in the direction that cam-
ber requires adjustment to adjust the camber.
(f) Tighten nut.
Torque: 15310 N.m
(g) Install front wheels.
Torque: 10310 N.m
(h) Check camber.89
