Chilton Asian Service Manual 2004 Edition [2004 Edition] 1401842356, 9781401842352

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CHILTON ASIAN SERVICE MANUAL 2004 Edition

THOMSON

DELMAR

*LEARNING

Australia

• Canada

• Mexico

• Singapore

• Spain

• United

Kingdom

• Un

THOMSON

-

*-

DELMAR

LEARNING

Chilton Asian Service Manual 2004 Edition

Vice President, Technology and Trades SBU: Alar Elken Executive Director, Professional Business Unit: Greg Clayton Publisher, Professional Business Unit: David Koontz

COPYRIGHT 2004 by Delmar Learning, a division of Thomson Learning, Inc. Thomson Learning™ is a trademark used herein under license. Printed in the United States of America 1 2 3 4 5 6 XX 07 06 05 04 03 For more information contact Delmar Learning Executive Woods 5 Maxwell Drive, PO Box 8007, Clifton Park, NY 12065-8007 Or find us on the World Wide Web at :

www.trainingbay.com or, www.chiltonsonline.com

Channel Manager: Beth A. Lutz

Production Editor: Elizabeth Hough

Marketing Specialist: Brian McGrath

Editorial Assistant: Kristen Shenfield

Production Director:

Editors:

Mary Ellen Black

Timothy A. Crain Thomas A. Mellon Richard J. Rivele Christine L. Sheeky

Production Manager: Larry Main

ALL RIGHTS RESERVED. No part of this work covered by the copyright hereon may be reproduced in any form or by any means — graphic, electronic, or mechanical, including photocopying, recording, taping, Web distribution, or information storage and retrieval systems — without the written permission of the publisher. us by For permission to use material from the text or product, contact Tel. Fax

ISBN: 1 -401 8-4235-6

(800)730-2214 (800)730-2215

www.thomsonrights.com

NOTICE

TO THE READER

Publisher does not warrant or guarantee any of the products described herein or perform any independent analysis in connection with any of the product information contained herein. Publisher does not assume, and expressly disclaims, any obligation to obtain and include information other than that provided to it by the manufacturer. The reader is expressly warned to consider and adopt all safety precautions that might be indicated by the activities herein and to avoid all potential hazards. By following the instructions contained herein, the reader willingly assumes all risks in connection with such instructions. The publisher makes no representation or warranties of any kind, including but not limited to, the warranties of fitness for particular purpose or merchantability, nor are any such representations implied with respect to the material set forth herein, and the publisher takes no responsibility with respect to such material. The publisher shall not be liable for any special, material. consequential, or exemplary damages resulting, in whole or part, from the readers' use of, or reliance upon, this

Table of Contents Sections Acura Acura Honda Honda Honda Honda Honda Hyundai Hyundai Infiniti Isuzu Isuzu and Honda Kia Kia Kia Lexus Mazda Mazda Mazda Mazda Mitsubishi Mitsubishi Nissan Nissan Nissan Nissan Nissan Subaru Subaru Suzuki Suzuki Toyota Toyota Toyota Toyota Toyota and Lexus Toyota Toyota and Lexus

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38

3.2TL, 3.2CL, 3.5RL, Integra, RSX, NSX MDX Accord, Civic, Prelude, S2000 Element CR-V Odyssey Pilot Accent, Elantra, Sonata, Tiburon, XG 300 Santa Fe G20, G35, 130, 135, Q45 Hombre Amigo, Axiom, Rodeo, Rodeo Sport, Trooper, Vehicross, Passport Sephia, Spectra, Rio, Optima Sedona Sportage ES 300, IS 300, GS 300, GS 400, GS 430, LS 400, LS430, SC 300, SC 400 626, Miata, Millenia, Protege B-Series Trucks MPV Tribute Diamante, Eclipse, Galant, Lancer, Mirage Montero, Montero Sport Altima, Maxima, Sentra Frontier, Xterra Murano Quest Pathfinder, QX4 Legacy, Legacy Outback, SUS, Impreza, Impreza Outback, Impreza Outback Sport, WRX, Baja Forrester Esteem, Swift Vitara, Grand Vitara Avalon, Camry, Camry Solara, Celica, Corolla, Echo, GT-S, Supra, MR2 Tundra Sienna Tacoma Rav4, 4Runner, Highlander, RX300 Matrix Land Cruiser, Sequoia, LX470

Model Index Model

Section No.

130 135 3.2CL 3.2TL 3.5RL 4Runner 626

Section No.

10-1 10-1 1-1 1-1 1-1

Accent Accord Altima Amigo Avalon Axiom

36-1 17-1 8-1 3-1

GT-S

C

Legacy Outback LS 400 LS 430 LX470

CR-V

32-1 4-1

D

Diamante E

Echo Eclipse Elantra Element Esteem ES 300

21-1 32-1 21-1 8-1 5-1

F

Forrester Frontier G

30-1 16-1 29-1 24-1 10-1 10-1 21-1 31-1 16-1 16-1

36-1 11-1 28-1 28-1 1-1 28-1

Q45 Quest QX4 Rav4 Rio

21-1

Matrix Maxima MDX Miata Millenia Mirage

38-1 37-1 2-1 23-1 17-1 17-1

Montero Montero Sport MPV MR2 Murano NSX Odyssey Optima Passport Pathfinder Pilot Prelude Protege

38-1 28-1 28-1 16-1 16-1

21-1 22-1 22-1 19-1 N 0

32-1 25-1 1-1 6-1

P

13-1

S2000 Santa Fe

16-1 16-1

Sephia Sequoia Sienna

14-1 23-1 13-1

Sonata

38-1 8-1 34-1

Spectra Sportage Supra SUS

13-1 15-1 T

Tacoma Tiburon Tribute Trooper

17-1

32-1 28-1 30-1 8-1 35-1

Tundra V

Vehicross Vitara

20-1 12-1 33-1

W

12-1

WRX X

12-1 7-1 27-1 3-1

36-1 13-1 12-1 1-1 12-1 36-1 3-1 9-1

SC 300 SC 400 Sedona Sentra

Swift

10-1 26-1 27-1

S

16-1

M

R

Rodeo Rodeo Sport RSX RX300

L

28-1 18-1 32-1 32-1 32-1 3-1

16-1 32-1

Impreza Impreza Outback Impreza Outback Sport Integra IS 300

B

Camry Camry Solara Celica Civic Corolla

H

1

Lancer Land Cruiser Legacy

Baja B-Series Trucks

Q

Highlander Hombre

23-1 12-1 32-1 12-1

Section No.

Model

GS 430

A

G20 G35 Galant Grand Vitara GS 300 GS 400

Model

XG 300 Xterra

31-1 28-1 8-1 24-1

EDITORIAL POLICY Manufacturer and Model Coverage This manual does not cover every make and model that is currently available on the market. Rather, the Chilton editorial staff makes judicious decisions as to which makes and models warrant coverage, based on which vehicles are serviced by most technicians. In general, this manual does not cover: • Exotic vehicles (e.g. Rolls-Royce, Ferrari, Dodge Viper) • Vehicle manufacturers with no current U.S. presence (e.g. Fiat and Peugeot) • Vehicle models that have not sold enough units to be a factor in the repair market

Model Year Information This manual is published toward the end of the year prior to the edition year. Every effort is made to gather current data from the Original Vehi¬ cle Manufacturers (OEMs) when they publish it. Different OEMs choose to release their new model information at different times of the year. Indeed, the same OEM can publish information early one season and late the next season. As a result, not all models are equally current when each edition of this manual is published. Although information in this manual is based on industry sources and is as complete as possible at the time of publication, some vehicle man¬ ufacturers may make changes which cannot be included here. Information on very late models may not be available in some circumstances. While striving for total accuracy, the publisher cannot assume responsibility for any errors, changes, or omissions that may occur in the compilation of this data.

Safety Notice Proper service and repair procedures are vital to the safe, reliable operation of all motor vehicles, as well as the- personal safety of those per¬ forming the repairs. This manual outlines procedures for servicing and repairing vehicles using safe, effective methods. The procedures contain many NOTES, WARNINGS and CAUTIONS which should be followed along with standard safety procedures to reduce the possibility of personal injury or improper service which could damage the vehicle or compromise its safety. Repair procedures, tools, parts, and technician skill and experience vary widely. It is not possible to anticipate all conceivable ways or condi¬ tions under which vehicles may be serviced, or to provide cautions for all possible hazards that may result. Standard and accepted safety precau¬ tions and equipment should be used when handling toxic or flammable fluids, and safety goggles or other protection should be used during cut¬ ting, grinding, chiseling, prying, or any other process that can cause material removal or projectiles. Some procedures require the use of tools specially designed for a specific purpose. Before substituting another tool or procedure, you must be completely satisfied that neither your personal safety, nor the performance of the vehicle will be endangered.

LOCATING AND USING THE INFORMATION Organization To find where a particular model section is located, look in the Table of Contents. On the first page of each model section, main topics are list¬ ed with the page number on which they may be found. Following the main topics is an alphabetical listing of all of the procedures within the sec¬ tion and their page numbers.

Part Numbers

Part numbers listed in this book are not recommendations by the publisher for any product by brand name. They are references that can be used with interchanges manuals and aftermarket supplier catalogs to locate each brand supplier’s discrete part number.

Special Tools Special tools are recommended by the vehicle manufacturer to perform specific jobs. When necessary, special tools are referred to in the text by the part number of the tool manufacturer. These tools may be purchased, under the appropriate part number, from your local dealer or regional distributor, or an equivalent tool can be purchased locally from a tool supplier or parts outlet. Before substituting any tool for the one recommend¬ ed, read the previous Safety Notice.

ACKNOWLEDGEMENT

The publisher would like to express appreciation to the following vehicle manufacturers for their assistance in producing this publication. No further reproduction or distribution of the material in this manual is allowed without the expressed written permission of the vehicle manufacturers and the publisher. American Honda Motor Co., including Acura and Honda Division Fuji Heavy Industries Ltd., including Subaru Isuzu Motors Ltd. Hyundai Group, including Hyundai and Kia Motor Mazda Motor Corp. Mitsubishi Nissan North America, including Infiniti and Nissan Division Suzuki Motor Corp. Toyota Motor Sales USA, including Lexus and Toyota Division

ACURA 3.2TL • 3.2CL • 3.5RL • Integra • RSX • NSX BRAKES . ...1-112 DRIVE TRAIN . . 1-93 ENGINE REPAIR . . 1-18 FUEL SYSTEM . . 1-89 PRECAUTIONS . . 1-18 SPECIFICATION CHARTS . . 1-2 STEERING AND SUSPENSION . . 1-99 A Air Bag . . 1-99 . 1-100 Disarming . Precautions . . 1-99 Alternator . . 1-19 Removal & Installation . . 1-19 B . 1-112 Brake Caliper . Removal & Installation . . 1-112 C Camshaft and Valve Lifters.... . 1-63 Removal & Installation . . 1-63 Clutch . . 1-97 Removal & Installation . . 1-97 . 1-105 Coil Spring . Removal & Installation . . 1-105 CV-Joints . . 1-99 Overhaul . . 1-99 Cylinder Head . . 1-46 Removal & Installation . . 1-46 D . 1-113 Disc Brake Pads . Removal & Installation . . 1-113 Distributor . . 1-18 Removal & Installation . . 1-18 F L

Engine Assembly . . 1-21 Removal & Installation . . 1-21 Exhaust Manifold . . 1-61 Removal & Installation . . 1-61

F Front Crankshaft Seal . 1-62 Removal & Installation . 1-62 Fuel Filter . 1-90 Removal & Installation . 1-90 Fuel Injector . 1-91 Removal & Installation . 1-91 Fuel Pump . 1-91 Removal & Installation . 1-91 Fuel System Pressure . 1-89 Relieving . 1-89 Fuel System Service Precautions . 1-89 H Halfshaft . 1-98 Removal & Installation . 1-98 Heater Core . 1-27 Removal & Installation . 1-27 Hydraulic Clutch System . 1-98 Bleeding . 1-98 I Ignition Timing . 1-20 Adjustment . 1-20 Intake Manifold . 1-58 Removal & Installation . 1-58 L Lower Ball Joint . 1-107 Removal & Installation . 1-107 Lower Control Arm . 1-108 Control Arm Bushing Replacement . Removal & Installation . 0 Oil Pan . Removal & Installation . Oil Pump . Removal & Installation .

1-110 1-108 1-70 1-70 1-73 1-73

P Piston and Ring . 1-88 Positioning . 1-88 R Rack and Pinion Steering Gear. ...1-101 Removal & Installation . 1-101 Rear Main Seal . 1-77 Removal & Installation . 1-77 Rocker Arms/Shafts . 1-51 Removal & Installation . 1-51 S

Starter Motor . Removal & Installation . Strut . Removal & Installation . T

1-69 1-69 1-103 1-103

Timing Belt . Removal & Installation . Timing Chain . Removal & Installation . Transaxle Assembly . Removal & Installation . U

1-78 1-78 1-84 1-84 1-93 1-93

Upper Ball Joint . Removal & Installation . Upper Control . Control Arm Arm Bushing

1-107 1-107 1-108

Replacement . Removal & Installation . V Valve Lash . Adjustment . W

1-108 1-108

Water Pump . Removal & Installation . Wheel Bearings . Adjustment . Removal & Installation .

1-26 1-26 1-110 1-110 1-110

1-67 1-67

ACURA

1-2

3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

SPECIFICATION CHARTS ENGINE AND VEHICLE IDENTIFICATION Liters (cc)

Code

Engine Cu. In. 112 110

Cyl. 4

B18B1

1.8(1834)

B18C1

1.8(1797)

B18C5

1.8(1797)

110

4

K20A2

2.0(1999)

122

4

K20A3

2.0(1999)

122

C30A1

3.0 (2977)

183

6

J30A1

3.0 (2997)

6

C32A6

3.2 (3206)

183 196

C32B1

3.2 (3206)

J32A1

3.2 (3210)

C35A1

3.5 (3474)

PGM-FI: Programmed

211

4

6 6 6 6

Year

Y

2000

1

2001

Eng. Mfg.

DOHC

Honda

PGM-FI

DOHC DOHC

Honda Honda

PGM-FI

DOHC

Honda

3

PGM-FI

DOHC DOHC

Honda

4

PGM-FI

PGM-FI PGM-FI PGM-FI PGM-FI PGM-FI PGM-FI

SOHC SOHC DOHC

2 2002 2003 2004

Honda Honda Honda

SOHC

Honda Honda

SOHC

Honda

PGM-FI

Fuel Injection

DOHC:

Double Overhead Camshaft

SOHC:

Single Overhead Camshaft

©

196 196

4

Model Year Code©

Engine Type

Fuel Sys.

1 0th digit of the Vehicle Identification Number (VIN)

42356-inte-coi

GENERAL ENGINE SPECIFICATIONS Engine Displacement Year 2000

2001

Model Integra

Engine

Liters (cc) ID B18B1/© 1.8(1834) 1.8(1797)

B18C1/©

Integra GSR NSX

3.0 (2977)

NSX

3.2 (3206)

C30A1/NA1 C32B1/NA2

3.2TL

3.2 (3206)

J32A1/UA5

3.5RL

3.5 (3474)

C35A1/KA9

Integra

1.8 (1834)

B18B1/©

Integra GSR NSX

1.8(1797)

B18C1/©

3.0 (2977)

C30A1/NA1 C32B1/NA2

NSX

3.2 (3206) 3.2 (3206) 3.2(3210)

J32A1/UA5

3.5 (3474) 2.0(1999)

C35A1/KA9 K20A3

RSX® NSX

2.0(1999)

K20A2

3.5RL 2002

RSX

3.0 (2977)

J32A2/YA4

C30A1/NA1

NSX

3.2 (3206)

3.2TL

3.2 (3206)

C32B1/NA2 J32A1/UA5

3.2CL

3.2(3210)

J32A2/YA4

3.5RL

3.5 (3474) 2.0(1999)

C35A1/KA9

RSX RSX©

2.0(1999)

K20A2

2003-04

NSX

K20A3

NSX

3.0 (2977) 3.2 (3206)

C30A1/NA1 C32B1/NA2

3.2TL

3.2 (3206)

J32A1/UA5

3.2CL

3.2 (3210)

J32A2/YA4

3.5RL

3.5 (3474)

Type PGM-FI PGM-FI

3.2TL 3.2CL

Fuel System

C35A1/KA9

PGM-FI PGM-FI PGM-FI PGM-FI PGM-FI PGM-FI PGM-FI PGM-FI PGM-FI PGM-FI PGM-FI PGM-FI PGM-FI PGM-FI PGM-FI PGM-FI PGM-FI PGM-FI PGM-FI PGM-FI PGM-FI PGM-FI PGM-FI PGM-FI PGM-FI

PGM-FI: Programmed ©

Net Horsepower

Net Torque @ rpm

Com-

Bore x Stroke pression

0 rpm 140 @6300

(ft. lbs.) (in.) 3.19x3.50 127 0 5200

170 @7600 252 @6600

128 0 6200 210 0 5300

3.19x3.43 3.54x3.07

10.0:1 10.2:1

290@71 00

22405500

3.66x3.07

225 @5500

216 0 5000

3.50x3.39

10.2:1 9.8:1

21065200

224 0 2800 127 0 5200

3.54x3.58

140 @6300

3.19x3.50

9.6:1 9.2:1

170 @7600

128 0 6200

3.19x3.43

10.0:1

252 @6600

210 0 5300

3.54x3.07

290@71 00

22405500

3.66x3.07

10.2:1 10.2:1

50 0 3000

225 @5500

216 0 5000

3.50x3.39

26006100

23203500

9.8:1 10.5:1

710 3000 71 @3000

21005200

224 0 2800

160 @6500

14104000 142 0 6000

200 @7400

3.50x3.39 3.54x3.58 3.39x3.39 3.39x3.39

Ratio 9.2:1

Oil Pressure 0 rpm 50 0 3000 50 0 3000 50 0 3000 50 0 3000 7103000 50 0 3000 50 0 3000 50 0 3000 50 0 3000

9.6:1

50 0 3000 44 0 3000

9.8:1 11.0:1

44 0 3000

25206600

210 0 5300

3.54x3.07

10.2:1

50 0 3000

29007100

224 0 5500

3.66x3.07

10.2:1

22505500

216 0 5000

3.50x3.39

50 0 3000 71 @3000

26006100 210 0 5200

232 0 3500

3.50x3.39

9.8:1 10.5:1

71 @3000

22402800

3.54x3.58 3.39x3.39

9.6:1

200 0 7400 252 @6600

14104000 142 0 6000

50 0 3000 4403000 44 0 3000

21005300

3.54x3.07

290 0 7100 22505500

224 0 5500 216 0 5000

3.66x3.07

260@61 00

232 0 3500

3.50x3.39

21005200

22402800

3.54x3.58

160 0 6500

3.39x3.39

3.50x3.39

9.8:1 11.0:1 10.2:1

50 0 3000 10.2:1 9.8:1 10.5:1 9.6:1

50 0 3000 7103000 71 @3000 50 0 3000

Fuel Injection

DB7: 4 door DC4: 3 door

©

DB8: 4 door (Except Type R) DC2: 3 door

©

Type-S

42356-INTE-C02

1-3

ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX Gap

Pump ENGINE TUNE-UP Timing SPECIFICATIONS

Year

Engine ID/VIN

2000

1.8 (1834)

B18B1/©

1.8 (1797) 3.0 (2977)

C30A1/NA1

3.2 (3206)

C32B1/NA2

3.5 (3474)

C35A1/KA9

3.2(3210) 2001

B18C1/CD

1.8 (1834) 1.8(1797)

J32A1/UA5 B18B1/© B18C1/CD

(in)

(de9)

MT 16B

0.043 0.0390.051

AT 16B

(PSj) 40-47®

(rpm) Speed MT

0.047 0.043-

16B 15B

47-53®

700-800

700-800

—

15B

0.043 0.039-

750-850

10B

—

43-50®

16B

0.043 0.0390.051

3.2 (3206) 3.5 (3474) 3.2 (3206) 3.2 (3210)

C32B1/NA2

16B

40-47©

16B

48-55®

600-700

—

630-730

700-800 700-800

C35A1/KA9 J32A1/UA5 J32A2/YA4

0.047 0.0430.043 0.0390.043 0.039-

—

43-50® 15B 10B 10B —

2.0(1999)

K20A3

2.0(1999)

K20A2

3.0 (2977)

C30A1/NA1

3.2 (3206)

C32B1/NA2

3.5 (3474)

C35A1/KA9

0.043 0.0390.043 0.039-

J32A1/UA5

3.2 (3210)

J32A2/YA4

0.043 0.039-

750-850

—

630-730

41-48®

8B

8B

8B

8B

600-700

600-700

650-750

650-750

15B

750-850

15B

HYD 0.007 0.006-

0.008 0.007HYD

0.006-

0.0070.013

0.005

0.008

0.008-

0.011-

0.007 0.003-

0.008 0.0060.008

0.007 0.0060.007 0.006HYD 0.006-

0.0070.008 0.007HYD 0.007-

0.009

0.013

0.009

0.013

0.0080.005 0.008-

0.0110.008 0.0110.008 0.0060.008

0.007 0.006-

—

600-700

0.007 0.006HYD

—

630-730

—

700-800

43-50©

0.0070.008 0.007HYD

0.006-

41-48©

10B

0.007-

750-850

—

—

0.0060.008

0.007 0.006-

730-830

47-53© 15B

0.008

0.0030.007

47-53® 15B

0.007 0.003-

700-800

47-52©

10B 0.043 0.039-

730-830

600-700

—

0.043 0.0393.2 (3206)

—

47-52©

0.047 0.0430.04730.04

700-800

—

41-48© —

0.043 0.0392002

47-53®

—

Ex

0.005

0.009

750-850

15B 15B

750-850

—

16B 15B

730-830

41-48©

—

0.047 0.043-

In.

0.008

47-53® 15B

0.047 0.043-

C30A1/NA1

AT

700-800

47-53® 3.0 (2977)

Valve Clearance

48-55® 16B 15B

0.043 0.039-

Idle

Fuel

Ignition

Spark Plug

Engine Displacement Liters (cc)

0.009

41-48®

0.009 0.008-

0.0070.013

0.013 0.011-

42356-INTE-C03

0.008-

0.011-

ACURA

1-4

3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX Pump Gap ENGINE TUNE-UP Timing SPECIFICATIONS

Year

Engine ID/VIN

2.0 (1999)

K20A3

2003-04

2.0(1999) 3.0 (2977)

K20A2 C30A1/NA1

0.043 0.039-

C32B1/NA2

3.5 (3474)

C35A1/KA9

3.2(3210)

J32A1/UA5 J32A2/YA4

AT

47-52©

(rpm) Speed MT 600-700

0.043 0.039-

3.2 (3206)

3.2 (3206)

MT

Valve

Fuel

Ignition (deg.)

Spark Plug

Engine Displacement Liters (cc)

Idle

0.047 0.0430.047 0.0430.043 0.0390.043 0.039-

Clearance In. Ex

AT 600-700

8B 8B 15B

) (in'— —

—

8B 8B 15B

47-52© (Psi)

650-750

650-750

750-850

730-830

47-53©

15B

47-53©

—

15B

43-50©

—

10B 10B

41-48©

750-850

0.005

0.008

0.007 0.003-

0.008

0.007 0.006-

0.008 0.007-

0.007 0.006-

0.008

600-700 HYD 0.006-

—

630-730

0.009

HYD 0.0070.0070.013

41-48©

—

700-800

0.043 0.039-

0.009 0.008-

NOTE: The Vehicle Emission Control Information label reflects specification changes during production and must be used if they differ from this chart.

0.013 0.011-

0.008-

B: Before Top Dead Center

0.011-

HYD: Hydraulic ©

0.006-

DB7: 4 door DC4: 3 door

© At idle, pressure regulator vacuum hose disconnected ®

DB8: 4 door (Except Type R) DC2: 3 door 42356-INTE-C04

FRONT

OF CAR 79233G04

1.8L engines Firing order: 1-3-4-2 Distributor rotation: Clockwise

ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

3.0L (J30A1) engine

3.0L (C30A1) and 3.2L (J32A1, C32A6, C32B1) engines

Firing order: 1 —4— 2— 5— 3— 6 Distributor rotation: Counterclockwise

Firing order: 1-4-2-5-3-6 Distributorless ignition system (one coil per cylinder)

Front of the Vehicle

79233G33

3.5L engine Firing order: 1-2-3-4-5-6 Distributorless ignition system (one coil per cylinder)

1-5

1-6

ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

79234G03

Accessory drive belt routing— 3. OL engine except NSX

©

DB7: 4 door DC4: 3 door

©

DB8: 4 door (Except Type R) DC2: 3 door

©

Automatic transmission: 5.0

©

Type-S

© Automatic transmission: 5.3 Manual Transmission: 5.4

Manual transmission: 4.6 42356-INTE-C05

1-8

ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

VALVE SPECIFICATIONS _

_ Engine Displacement Engine Year 2000

Liters (cc) 1.8 (1834)

ID/VIN

B18B1/©

Seat Angle 45 (deg.)

Spring Stem-to-Guide Stem Diameter Clearance Face Spring Test Installed Angle Pressure Height _ (inj_ _ (in.) 45 Exhaust Intake Exhaust Intake (in.) in.) ® (lbs. (deg.) NA

45 1.8 (1797)

45

B18C1/© 45

3.0 (2977)

45 NA

C30A1/NA1 45

3.2 (3206)

NA

3.2 (3210)

J32A1/UA5

45 45

45 45

1.8 (1834)

B18B1/©

45

NA NA

NA

NA NA

45 NA

1.8(1797)

45

B18C1AD

NA

45 3.0 (2977)

C30A1/NA1

45 3.2 (3206)

NA

45

NA NA

45 NA

C32B1/NA2

NA

C35A1/KA9

NA

45

NA

45 3.2 (3210)

NA

45 3.2(3210) 2.0(1999)

NA

45

J32A1/UA5 45

2002

NA

45

J32A2/YA4

45

NA NA

K20A3

NA

45 2.0(1999)

K20A4

45 3.0 (2977)

NA

45 45

3.2 (3206)

NA NA

C30A1/NA1 45 C32B1/NA2

NA NA

45

NA

45 3.5 (3474)

C35A1/KA9

NA

45

NA

45 3.2(3210) 3.2(3210)

45

J32A2/YA4 J32A1/UA5

45

45

0.2594

0.2583

0.0010-

0.00200.0031

0.25910.2159

0.2150 0.2579-

0.00200.0030

0.21560.2159

0.00200.0030

0.21560.2159

0.2150 0.2146-

0.0020

0.00200.0030

0.21560.2161

0.2150 0.2146-

0.0010-

0.0020-

0.0018 0.0008-

0.0031

0.21570.2163

0.2150 0.2146-

0.0022 0.0010-

0.00100.0029

NA NA

NA NA

0.21460.2150

0.0020

0.00220.0030

0.21590.2594

0.21460.2583

0.00100.0022

0.00200.0031

0.25910.2159

0.2150 0.2579-

0.00100.0020 0.0010-

0.00200.0030 0.0020-

0.21560.2159

0.2150 0.2146-

0.21560.2159

0.2150 0.2146-

0.00200.0030

0.21560.2161

0.2150 0.2146-

0.00200.0031

0.21570.2163

0.0018

0.00220.0031

0.21590.2163

0.2150 0.2146-

0.00080.0022

0.00220.0031

0.21590.2159

0.21460.2150

0.0012-

0.00220.0031

0.21560.2159

0.21460.2150

0.00220.0030

0.21560.2159

0.21460.2150

0.00200.0030

0.21560.2159

0.2150 0.2146-

0.00100.0020

0.00200.0030

0.21560.2161

0.21460.2150

0.00100.0018

0.0020-

0.21570.2163

0.0031 0.00220.0031

0.21590.2163

0.0029

45 3.5 (3474)

0.0030

0.0010-

NA

45 2001

0.0020

0.0020

C32B1/NA2 C35A1/KA9

NA

45 NA

3.5 (3474)

NA NA

0.00100.0020 0.00100.0018 0.0008-

0.0022 0.00120.0020 0.00100.0029

0.00080.0018 0.0008-

0.0030

0.0022-

0.2159-

0.2150 0.2146-

0.21460.2150 0.21460.2150 42356-INTE-C06 0.2146-

1-9

3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

VALVE SPECIFICATIONS Spring

Year

Engine Displacement Liters (cc)

Engine ID/VIN

2.0(1999)

K20A3

2.0 (1999)

K20A4

2003-04

3.0 (2977)

Face

Seat Angle

Angle

Spring Test Pressure

Installed Height

(deg.) 45

(deg.)

(lbs.NA @ in.)

NA (in.)

45

45

45

45

NA

C30A1/NA1

45

C32B1/NA2

Exhaust

NA NA

0.00220.0031

0.21560.2159

0.21460.2150

NA

0.00120.0020

0.00220.0030

0.21560.2159

0.21460.2150

NA

0.00100.0029

0.00200.0030

0.21560.2159

0.21460.2150

0.00100.0020

0.00200.0030

0.21560.2161

0.21460.2150

0.00100.0018

0.00200.0031

0.21570.2163

0.2150 0.2146-

0.00080.0018

0.00220.0031

0.21590.2163

0.2150 0.2146-

0.0022-

0.2159-

0.2146-

45 NA

NA

45

NA

NA

0.0008NA: Not Available

(in.)

0.2150

NA

J32A2/YA4 J32A1/UA5

Intake 0.2159

45 3.2 (3210)

Exhaust 0.0031

NA

45

C35A1/KA9 45

3.2 (3210)

iinJ

0.0022 0.00120.0022

NA 45

3.5 (3474)

Intake

Stem Diameter

45

45 3.2 (3206)

Stem-to-Guide Clearance

©DB7: 4 door DC4: 3 door

(D DB8: 4 door (Except Type R) DC2: 3 door 42356-INTE-C07

1I i In U

ACURA

3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

TORQUE SPECIFICATIONS All readings in ft. lbs. Engine Year

Displacement Liters (cc)

Engine IDA/IN

2000

1.8(1834)

B18B1/©

1.8(1797)

B18C1/©

3.2 (3206)

C30A1/NA1 C32B1/NA2

3.5 (3474)

C35A1/KA9

3.0 (2977)

3.2 (3210) 2001

1.8 (1834) 1.8(1797)

2002

©

56

®

© 29

181

56

®

33

181

®

181 130 130

©

J32A1/UA5 B18B1/©

©

B18C1/©

© 56

© 56

©

©

©

©

56

®

3.5 (3474) 3.2(3210)

C35A1/KA9

56

®

33

J32A2/YA4

©

©

®

©

©

22

181

C30A1/NA1

®

© 29

181

®

33

181

©

®

3.2 (3206)

C32B1/NA2

3.5 (3474)

C35A1/KA9

2.0(1999)

©

56 56 ©

J32A2/YA4 J32A1/UA5

©

©

® 14

56 ©

©

22 © 29

©

K20A3 K20A2

©

3.0 (2977)

C30A1/NA1

©

3.2 (3206)

®

3.5 (3474)

C32B1/NA2 C35A1/KA9

56

®

33

3.2(3210)

J32A2/YA4

©

©

®

©

®

3.2(3210)

©

J32A1/UA5

DB7: 4 door

©

14 ft. lbs. plus 1 1 6 degrees

DC4: 3 door

©

Manual transmission: 76 ft. lbs.

©Step

Step 2: 63 ft. lbs. ©Step

Automatic transmission: 54 ft. lbs.

1:22 ft. lbs.

Step 2: 23 ft. lbs.

DC2: 3 door

Step 3: Side (10mm) 36 ft. lbs.

©Step

1:22 ft. lbs.

1: 14 ft. lbs.

13

80

13

80

22 23 22 23

16

33 25

16

33

80

13

80 80

13 ® 13

80 80 80 80

13 13

80 80 80

33

©

80

22

13

80

22 23

13

80

© 54 90 © 76

16 16 16

23

54 54

80

13 33 25

54

80

13

22 23

16 16 16

©Step

13

22 23

181

181 181

80

16

80 80

1: 14 ft. lbs.

Step 2: Rotate 90 degrees ©Step

1:29 ft. lbs.

Step 2: Rotate 90 degrees Step 3: Rotate an additional 90 degrees Step 4 (new bolts only): additional 90 degrees ©Step

1:22 ft. lbs.

Step 2: Rotate 56 degrees Manual trans.: 54 ft. lbs.

1:29 ft. lbs.

Step 2: 51 ft. lbs.

Cap Nos. 2, 3 and 4: 49 ft. lbs.

Step 2: 33 ft. lbs.

80 80 80

80

Auto trans.: 76 ft. lbs.

Step 2: Cap Nos. 1,5: 56 ft. lbs.

©Step

13

16

® ©Step

23

181 181

® Step 1 : Outer (9mm) 29 ft. lbs. Step 2: Inner (1 1mm) 56 ft. lbs.

13 13

54

Step 2: Side bolts 36 ft. lbs.

DB8: 4 door (Except Type R)

22 23 25 23 22

16 16

54

® Step 1: Cap bolts 48 ft. lbs.

1: 14 ft. lbs.

16 16 16 17

16

181

181

80

13

16 16 16

54 © 54 90 76 ©

181

80

13 25

16

181 181

13

80

© 76

181 181

56

Nut

16

16 17 16

54 181 181

23

17

76 54 © 54

181

K20A2

2.0(1999)

17

© 76 76 ©

181

©

©

Manifold Spark Intake Exhaust Plugs 13 23

181

®

J32A1/UA5 K20A3

Bolts Flywheel

130

® 14

3.2 (3210) 2.0(1999)

2.0(1999)

©

© 56

©

C30A1/NA1 C32B1/NA2

3.2 (3210)

©

©

3.0 (2977) 3.2 (3206)

3.2 (3210)

©

©

© 29

3.0 (2977)

2003-04

Cylinder Main Rod Crankshaft Head Bearing Bearing Damper 56 Bolts Bolts Bolts Bolts 130

Step 3: 72.3 ft. lbs. @

Step 1 : Cap bolts 56 ft. lbs.

®

NGK type IFRG-11KS

& Denso type SK22PRM11S:

18 ft. lbs.

All others: 13 ft. lbs.

Step 2: Side bolts 36 ft. lbs.

Cap bolts: 29 ft. lbs. Cap bridge bolts: 48 ft. lbs. 42356- INTE-C08

1-11 ACURA

3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

CRANKSHAFT _

AND CONNECTING ROD SPECIFICATIONS

All measurements

Engine _ Displacement Engine Main Brg.

are given

in inches. _

Crankshaft _ Main Brg. Oil Shaft Thrust

Connecting Rod _ Journal Oil Side

Year

Liters (cc)

2000

1.8(1834)

B18B1/©

©

©

0.0040-0.0180

4

1.7707-1.7717

0.0008-0.0015

0.0060-0.0160

1.8 (1797)

B18C1/©

©

©

0.0040-0.0180

4

1.7707-1.7717

0.0013-0.0020

0.0060-0.0160 0.0060-0.0120 0.0060-0.0120

2001

2002

2003-04

©

Clearance

End-play

on No.

Diameter

Clearance

Clearance

0.0009-0.0019

0.0040-0.0110

3

2.0463-2.0472

0.0009-0.0019

0.0040-0.0110

3

2.0463-2.0472

0.0016-0.0025

2.8337-2.8346

0.0008-0.0017

0.0040-0.0140

3

2.1644-2.1654

0.0008-0.0017

0.0060-0.0140

2.6762-2.6772

0.0008-0.0017

0.0040-0.0110

3

2.1248-2.1257

0.0009-0.0018

0.0060-0.0120

B18B1/©

©

®

0.0040-0.0180

4

1.7707-1.7717

0.0008-0.0015

0.0060-0.0160

1.8 (1797)

B18C1/©

©

©

0.0040-0.0180

4

1.7707-1.7717

0.0013-0.0020

0.0060-0.0160

3.0 (2977)

C30A1/NA1

2.5187-2.5197

0.0009-0.0019

0.0040-0.0110

3

2.0463-2.0472

0.0016-0.0025

0.0060-0.0120

3.2 (3206)

C32B1/NA2

2.5187-2.5197

0.0009-0.0019

0.0040-0.0110

3

2.0463-2.0472

0.0016-0.0025

0.0060-0.0120

3.2 (3210)

J32A1/UA5

2.8337-2.8346

0.0008-0.0017

0.0040-0.0140

3

2.1644-2.1654

0.0008-0.0017

0.0060-0.0140

3.2 (3210)

J32A2/YA4

2.8337-2.8346

0.0008-0.0017

0.0040-0.0140

3

2.1644-2.1654

0.0008-0.0017

0.0060-0.0140

3.5 (3474)

C35A1/KA9

2.6762-2.6772

0.0008-0.0017

0.0040-0.0110

3

2.1248-2.1257

0.0009-0.0018

0.0060-0.0120

2.0(1999)

K20A3

2.1648-2.1657

4

1.7707-1.7717

0.0008-0.0019

0.0060-0.0160

K20A2

2.1646-2.1655

© ©

0.0040-0.0140

2.0(1999)

0.0040-0.0140

4

1.8888-1.8898

0.0013-0.0024

0.0060-0.0160

3.0 (2977)

C30A1/NA1

2.5187-2.5197

0.0009-0.0019

0.0040-0.0110

3

2.0463-2.0472

0.0016-0.0025

0.0060-0.0120

3.2 (3206)

C32B1/NA2

2.5187-2.5197

0.0009-0.0019

0.0040-0.0110

3

2.0463-2.0472

0.0016-0.0025

0.0060-0.0120

3.2 (3210)

J32A1/UA5

2.8337-2.8346

0.0008-0.0017

0.0040-0.0140

3

2.1644-2.1654

0.0008-0.0017

0.0060-0.0140

3.2 (3210)

J32A2/YA4

2.8337-2.8346

0.0008-0.0017

0.0040-0.0140

3

2.1644-2.1654

0.0008-0.0017

0.0060-0.0140

3.5 (3474)

C35A1/KA9

2.6762-2.6772

0.0008-0.0017

0.0040-0.0110

3

2.1248-2.1257

0.0009-0.0018

0.0060-0.0120

2.0(1999)

K20A3

2.1648-2.1657

2.0(1999)

K20A2

3.0 (2977)

3.0 (2977)

C30A1/NA1

2.5187-2.5197

3.2 (3206)

C32B1/NA2

2.5187-2.5197

3.2(3210)

J32A1/UA5

3.5 (3474)

C35A1/KA9

1.8 (1834)

0.0040-0.0140

4

0.0060-0.0160

0.0040-0.0140

4

1.7707-1.7717 1.8888-1.8898

0.0008-0.0019

2.1646-2.1655

© ©

0.0013-0.0024

0.0060-0.0160

C30A1/NA1

2.5187-2.5197

0.0009-0.0019

0.0040-0.0110

3

2.0463-2.0472

©©01 6-0.0025

0.0060-0.0120

3.2 (3206)

C32B1/NA2

2.5187-2.5197

0.0009-0.0019

0.0040-0.0110

3

2.0463-2.0472

0.0016-0.0025

0.0060-0.0120

3.2(3210)

J32A1/UA5

2.8337-2.8346

0.0008-0.0017

0.0040-0.0140

3

2.1644-2.1654

0.0008-0.0017

0.0060-0.0140

3.2(3210)

J32A2/YA4

2.8337-2.8346

0.0008-0.0017

0.0040-0.0140

3

2.1644-2.1654

0.0008-0.0017

0.0060-0.0140

3.5 (3474)

C35A1/KA9

2.6762-2.6772

0.0008-0.0017

0.0040-0.0110

3

2.1248-2.1257

0.0009-0.0018

0.0060-0.0120

DC4: 3 door 1,2, 4 and 5: 2.1644-2.1654

No. 3: 2.1642-2.1651 ©

Journal Dia.

0.0016-0.0025

DB7: 4 door

©Nos.

ID/VIN

©

DB8: 4 door (Except Type R) DC2: 3 door

©Nos.

1 , 2, 4 and 5:2.1644-2.1654

No. 3: 2.1643-2.1653

©Nos.

1, 2, 4 and 5: 0.0009-0.0017

No. 3: 0.0012-0.0019 © Nos. 1 , 2, 4 and 5: 0.0007-0.001 6 No. 3: 0.0010-0.0019

Nos. 1 ,2,4, and 5: 0.0009-0.001 7 No. 3: 0.0012-0.0019 42356-INTE-C09

ACURA

1-12

3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

PISTON AND RING SPECIFICATIONS _

All measurements

1.8(1797)

B18C1/©

0.0004-0.0016

3.0 (2997)

J30A1/YA2

0.0006-0.00160

0.0080-0.0140 0.0080-0.0140

Ring Side Clearance _ Ring Gap _ Oil Bottom Top Oil Bottom Compression Control Compression Compression Control NA 0.0018-0.0028 0.0160-0.0220 0.0018-0.0026 0.0080-0.0200 NA 0.0160-0.0220 0.0018-0.0028 0.0080-0.0200 0.0016-0.0026 NA 0.0160-0.0220 0.0014-0.0024 0.0012-0.0022

3.2 (3206)

C32B1/NA2

0.0002-0.0012

0.0080-0.0120

0.0140-0.0200

0.0080-0.0280

0.0014-0.0026

0.0012-0.0024

3.2(3210)

J32A1/UA5

0.0006-0.00160

0.0160-0.0220

0.0012-0.0022

C35A1/KA

0.0010-0.0020

0.0080-0.0280 ®

0.0014-0.0024

3.5 (3474)

0.0080-0.0140 0.0100-0.0160

0.0022-0.0031

1.8(1834)

B18B1/©

0.0004-0.0016

0.0080-0.0140

0.0160-0.0220

0.0018-0.0028

1.8(1797)

B18C1/©

0.0004-0.0016

0.0080-0.0140

0.0018-0.0028

0.0016-0.0026

3.0 (2977)

C30A1/NA1

0.0002-0.0014

0.0100-0.0160

0.0160-0.0220 0.0140-0.0200

0.0080-0.0200 0.0080-0.0200

0.0012-0.0022 0.0018-0.0026

0.0080-0.0280

0.0012-0.0022

0.0012-0.0022

3.0 (2997)

J30A1/YA2

0.0006-0.00160

0.0080-0.0140

0.0160-0.0220

0.0080-0.0280

0.0014-0.0024

0.0012-0.0022

3.2 (3206)

C32B1/NA2

0.0080-0.0120

0.0140-0.0200

0.0080-0.0280

J32A1/UA5

0.0080-0.0140

0.0160-0.0220

3.5 (3474)

0.0010-0.0020

0.0100-0.0160

0.0160-0.0220

1.8(1834)

C35A1/KA B18B1/©

0.0080-0.0280 ®

0.0014-0.0026 0.0014-0.0024

0.0012-0.0024

3.2 (3210)

0.0002-0.0012 0.0006-0.00160 0.0004-0.0016

0.0080-0.0140

0.0160-0.0220

0.0080-0.0200

0.0022-0.0031 0.0018-0.0028

1.8(1797)

B18C1/©

0.0004-0.0016

0.0080-0.0140

0.0160-0.0220

0.0080-0.0200

0.0018-0.0028

0.0016-0.0026

3.0 (2977)

C30A1/NA1

0.0002-0.0014

0.0100-0.0160

0.0140-0.0200

0.0080-0.0280

0.0012-0.0022

3.0 (2997)

J30A1/YA2

0.0006-0.00160

0.0160-0.0220

3.2 (3206)

C32B1/NA2

0.0140-0.0200

0.0080-0.0280 0.0080-0.0280

0.0014-0.0026

0.0012-0.0024

3.2(3210)

J32A1/UA5

0.0002-0.0012 0.0006-0.00160

0.0080-0.0140 0.0080-0.0120

0.0012-0.0022 0.0014-0.0024

0.0080-0.0140

0.0160-0.0220

0.0080-0.0280

0.0014-0.0024

3.2(3210)

J32A2/YA4

0.0006-0.00160

0.0080-0.0140

0.0160-0.0220

0.0014-0.0024

0.0012-0.0022 0.0012-0.0022

3.5 (3474)

C35A1/KA

0.0010-0.0020

0.0100-0.0160

0.0160-0.0220

0.0080-0.0280 ®

0.0022-0.0031

0.0012-0.0022

2.0(1999)

K20A3 K20A2

0.0008-0.0016

0.0080-0.0014

0.0160-0.0220

0.0100-0.0260

0.0014-0.0024

0.0012-0.0022

0.0008-0.0016

0.0080-0.0140

0.0080-0.0280

0.0002-0.0014

0.0100-0.0160

3.0 (2997)

0.0006-0.00160

0.0080-0.0140

0.0160-0.0220

0.0080-0.0280 0.0080-0.0280

0.0016-0.0026 0.0012-0.0022

0.0018-0.0028

C30A1/NA1 J30A1/YA2

0.0200-0.0260 0.0140-0.0200

C32B1/NA2

0.0002-0.0012

0.0080-0.0120

0.0140-0.0200

0.0080-0.0280

0.0014-0.0024 0.0014-0.0026

0.0012-0.0022

3.2 (3206) 3.2(3210)

J32A1/UA5

0.0006-0.00160

0.0080-0.0140

0.0014-0.0024

J32A2/YA4

0.0006-0.00160

0.0080-0.0140

0.0160-0.0220 0.0160-0.0220

0.0080-0.0280

3.2(3210)

0.0014-0.0024

0.0012-0.0022

3.5 (3474)

C35A1/KA

0.0010-0.0020

0.0100-0.0160

0.0160-0.0220

0.0080-0.0280 ®

0.0022-0.0031

2.0(1999)

K20A3

0.0008-0.0016

0.0160-0.0220

0.0100-0.0260

0.0014-0.0024

2.0(1999)

K20A2

0.0008-0.0016

0.0080-0.0014 0.0080-0.0140

0.0012-0.0022 0.0012-0.0022

0.0200-0.0260

0.0080-0.0280

0.0016-0.0026

0.0018-0.0028

3.0 (2977)

C30A1/NA1

0.0140-0.0200

0.0080-0.0280

0.0012-0.0022

J30A1/YA2

0.0002-0.0014 0.0006-0.00160

0.0100-0.0160

3.0 (2997)

0.0080-0.0140

0.0160-0.0220

C32B1/NA2

0.0002-0.0012

0.0080-0.0120

0.0140-0.0200

0.0014-0.0024 0.0014-0.0026

0.0012-0.0022 0.0012-0.0022

3.2 (3206)

0.0080-0.0280 0.0080-0.0280

3.2(3210)

J32A1/UA5

0.0006-0.00160

0.0160-0.0220

0.0080-0.0280

0.0014-0.0024

3.2(3210)

J32A2/YA4

0.0006-0.00160

0.0080-0.0140 0.0080-0.0140

0.0160-0.0220

3.5 (3474)

C35A1/KA

0.0010-0.0020

0.0100-0.0160

0.0160-0.0220

0.0080-0.0280 ®

0.0014-0.0024 0.0022-0.0031

_ Engine Top Piston Displacement Engine Liters (cc) ID/VIN Clearance Compression Year 1999 B18B1/© 1.8 (1834) 0.0004-0.0016 0.0080-0.0140

2000

2001

2002

2.0(1999) 3.0 (2977)

2003-04

are given in inches _

0.0080-0.0280

0.0160-0.0220

0.0012-0.0022 0.0012-0.0022 0.0018-0.0026

0.0012-0.0022

0.0012-0.0022 0.0012-0.0024 0.0012-0.0022

0.0012-0.0024 0.0012-0.0022 0.0012-0.0022 0.0012-0.0022

NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA NA

NA; Not Applicable

©

DB7: 4 door DC4: 3 door

©

DB8: 4 door DC2: 3 door (Except Type R)

®

RIKEN: 0.0080-0.0280 inches TEIKOKU:

0.0080-0.0200 inches 42356-INTE-C1 0

1-13 3.2TL • 3.2CL • 3.5RL • INTEGRA

• RSXACURA • NSX Steering

WHEEL ALIGNMENT Camber

Caster Range Year 2000

Model 3.2 TL

F

R 3.5 RL

F

R Integra ©

F

R Integra ©

F

R NSX®

F

R NSX©

F

R 2001

3.2 TL

F

R 3.2 CL

F

R 3.5 RL Integra ©

NSX®

R NSX©

F R

2002

3.2 TL

F R

3.2 CL 3.5 RL

F

RSX©

—

0.25 —

+8.23 —

1.00 —

+2.80 — +2.80

1.00 —

—

1.00 — 0.25 — 0.25 — 1.00 — 1.00

— +2.81 — +1.16 —

+1.16 — +8.00 — +8.23 — +2.80 — +2.80

—

—

F

+2.81

—

—

F

1.00

R

—

+1.16 —

1.00 —

+1.16 —

0.25 —

+8.00 —

0.25 —

+8.23 —

F F R

NSX©

0.25 —

— +8.00

1.00

R NSX®

1.00 —

R R RSX®

+1.16 — +1.16

1.00

F

—

1.00 —

F

R

+2.80 +2.81 —

R

F

(Deg)

1.00 —

1.00 —

F

R Integra ©

(+/-Deg.) 1.00 —

Preferred Setting

F R

Axis (Deg) Inclination

Preferred -0.50 Setting (Deg.) -0.50 0

Toe-in 0+/-0.06

0.50 1.00 1.00

0

0.06+/- 0.06 0 +/- 0.06

1.00 1.00 1.00 1.00

+0.16 -0.33 +0.75 -1.50 +0.16 -2.00 +0.50

Range (+/-Deg.) 1.00

0.17 0.50

-0.50 +0.50

(in)

0.06 +/- 0.06 0 +/- 0.06 0.16+/- 0.16 0 +/- 0.06 0.06 +/0.14+/0.18+/0.14+/-

0.06 0.04 0.06 0.04

0.17 0.50 1.00

-0.50 0

0.18+/- 0.06 0+/-0.06

0.50 1.00 1.00

-0.50 0

0.06 +/- 0.06 0+/-0.06

1.00 1.00 1.00 1.00 1.00 1.00 0.17 0.50 0.17 0.50 1.00 0.50 1.00 1.00 1.00

—

0

0.06 +/- 0.06 0+/-0.06 0.06 +/- 0.06 0+/-0.16

—

+0.16 -0.33

0.16+/- 0.16 0+/-0.06

—

+0.75 -1.50 +0.16 +0.50 -2.00

-0.5 +0.50 0 -0.50 0 -0.50

0.17 0.50 0.17 0.50

0.06 +/- 0.06 0.14+/- 0.04 0.18+/- 0.06 0.14+/- 0.04 0.18+/- 0.06 0 +/- 0.06

0

0.06 +/- 0.06 0+/-0.06

0

0.06+/- 0.06 0+/-0.06

1.00 1.00 1.00 1.00 1.00

— — — — — — — — — — — — — — —

+0.16 -0.33 -1.50 +0.75 +0.16

-2.00 +0.50

+0.50

0.06+/- 0.06 0+/-0.16 0.16+/- 0.16 0+/-0.06 0.06 +/0.14+/0.18+/0.14+/0.18+/-

0.06 0.04 0.06 0.04 0.06

— —

— — — — — — — — — — — —

— — — — — — — — 42356-INTE-C11

1-14

ACURA 3.2TL • 3.2GL • 3.5RL • INTEGRA • RSX • NSX Steering

WHEEL ALIGNMENT Camber

Caster Preferred Setting

Range Year

(+/-Deg.)

Model 3.2 TL

2003-04

F R

3.2 CL 3.5 RL RSX®

F

1.00

R

_

F

1.00

NSX®

F

NSX©

F

0.25

R ©

—

(Deg.) -0.50 0

—

+1.16

0

1.00 1.00

+0.16 -0.33 +0.75 -1.50 +0.16 +0.50 -2.00

1.00 1.00

—

+1.16 1.00

—

+8.00 —

—

+8.23 —

0.25 —

0.17 0.50 +0.50

0.17

Toe-in 0 +/- 0.06

-0.50 0

0.50 1.00 1.00 1.00

+2.81

1.00

_

F

+2.80

—

R R

—

1.00

F

(+/-Deg.)

+2.80

—

_

Range 1.00

1.00

R

R RSX©

(Deg)

Setting -0.50 Preferred

(»"•) _

0.50

Axis Inclination (Deg-) — —

0.06 +/- 0.06 0 +/- 0.06

—

0.06 +/- 0.06 0 +/- 0.06

—

0.06 +/- 0.06 0+/-0.16

—

0.16+/- 0.16 0 +/- 0.06

—

0.06 +/- 0.06

—

0.14+/- 0.04 0.18+/- 0.06

—

0.14+/- 0.04 0.18+/- 0.06

—

— — — —

—

Except Type R

©TypeR ©Except

TypeS

©TypeS 42356-INTE-C12

TIRE, WHEEL AND BALL JOINT SPECIFICATIONS Tire Pressures

OEM Tires Year

2000

2001

2002

2003-04

Inteqra

P195/55VR15

None

3.2TL

P205/60VR16

None

3.5RL

None

NSX

P225/55/R16 ©

Integra

PI 95/55VR1 5

3.2TL

P205/60VR16

3.2CL

P205/60VR16

3.5RL NSX

P225/55/R16 ©

RSX

P205/55R16

None

3.2TL 3.2CL

P205/60VR16

3.5RL NSX

P225/55/R1 6 ©

None None None

RSX

P205/55R16

3.2TL

P205/60VR16

3 2CL 3.5RL

P205/60VR16 P225/55/R16 ©

NSX

P205/60VR16

None None None None None None

None None None

29 32

29 32 32

29

29 32 29

29 30 29 29 29

32 32 32 29 29

32 32 32 29 29

None

32

None 32

OEM: Original Equipment Manufacturer PSI: Pounds Per Square Inch STD: Standard OPT: Optional NS: Not Specified by manufacturer ©

Front tires: P215/40R1 7 Rear tires: P255/40R17

30 29 29 29

29 30 29 29

None

Wheel 6-JJ 6-JJ

29 30

Ball Joint NS

6-JJ 6-JJ 6-JJ

NS NS NS

6-JJ 6-JJ 6-JJ

NS NS

6-JJ 6-JJ

NS

6-JJ

NS NS NS

NS

6-JJ 6-JJ 6-JJ

NS NS NS

6-JJ 6-JJ NS 6-JJ 6-JJ 6-JJ

NS NS

29

NS

29

NS

ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

1 _1 C ■

■ wl

BRAKE SPECIFICATIONS All measurements

in inches unless noted _ Brake Drum Diameter

Minimum

_ Brake Disc _ Original Max. Maximum Lining Original Minimum Maximum Inside Wear Machine Thickness Year _

Model _

2000

3.5RL 3.2TL

Thickness

F

0.910

R

0.350

F

1.100

R Integra

F R

NSX

F R

2001

3.5RL 3.2TL 3.2CL

NSX 2002

3.5RL

3.2CL RSX

RSX Type-S NSX 3.5RL

2003-04

RSX

RSX Type-S NSX

0.004

0.350 0.830 0.350 1.100

0.310 1.020 0.750

0.004 0.004 0.004 0.004 0.004 0.004

—

—

—

Rear — 0.06

28

36 17

—

80

36

—

—

—

—

—

0.06 — 0.06

© —

41 —

© —

6.693© —

© —

—

—

—

—

0.06

—

24

—

—

—

0.06

—

80

—

—

—

—

80

36 24 36

—

—

—

0.06

0.06 —

80

36

—

—

—

—

0.06

28

17

—

—

—

0.06 —

—

80

36

© —

41

17

© —

41 — 80

0.004

R

0.350 1.100

0.310 1.020

0.004 0.004

© —

6.693© —

© —

0.004 0.004

© —

6.693© —

© —

—

—

—

0.06 —

—

—

—

0.06

0.06 —

—

—

—

—

0.06

—

—

—

—

—

—

0.06 —

— 0.06

—

—

—

6.693© —

© —

0.350

0.310

F

0.830

0.750

R

0.310

F

0.350 1.100

R

0.830

1.020 0.750

F

0.910

0.830

0.350

0.300

0.004 0.004 0.004 0.004 0.004

F

1.100

1.020

R

0.350

0.310

0.004 0.004

R

1.100 0.350

1.020

© —

0.310

0.004

F

0.830

0.750 0.310

0.004

© —

6.693® —

© —

—

—

—

—

—

—

—

—

—

F

R

0.350

F

0.980 0.350

R F

1.100

R

0.830

F

0.910 0.350 1.100

F

0.350

F

1.100

R

0.350

0.910 0.310 1.020 0.750 0.830 0.300 1.020 0.310 1.020

F

0.830

0.310 0.750

R

0.350

0.310

F

0.910 0.310

F

0.980 0.350 1.100

R

0.830

0.750

R

1.020

0.004

0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004 0.004

80

—

1.020

F

(ft. lbs.) (ft. lbs.)

0.06 —

1.100

0.004

Bracket Mounting Bolts Bolts

Front

F

R 3.2CL

1.020

Diameter Limit Diameter

0.350

R 3.2TL

0.300

0.004 0.004

R

R 3.2TL

Runout

0.830 0.300

R Integra

0.830

0.310 0.750

0.830 0.910

F

Thickness

Brake Caliper

0.06 —

0.06 —

36 17

— 80 28

36 24 36 24

80

36

80

17

—

36 41

17 36

© —

0.06 —

80 80 41 —

0.06

—

—

—

—

0.06 —

0.06

—

—

—

0.06

—

80

—

—

—

—

0.06

80

24 24 36 24 36

—

—

—

—

80

36

—

—

—

0.06 —

0.06

28

—

—

—

0.06

—

80

© —

6.693© —

© —

—

© —

41

© —

6.693© —

© —

—

—

—

—

—

—

0.06 — 0.06

—

—

—

—

—

—

—

—

—

—

0.06 —

0.06 —

© —

80

17 24

17 36 36 17 24

© —

—

0.06 —

— 41 —

24

—

24

80

24 36

0.06 —

0.06 — 0.06

80

36

NA: Not Available F: Front R: Rear ©

Rear parking brake drum: 6.693 inches

© Rear parking brake drum maximum

diameter 6.732 inches

® Rear pad: 0.06 inches Rear parking brake shoes: 0.04 inches 42356-INTE-C14

1-16

ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

SCHEDULED

MAINTENANCE

INTERVALS

ACURA— 3.2CL, 3.2TL, 3.5RL, INTEGRA,

TO BE SERVICED

TYPE OF SERVICE

Engine oil

R

Rear brake discs, calipers &

S/I

A/C filter

R

A/C filter (3.5RL)

R

Brake hoses & lines (includinq ABS)

S/I

Cooling system hoses & connections

S/I

Driveshaft boots

S/I

Exhaust system

S/I

Front brake discs & calipers

S/I

Fuel pipes, hoses & connections

S/I

Suspension components

S/I

Suspension mounting bolts

S/I

Tie rods, steering gear box & boots

S/I

Steering operation, tie rod ends, steering gearbox & boots

S/I

Valve clearance (NSX)

S/I

Parking brake

S/I R

Air cleaner element

Y

Y

22.5

30

Y

Y

S/I

pads Rotate tires

7.5

15

Y

Y Y

Y

VEHICLE 37.5

✓

RSX & NSX

45 MILEAGE

INTERVAL

52.5

Y

✓

Y

Y ✓ ✓

Y Y

60

Y

82.5

67.5 75

Y y

(xIOOO)

✓

Y

90

✓

✓ y

y Y Y

97.5

Y Y

Y

y

y

Y

Y

y Y

y y

✓

Y

Y y

Y Y

y

Y

y

Y

Y

Y

Y

Y

y

Y

Y

Y

y Y

Y

Y Y

Y Y

Y y

Y Y

Y

Y

Y

Y

y

✓

Y

Y

Y

y

Y

Y

Y

Y y Y

Y Y Y

Y

Y

Y

Y

R

Y

Y

R

Y

Y

Automatic transmission fluid

R

Brake fluid (including ABS)

Y

(Inteqra & RSX) Brake fluid (including ABS) (3.5RL) Brake fluid (including ABS)

Y

y

R

(3.2TL & NSX) Front differential fluid (3.2TL

R

& 3.5RL) Manual transmission fluid ABS operation Drive belt(s) Spark plugs (Integra exc.

Y

Y Y Y Y

S/I S/I

Y Y

Y y y

R

y

Y

Y

R

Y

Y

R

Y

R

GSR & RSX exc. Type S) Spark plugs (3.2TL, Integra GSR & NSX) Spark plugs (3.5.RL) Engine coolant

R

y

Y

✓

1-17 ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

SCHEDULED

MAINTENANCE

INTERVALS

ACURA— 3.2CL, 3.2TL, 3.5RL, INTEGRA, TO BE SERVICED

TYPE OF SERVICE

ABS high pressure hose

7.5

15

22.5

30

VEHICLE 37.5

RSX & NSX

MILEAGE INTERVAL 45 52.5 60

(xIOOO) 82.5 67.5

75

97.5 90

R

(NSX) Fuel filter

R

PCV valve

✓

S/I

Timing belt (except as noted below)

R

Timing belt & timing balancer

R

belt (3.5RL) ©

✓

R

Transmission fluid Distributor, ignition cap &

S/I

rotor (Integra) Idle speed (3.2TL, Integra & NSX]

S/I

Idle speed (3.5RL) ©

S/I

Ignition wires

S/I

TWC

converter heat shield

Water pump

S/I S/I

Water pump (3.5RL) ©

S/I

R: Replace

V V V S

V S S V

✓

S/I: Service or Inspect

©

Replace at 105,000 miles.

©

Service or inspect at 105,000 miles.

FREQUENT OPERATION MAINTENANCE (SEVERE SERVICE) If a vehicle Is operated under any of the following conditions it is considered severe service: ■ Extremely dusty areas. -50% or more of the vehicle operation is in 32°C (90°F) or higher temperatures, or constant operation In temperatures below 0°C (32°F). -Prolonged idling (vehicle operation in stop and go traffic). -Frequent short running periods (engine does not warm to normal operating temperatures). -Police, taxi, delivery usage or trailer towing usage. Oil & oil filter: change every 3750 miles. Brake hoses & lines (including ABS) (3.5RL): service or inspect every 7500 miles. Cooling system hoses & connections (3.5RL): service or inspect every 7500 miles. Driveshaft boots (3.2TL & 3.5RL): check every 7500 miles. Exhaust system (3.5RL): check every 7500 miles. Brake discs, calipers & pads: service or inspect every 7500 miles. Fuel pipes, hoses & connections (3.5RL): check every 7500 miles. Power steering system: service or inspect every 7500 miles. Suspension components: service or inspect every 7500 miles. Tie rod ends, steering gear box & boots (3.2TL & 3.5RL): service or inspect every 7500 miles. Air cleaner element (NSX): service or inspect every 7500 miles. Air cleaner element (except NSX): service or inspect every 15,000 miles. Front differential fluid (3.2TL, 3.5RL): replace every 15,000 miles. Transmission fluid (NSX): replace every 15,000 miles. Transmission fluid (3.2TL & 3.5RL): replace every 30,000 miles Timing belt (3.2TL): replace every 60,000 miles. Water pump (3.2TL): service or inspect every 60,000 miles. 42356-INTE-C16

1-18

ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

PRECAUTIONS Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage and important points to take into consideration when servicing a motor vehicle: • Never open, service or drain the radia¬ tor or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. • Observe all applicable safety precau¬ tions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. • Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. • Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken

brake fluid internally, seek medical assis¬ tance IMMEDIATELY. • The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas as soon as possible after expo¬ sure to used engine oil. Soap and water, or waterless hand cleaner should be used. • All new vehicles are now equipped with an air bag system. The system must be dis¬ abled before performing service on or around system components, steering col¬ umn, instrument panel components, wiring and sensors. Failure to follow safety and dis¬ abling procedures could result in accidental air bag deployment, possible personal injury and unnecessary system repairs. • Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a non-deployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section. • Clean, high quality brake fluid from a sealed container is essential to the safe and proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid

becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint. • Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine damage. • Timing belt maintenance is extremely important! Many models utilize an interfer¬ ence type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing poten¬ tially serious (also time consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this section for the recommended replace¬ ment interval for the timing belt and to the timing belt procedure for belt replacement and inspection. • Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer system(s) and may require the computer to undergo a relearning process once the neg¬ ative battery cable is reconnected. • When servicing drum brakes, only dis¬ assemble and assemble one side at a time, leaving the remaining side intact for refer¬ ence. • Only an MVAC— trained, EPA-certified automotive technician should service the air conditioning system or its components. • The radio may contain a coded theft protection circuit. Always obtain the code number before disconnecting the battery.

ENGINE REPAIR ^Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer system. The computer may undergo a relearning process once the negative battery cable is recon¬ nected.

Distributor REMOVAL & INSTALLATION 1.8L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable

• Engine wiring harness and connec¬ tors from the distributor tor cap • Spark plug wires from the distribu¬ 3. If removing the ignition coil, remove the distributor cap, rotor, and cap seal, then remove the leak cover. 4. Remove or disconnect the following: • 2 screws to disconnect the wires from the coil • Ignition coil screws and slide the housing ignition coil out of the distributor • Distributor hold-down bolts • Distributor from the cylinder head

To install:

5. Use a new 0— ring coated with engine oil, on the distributor housing. 6. Slip the distributor into position.

’•-Lugs on the end of the distributor and the matching grooves in the camshaft end are offset to eliminate any possibility of installing the distrib¬ utor 180 degrees out of time.

7. Install the hold-down bolts and hand tighten them. 8. Slide the ignition coil into the dis¬ tributor housing and install the 2 mounting screws. 9. Install or connect the following: • 2 wires to the coil and install the 2 screws. • Distributor leak cover, rotor, cap seal, and cap • Engine wiring harness and connec¬ tor to distributor • Spark plug wires • Negative battery cable

ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

10. Set the timing, then tighten the hold down bolts to 16 ft. lbs. (22 Nm). 3.0L Engines

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • The negative battery cable • The spark plug and coil wires from the distributor cap • Harness connector(s) from the dis¬ tributor • Distributor mounting bolts • Distributor from the cylinder head

Alternator REMOVAL & INSTALLATION 1.8L and 3.5L Engines

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Both battery cables • 4 prong connector and the black wire from the rear of the alternator • Alternator adjusting bolt(s) • Mounting bolt(s) • Alternator belt • Alternator assembly To install:

3. Install or connect the following: • Alternator assembly • Mounting bolts and tighten them to 33 ft. lbs. (44 Nm) • Alternator adjusting bolt, hand tight • Alternator belt 4. Adjust alternator belt to tension. 5. Tighten the 8 x 1.25mm locknut/lock bolt(s) to 16 ft. lbs. (22 Nm). 6. Install or connect the following: • 4 prong connector and the black wire to the rear of the alternator • Both battery cables

■

■ 5J

pressor clutch wiring connector from the fan shroud Be sure to adjust the alternator belt to the proper tension or alternator bearing failure may occur.

• A/C condenser fan shroud assembly • Ground cable • 4 prong connector • Alternator and bracket assembly

'•The Powertrain Control Module

To install:

(PCM) idle memory must be reset after reconnecting the battery. Start the engine and hold it at 3000 rpm until the cooling fan comes on. Then allow the engine to idle for about 5 minutes with all accessories OFF and with the trans¬ mission in Park or Neutral.

3. Install or connect the following: • Alternator and bracket assembly and tighten the 10 x 1.25 mounting bolts to 33 ft. lbs. (44 Nm) and the 8 x 1.25mm locknut/lock bolt(s) to 16 ft. lbs. (22 Nm)

2.0L Engines

To install:

3. Install or connect the following: • New 0— ring coated with engine oil, on the distributor housing • Distributor • Mounting bolts and tighten them to 13 ft. lbs. (18 Nm) • Spark plug and coil wires • Negative battery cable 4. Check the ignition timing with a tim¬ ing light. The timing marks are located on the crankshaft pulley and lower timing cover. If the timing is not within specifica¬ tion replace the PCM module.

1.1Q

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Both battery cables • Drive belt • Auto tensioner • Connector and the black wire from the rear of the alternator • Mounting bolt(s) • Alternator assembly To install:

3. Install or connect the following: • Alternator assembly • Mounting bolts and tighten them to 16 ft. lbs. (22 Nm) • Connector and the black wire to the rear of the alternator • Auto tensioner • Drive belt • Both battery cables

Be sure to adjust the alternator belt to the proper tension or alternator bearing failure may occur. '•The Powertrain Control Module (PCM) idle memory must be reset after reconnecting the battery. Start the engine and hold it at 3000 rpm until the cooling fan comes on. Then allow the engine to idle for about 5 minutes with all accessories OFF and with the trans¬ mission in Park or Neutral. 3.0L Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Battery cover • Both battery cables • Engine cover • Accessory drive belt • Fan motor connector and A/C com¬

•• 4Ground prong cable connector • A/C condenser fan shroud assembly • Accessory drive belt • Front engine cover •There is no belt tension adjustment due to the use of an automatic ten¬ sioner.

• Both battery cables • Battery cover 4. The Powertrain Control Module (PCM) idle memory must be reset after reconnecting the battery. Start the engine and hold it at 3000 rpm until the cooling fan comes on. Then allow the engine to idle for about 5 minutes with all accessories OFF and with the transmission in Park or Neutral. 3.2L Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Both battery cables • Adjusting bolts • Accessory drive belt • Mounting bolts 3. Turn the alternator 90°in a counter-clockwise • Alternator direction. • • • •

4 prong connector Harness clip and bracket assembly Black wire from the terminal Alternator from the vehicle

To install:

4. •Install or connect the following: Alternator • Black wire • Harness clip and bracket assembly and t tighten the bolt to 8.7 ft. lbs. (12 Nm) • 4 prong connector • Mounting bolts and tighten the 10 x 1.25mm bolts to 33 ft. lbs. (44 Nm), the 8 x 1.25mm locknut/lock bolt(s) to 16 ft. lbs. (22 Nm) and the 6 x 1.0mm 104 inch lbs. (12 Nm) • Accessory drive belt

ACURA

1-20

3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

p

2.0L and 3.0L Engines (■•-There is no belt tension adjustment * due to the use of an automatic ten¬ ••The ignition timing is controlled by sioner. the Powertrain Control Module (PCM) * 5. The Powertrain Control Module A and can be checked for diagnostic pur¬ (PCM) idle memory must be reset after poses. If the timing is out of specifica¬ I tion, all mechanical and electrical reconnecting the battery. Start the engine systems shouldI be checked for proper and hold it at 3000 rpm until the cooling fan operation before replacing the PCM. comes on. Then allow the engine to idle for

plug wire. While engine idles, point the light toward the pointer on the timing belt cover. 6. Inspect the ignition timing at idle. The specification is 6-10 degrees Before Top Dead Center (BTDC) at idle for the 2.0L

about 5 minutes with all accessories OFF and with the transmission in Park or Neu¬ tral.

for prope opera tems shoul check ¬ tion mbeecfhoarnid repla ed the PCM.r e cal cing and e lectriis incorrect, 7. If the ignition timing cal s ys¬

6. Connect the positive, then the nega¬ tive battery cable. Ignition Timing ADJUSTMENT 1.8L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Start the engine and hold the engine speed at 3000 rpm, until the radiator fan comes on. The engine should be at idle

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. To check the ignition timing, start the engine and allow it to fast idle at 3000 rpm with all electrical accessories off and the transmission in N or P. Allow the engine to warm up and reach normal operating tem¬ perature. The engine cooling fan should cycle at least 1 time. 3. Locate the Service Check (SCS) con¬ nector under the glove box. Connect the service connector tool part number 07PAZ— 001 01 00 to the SCS terminals. 4. Check the idle speed and adjust if necessary. 5. Connect a timing light to the No. 1

engines, or 8-12 degrees BTDC at 700-800 for 3.0L engines

replace the PCM. 8. Remove the service connector. 3.2L and 3.5L Engines

'■•The ignition timing is controlled by the Powertrain Control Module (PCM) and can be checked for diagnostic pur¬ poses. If the timing is out of specifica¬ tion, all mechanical and electrical systems should checked for proper operation before replacing the PCM.

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

speed and at normal operating tempera¬ ture. Be sure all electrical devices (radio, air conditioning, lights, etc.) are turned OFF. 3. Locate the Service Check (SCS) con¬ nector: • 1.8L engines: behind the right kick panel the SCS service connector 4. Connect (part number 07PAZ— 001 01 00) to the ser¬ vice check connector. 5. Connect a timing light to No. 1 igni¬ tion wire and point the light toward the pointer on the timing belt cover. 6. Check the idle speed and adjust if necessary. 7. The red mark on the crankshaft pul¬ ley should be aligned with the pointer on the timing belt cover.

7923BG03

Service check connector — 3.2TL and 3.5RL

SERVICE

LOOP

’•-The white mark on the crank pulley is Top Dead Center (TDC).

8. Adjust the ignition timing by loosen¬ ing the distributor mounting bolts and rotat¬ ing the distributor housing to adjust the timing. Set as follows: • 1.8L (Except Type R): 16 degrees Before Top Dead Center (BTDC) at 700-800 rpm • 1.8L (Type R): 16 degrees BTDC at 750-850 rpm 9. Tighten the distributor bolts to 17 ft. lbs. (24 Nm) and recheck the timing.

LIGHT

7923BG04

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Timing light attachment — 3.2TL

1-21

3.

2C

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3.2TL • 1 * 3.5RL • INTE 8. GRRaise transaxle 2. To check the ignition timing, start the A • the • Engine wiring harness connectors RSXengine • NSand X 0 on the right side of the engine assembly all the way and remove it from the engine and allow it to fast idle at 3000 rpm vehicle. with all electrical accessories off and the compartment . • Fuel feed hose transmission in N or P. Allow the engine to 9. Separate the engine and transaxle. • Throttle cable To install: warm up and reach normal operating tem¬ perature. The engine cooling fan should '■••Be careful not to bend the cable cycle at least 1 time. t f u w removal procedu when removing it. Replace the cable if re, hile sing he ollow¬ 3. Locate the Service Check (SCS) con¬ I n v i t ng or•qsuteTransax allaatliuoenle it gets kinked. s:i bolts: 47 ft. lbs. (64 Nm) nector under the glove box and connect the s the re vers o • Engine wiring harness connectors service connector tool part number f the (if equipped with a emanual transax le), or 43 ft. lbs. (59 Nm) (if 07PAZ— 001 0100 to it. on the left side of the engine com¬ transax le) with an automatic 4. Check the idle speed and adjust if equipped • partment Cruise control actuator necessary. • Rear mounting bracket: 87 ft. lbs. • Engine ground cable 5. Connect a timing light to the No. 1 • Power (118 Nm) steer ing belt plug wire. With the engine idling at normal operating temperature point the timing light • Power steering pump without dis¬ • (74 UpperNm)mounting bolts: 54 ft. lbs. connecting the hoses toward the pointer on the timing belt cover. • Air conditioning compressor belt • Torque converter bolts: 104 inch 6. Inspect the ignition timing. The speci¬ lbs. (12 Nm) (if equipped) • Clutch slave cylinder and pipe/ fications are as follows: hose assemb ly (if equipped ). Do • Transmission mount bolts: 47 ft. • 3.2L: 13-17 degrees Before Top lbs. (64 Nm) not discon nect the pipe/h ose Dead Center (BTDC) at 590-690 assembly. • Engine side mount bolt: 47 ft. lbs. rpm (64Nm) Nm) • Transmis sion ground cable and • 3.5L: 13-17 degrees BTDC at hose clamp • Rear mount bracket bolts: 40 ft. lbs. 700-800 rpm • Front wheels (54 Nm) ^All mechanical and electrical sys¬ • Lower splash shield • Right front mount/bracket bolts: 47 ft. lbs. (64 Nm) tems should checked for proper opera¬ 4. Drain the engine coolant, engine oil, Nm) tion before replacing the PCM. • Damper fork bolts: 47 ft. lbs. (64 and transmission fluid into sealable con¬ tainers. Reinstall the drain plugs using new 7. If the ignition timing is incorrect, replace the PCM. washers. Be careful not to overtighten the • Lower ball joints nuts: 40 ft. lbs. drain plugs. Only replace the PCM as a last resort. (54 Nm) ing: 5. Remove or disconnect the follow¬ 8. Remove the timing light. • Shift cable bolt: 10 ft. lbs. (14 9. Disconnect the special tool (SCS ser¬ • Shift rod and extension rod bolt: 16 vice connector) from the service check con¬ • Upper and lower radiator hoses ft. lbs. (22 Nm) nector. and the heater hoses from the engine • Front exhaust pipe nuts: 40 ft. lbs. (54 Nm) • Transmission oil cooler hoses (if Engine Assembly equipped) • A/C compressor bolts: 17 ft. lbs. • Radiator assembly (24 Nm) REMOVAL & INSTALLATION • Power steering pump bolts: 17 ft. • Air conditioning compressor with¬ lbs. (24 Nm) out disconnecting the hoses 1.8L Engines • Cruise control actuator bolts: 17 ft. • Heated Oxygen (HO2S) sensor con¬ lbs. (24 Nm) nector 1. Before servicing the vehicle, refer to • Front exhaust pipe from the the precautions in the beginning of this sec¬ 2.0L Engines exhaust manifold tion. • Shift rod and extension rod from 2. Relieve the fuel system pressure. 1. Before servicing the vehicle, refer to the transaxle (if equipped) 3. Remove or disconnect the following: the precautions in the beginning of this sec¬ • Shift cable cover, then disconnect • Both battery cables tion. the shift cable from the transaxle (if • Hood 2. Obtain the anti-theft code for the equipped) radio. • Strut brace (if equipped) • Damper fork • Battery cables from the 3. Drain the engine oil, coolant, and • Lower ball joints under-hood fuse/relay box and transmission oil (or fluid) into sealable con¬ • Halfshafts from the transaxle under-hood Antilock Brake (ABS) tainers and carefully reinstall the drain 6. Attach a hoist to the engine. System fuse/relay box plugs using new sealing washers. • Left and right front engine mounts • Air cleaner assembly and mounting 4. Properly relieve the fuel system and brackets bracket • Rear engine mount and bracket • Evaporative emission (EVAP) con¬ pressure. 5. Remove or disconnect the following: • Side engine mount trol canister hose and vacuum hose Battery and positive battery •• Negative • Transmission mount from the intake manifold cables 7. Check that the engine is completely • Brake booster vacuum hose clear of all vacuum, fuel and coolant hoses, • Fuel return hose • Intake manifold cover and electrical wiring.

1-22

ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

• Intake Air Temperature (IAT) sensor connector • Breather hose • Air cleaner housing • Intake air duct • Battery cable from the underhood fuse/relay box, then the harness clamps and ground cable • Throttle cover, if equipped 6. Fully open the throttle link and cruise control link by hand, then remove the cables from the links. Loosen the locknuts and remove the cables from the bracket. • Engine Control Module (ECM)/Powertrain Control Module (PCM) connectors and main wire harness connector • Harness clamps and grommet, then pull the engine wire harness through the bulkhead • Fuel feed hose • Evaporative Emission (EVAP) can¬ ister hose and brake booster vac¬ uum hose • Clutch slave cylinder and clutch line bracket mounting bolt, if equipped with a manual transaxle • Shift cable and select cable, on manual transaxles • Drive belt • Power steering pump and position aside without disconnecting the hoses • Bolt holding the power steering hose bracket • Radiator cap • Front wheels and tires • Splash shield • Air Fuel (A/F) ratio sensor connec¬ tor • Secondary Heated Oxygen (HO2) sensor connector • Three way catalytic converter assembly • Lower ball joints and stabilizer links • Halfshafts. Coat all machined sur¬ faces with clean engine oil, then tie plastic bags over the halfshaft ends to protect them. • Shift cable holder and the shift cable cover. To avoid damaging the control lever joint, be sure to remove the bolts holding the shift cable cover, on automatic transaxles. • Spring clip and control pin, then the shift cable from the control lever, on automatic transaxles • Lower hose • Automatic Transaxle Fluid (ATF) fil¬ ter mounting bolt, if equipped

42356-INTE-G03

Make alignment marks on the reference lines (A) that align with the centers of the rear sub frame mounting bolts (B), then remove the front subframe (C)

ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

• ATF cooler hoses, then plug the hoses and lines • Upper hose and heater hoses • Radiator 7. Attach a suitable engine tilt hanger to the engine. • Transaxle mount bracket support bolts/nuts • Upper bracket mounting bolt and nut 8. Make sure the hoist brackets are positioned properly, then raise the hoist to its full height. • Rear mount mounting bolts • Front mount bracket mounting bolt 9. Make alignment marks on the refer¬ ence lines that align with the centers of the rear subframe mounting bolts, then remove the subframe. • Compressor clutch connector and position the compressor aside without disconnect the refrigerant lines

• Any remaining electrical connec¬ tors, vacuum, fuel or coolant hoses 10. Slowly lower the engine about 6 in. (15 cm). Check that all hoses and wires are disconnected from the engine/transaxle. 11. Lower the engine all the way, then remove the chain hoist from the engine. 12. Remove the engine from under the vehicle. To install:

13. Installation is the reverse of the removal procedure, while using the follow¬ ing torque values: • Engine mount bracket: 33 ft. lbs. (44 Nm) • A/C compressor bracket: 33 ft. lbs. (44 Nm) • A/C compressor bolts: 16 ft. lbs. (22 Nm) • New subframe bolts: 76 ft. lbs. (103 Nm) • Rear mount mounting bolts: 43 ft. lbs. (59 Nm) • Upper bracket mounting bolt: 40 ft. lbs. (54 Nm) • Support bolts/nuts: 40 ft. lbs. (54 Nm) • Front engine mount bracket mount¬ ing bolts: 47 ft. lbs. (64 Nm) • A/T shift control cable: 7.2 ft. lbs. (9.8 Nm) • New catalytic converter self-lock¬ ing nuts: 25 ft. lbs. (33 Nm) • Catalytic converter bolt: 16 ft. lbs. (22 Nm) • ATF filter mounting bolt: 8.7 ft. lbs. (12 Nm) • Power steering pump bolts: 16 ft. lbs. (22 Nm)

• Power steering hose bracket bolt: 7.2 ft. lbs. (9.8 Nm) • M/T cable bolts: 7.2 ft. lbs. (9.8 Nm) • Clutch slave cylinder mounting bolts: 17 ft. lbs. (24 Nm) • Clutch line bracket mounting bolt: 7.2 ft. lbs. (9.8 Nm) • Battery cable harness clamp bolt: 8.7 ft. lbs. (12 Nm) • Air cleaner housing bolts: 8.7 ft. lbs. (12 Nm) • Intake manifold cover bolts: 8.7 ft. lbs. (12 Nm) 3.0L Engines

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Obtain the anti-theft code for the radio. 3. Drain the engine oil, coolant, and transmission oil (or fluid) into sealable con¬ tainers and carefully reinstall the drain plugs using new sealing washers. 4. Properly relieve the fuel system pres¬ sure. 5. Remove or disconnect the following: • Air cleaner assembly • Hood support struts and support the hood in a vertical position • Negative battery cable and then the cable • positive Strut brace • Battery, battery tray and the engine ground cable • Accelerator and cruise control cables from the throttle body and bracket • Battery cables from the underhood Antilock Brake System (ABS) fuse/relay box and underhood fuse/relay box assemblies • Engine wiring harness on the right side of the engine • Evaporative emission (EVAP) con¬ trol canister hose • Brake booster vacuum hose • Fuel feed and return hoses • Engine wiring harness on the left side of the engine • Accessory drive belt(s) • Power steering pump leaving the hoses attached • Shift cable (if equipped with a man¬ ual transmission) • Clutch slave cylinder leaving (if equipped) the hydraulic line attached • sion) Reverse light switch connector (if equipped with a manual transmis¬

1.0Q l

L.\J

• Cruise control vacuum tank (if equipped) • Front wheels • Lower splash shield • Center support beam • Heated nector Oxygen (HO2S) sensor con¬ • Front exhaust pipe from the mani¬ fold • Shift selector cable and cover (if mission) equipped with an automatic trans¬ • Damper fork • Lower ball joints • Driveshafts from the transaxle • 3.0L Crankshaft engine)pulley (if equipped with • VTEC/oil filter housing (if equipped with 3.0L engine) • • •

Upper and lower radiator hoses Transmission oil cooler hoses (if equipped) Radiator

• Air conditioning compressor leav¬ ing the hoses hoses attached • Heater 6. Attach a suitable engine lifting hoist to the engine lifting hooks and secure the engine.• • • •

Front engine mount Rear engine mount Side engine mount Transmission mount

7. Lift the engine slightly and check that all hoses, cables and wires have been prop¬ erly disconnected. raise the engine/transmis¬ Carefully sion8.from the vehicle. To install:

9. Installation is the reverse of the removal procedure, while using the follow¬ ing torque values: • Transmission mount bolts: 47 ft. lbs. (64 Nm) • Front engine mount bolts: 47 ft. lbs. (64 Nm) • Side engine mount bolts: 47 ft. lbs. (64 Nm) • Rear engine mount bolts: 47 ft. lbs. (64 Nm) • A/C compressor bolts: 16 ft. lbs. (22Nm) Nm) • VTEC/oil Nm) filter housing bolts (if with 3.0L engine): 16 ft. equipped lbs. (22 Nm) Nm) • Crankshaft pulley bolt (if equipped with 3.0L engine): 181 ft. lbs. (245 • Lower ball joint nuts: 40 ft. lbs. (54 • Damper fork bolts: 47 ft. lbs. (64

1IOA

ACURA

3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

• Front exhaust pipe nuts: 40 ft. lbs. (54 Nm) • Center support beam bolts: 37 ft. lbs. (50 Nm) • Splash shield bolts: 84 inch lbs. (9.5 Nm) • Power steering pump bolts: 16 ft. lbs. (22 Nm) • Strut brace bolts (if equipped): 16 ft. lbs. (22 Nm) 3.2L Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Do not remove the hood. Disconnect the hood support strut and reconnect it to hold the hood in a vertical position. 3. Properly relieve the fuel pressure. 4. Drain the engine oil, coolant, trans¬ mission fluid and the differential fluid. 5. Remove or disconnect the following: • Negative battery cable, then the positive battery cable • Battery and battery tray • Air cleaner assembly • Water bypass hoses (on 3.2CL) • Traction Control System (TCS) control valve actuator connector (on 3.2CL) • TCS control valve angel sensor connector (on 3.2CL) • Throttle cable and cruise control cable from the throttle and bracket • Left side engine wiring harness connectors • Fuel feed and return hoses • Brake booster vacuum hose • Battery cables from the under-hood fuse/relay box • Under-hood fuse/relay box • Powertrain Control Module (PCM) electrical connectors • Accessory drive belts • Power steering pump without dis¬ connecting the hoses • Vehicle Speed sensor (VSS) con¬ nector, then remove the VSS/power steering sensor leaving the fluid hoses attached • Front wheels • Lower splash shield • Heated Oxygen (HO2S) sensor con¬ nector • Front exhaust pipe from the mani¬ fold • Front damper forks • Lower ball joints from the steering knuckles • Halfshafts from the differential and the intermediate shaft

Nm)

• Shift cable cover • Shift cable with the control lever from the transaxle • Power steering hose clamps and the hoseengine mount control vacuum

• Side engine mount bracket bolts: 33 Nm) ft. lbs. (44 Nm) • ft. Sidelbs.engine mount through bolt: 40 (54 Nm) • Lower ball joint nuts: 40 ft. lbs. (54

• Upper and lower radiator hoses • Heater hoses

• Damper fork bolts: 47 ft. lbs. (64

• Transmission fluid cooler hoses • Ground cable

• Front exhaust pipe nuts: 40 ft. lbs. (54 Nm) • Shift cable and control lever bolts: 10 ft. lbs. (14 Nm)

• Power steering hose clamp from the rear beam assembly 6. Attach a suitable chain hoist to the engine lifting hooks and support the engine.

• Power steering pump bolts: 16 ft. lbs. (22 Nm)

'■►The engine and transmission assem¬ bly is removed by lowering it from the vehicle. Be sure the vehicle is in a

3.5L Engine

position that will allow transmission assembly ance to be moved from once it is lowered away vehicle.

the precautions in the beginning of this sec¬ tion.

the engine and enough clear¬ the vehicle from the

7. Remove or disconnect the following: • Side, rear and front engine mount support fasteners • Front suspension radius rod bolts 8. Make alignment marks on the front beam and remove the front beam. 9. Remove or disconnect the following: • Air conditioning compressor leav¬ ing the hoses attached • Rear mounts from the engine and transmission 10. Check that all hoses, cables and wires have been properly disconnected and slowly lower the engine about 6 inches (150 mm). Recheck that all hoses, cables and wires have been properly disconnected. 1 1 . Carefully lower the engine/transmis¬ sion assembly from the vehicle. To install:

12. Installation is the reverse of the removal procedure, while using the follow¬ ing torque values: • Transmission rear mount bolts: 28 ft. lbs. (38 Nm) • AirNm)conditioning compressor bolts: 16 ft. lbs. (22 Nm) Nm) beam nuts: 28 ft. lbs. (38 • Front

1. Before servicing the vehicle, refer to

ward.2. Move the front passenger’s seat for¬ 3. Relieve the fuel system pressure. 4. Drain the engine oil, coolant, trans¬ mission fluid and differential fluid. ing: Hood or disconnect the follow¬ 5.• Remove • Negative battery cable, then the positive battery cable • Strut brace • Engine cover • Air cleaner assembly and intake duct • Throttle cover Battery cable and cruise control •• Throttle cable from the throttle and bracket • Battery tray • Relay box • Ground cable and wiring harness clips from the firewall • Alternator and battery cables from the under-hood fuse/relay box • Underhood fuse/relay box • Left side engine wiring harness connectors • Fuel feed and return hoses • Brake booster vacuum hose • Evaporative emissions (EVAP) can¬ ister hose

• Front beam bolts: 76 ft. lbs. (103

• Transmission sub-harness connec¬ • tor Control box

• Rear bolts: 28 ft. lbs. (38 Nm) • Front suspension radius rod bolts: 119 ft. lbs. (162 Nm)

• Right side engine wiring harness connectors

• Front engine mount nut: 40 ft. lbs. (54 Nm) • Rear engine mount nut: 40 ft. lbs. (54 Nm) • Rear engine mount bolt: 28 ft. lbs. (38 Nm)

• Spark plug voltage detection mod¬ ule • Engine ground cables • Accessory drive belts • Power Steering Pressure (PSP) switch connector

1-25 ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

• Power steering pump leaving the hoses attached 6. Pull the carpet back under the front passengers seat and detach the secondary Heated Oxygen (HO2S) sensor connector. 7. Remove or disconnect the follow¬ ing: • Front wheels • Splash shield • Front suspension damper forks • Lower ball joints from the steering knuckles • Halfshafts from the transmission

• Air conditioning compressor with¬ out disconnecting the hoses • Vehicle Speed Sensor (VSS) leav¬ ing the hoses attached • Transmission stop collars • Front exhaust pipe from the vehicle • Wire harness cover and grommet • Three way catalytic converter • Converter heat shield • Transmission fluid cooler lines • Shift cable cover • Shift cable from the transmission • Control lever from the control shaft

Bracket Bolts Torque Specifications: 10 x 1.25 mm 38 Nm (3.9 kgf m 28 Ibf-ft)

RIGHT

•• Radiator Upper and lower radiator hoses • Heater hoses 8. Loosen the locknut on the fuel pres¬ sure regulator and rotate it 180 degrees. 9. Attach a chain hoist to the engine lifting eyelets. ing:10. Raise and safely support the vehicle. 11. Remove or disconnect the follow¬ • Shift cable guide • Transmission beam • Transmission mount and bracket REAR ENGINE HANGER

ENGINE

MOUNT

BRACKET

10 x 1.25 mm 44 N m (4.5 kgf-m, 33 Ibf-ft)

12 x 1.25 mm 64 N m (6.5 kgf-m, 47 Ibf-ft) Apply liquid gasket to the bolt threads. 10 x 1.25 mm 38 N m (3.9 kgf-m, 28 Ibf-ft) 12 x 1.25 mm 64 Nm

(6.5 kgf-m, 47 Ibf-ft)

10 x 1.25 mm 44 N-m (4.5 kgf-m, 33 Ibf-ft)

10 x 1.25 mm 44 N-m (4.5 kgf 33 Ibf-ft)

© Install the bolts. @8x1.25 mm kgf-m, 22 N-m (2.2 16 Ibf-ft)

8 x 1.25 mm 22 N-m (2.2 kgf m. 16 Ibf-ft) 10 x 1.25 mm 44 N-m (4.5 kgf-m, 33 Ibf-ft)

8 x 1.25 mm 22 N-m (2.2 kgf

10 x 1.25 mm

16 Ibf-ft)

44 N-m (4.5 kgf-m, 33 Ibf-ft) 7923BG77

View of the engine mounting bracket showing torque specifications— 3. 5RL

1-26

ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

• Rear timing belt cover • 5remove water pump mounting the water pump bolts and

(D 12 x 1.25 mm 54 N-m (5.5 kgf-m, 40 Ibf-ft)

® 10 x 1.25 mm 38 N-m (3.9 kgf-m, 28 Ibf-ft)

To install:

5. Install or connect the following: • Water pump and tighten the bolts to 108 inch lbs. (12 Nm) • Rear timing belt cover • Camshaft pulleys • Timing belt 6. Fill the engine with coolant and bleed the air from the cooling system. 7. Connect the negative battery cable and enter the radio security code. 8. Run the engine and check for cooling system leaks. 2.0L Engines

1 . Before servicing the vehicle, refer to 10 x 1.25 mm 38 N-m (3.9 kgf-m, 28 Ibf-ft) 7923BG78

Transmission beam bolt tightening sequence and torque specifications — 3.5RL

• Left and right front mount brackets from the mounts • Right and left engine mounts 12. Raise the engine slightly, be sure all connections have be removed. 13. Remove the engine/transmission from the vehicle. To install:

14. Installation is the reverse of the removal procedure, while using the follow¬ ing torque values: • Transmission mount bracket bolts: 28 ft. lbs. (38 Nm) • Right and left engine mount nuts: 47 ft. lbs. (64 Nm) • Left and right front mount through bolts: 52 ft. lbs. (74 Nm) • Transmission mount bolts: 28 ft. lbs. (38 Nm) Nm) • Shift cable bolts: 108 inch lbs. (12

the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable. 3. Drain the engine coolant. 4. •Remove or disconnect the following: Drive belt • Crankshaft pulley • For the K20A3 (base) engine, 6 bolts securing the water pump

Water Pump

REMOVAL & INSTALLATION 1.8L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable. 3. Drain the engine coolant. 4. Remove or disconnect the following: • Timing belt • Camshaft pulleys

• For the K20A2 (Type-S) engine, oil cooler jointp pipe and the 7 bolts • securing Water pum the water pump 5. Clean and inspect the 0— ring groove and mating surfaces. To install:

6. Install or connect the following: • Water pump with a new 0— ring. Tighten the mounting bolts to 8.7 ft. lbs. (12 Nm). • Crankshaft pulley • Drive belt

• Front exhaust pipe nuts: 40 ft. lbs. (54 Nm) • Transmission stop collar bolts: 28 ft. lbs. (38 Nm) • A/C compressor bolts: 16 ft. lbs. (22 Nm) • Nm) Lower ball joint nuts: 40 ft. lbs. (54 • Front suspension damper fork bolts: 41 ft. lbs. (69 Nm) • Power steering pump bolt: 33 ft. lbs. (44 Nm) • Nm) Power steering nut: 16 ft. lbs. (22

6 x 1.0 mm 12 N-m (1.2 kgf-m, 8.7 Ibf-ft) 42356-INTE-G04

Water pump mounting— 2. OL (K20A3) engine

ACURA

K

3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

1 .97 ■

»

*

ing belt if there is any doubt about its con¬ dition. 6. On 3.5 RL models, remove the left camshaft pulley and back cover. 7. On 2000-03 3.2 TL models and 2001-03 3.2 CL models, remove the timing belt tensioner. 8. Remove the water pump bolts. Then, remove the water pump and sprocket assembly from the engine block. To install:

9. Install the water pump with a new 0— ring. Use new bolts and tighten the 6mm Nm). mounting bolts evenly to 104 inch lbs. (12 Nm) and the 8mm bolts to 16 ft. lbs. (22

6 x 1.0 mm 12 Nm (1.2 kgf-m, 8.7 Ibfft) 42356-INTE-G05

Water pump mounting— 2. OL (K20A2) engine

3.0L, 3.2L and 3.5L Engines ^Perform this service operation with the engine cold.

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable. 3. Remove the front splash panel. 4. Drain the cooling system. 5. Remove the timing belt. Inspect the timing belt for any signs of damage or oil and coolant contamination. Replace the tim¬

*

7. Fill the engine with coolant and bleed the air from the cooling system. 8. Connect the negative battery cable and enter the radio security code. 9. Run the engine and check for cooling system leaks.

O-RING

10. If removed, install the timing belt rear cover and camshaft pulley. 1 1 . If removed, install the timing belt tensioner. 12. Install or connect the following: • Timing belt and timing belt covers • Accessory drive belts 13. Close the cooling system drain plug. Refill and bleed the cooling system. 14. Connect the negative battery cable. 15. Start the engine, allow it to reach normal operating temperature, check for leaks, and top off as necessary.

Heater Core REMOVAL & INSTALLATION Integra and RSX ^Be sure to acquire the anti-theft code for the radio; then, write down the frequencies for the preset buttons.

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable.

UT

CA IO

After disconnecting the negative bat¬ tery cable, wait for at least 3 minutes energy. for the SRS module to deplete its

N

12 N m (1.2 kgf-m,

8.7 Ibf ft)

7923BG79

Water pump mounting and bolt torque specifications — 3.5L engine

3. Drain the cooling system into a clean container for reuse. 4. Remove or disconnect the following: • Heater hoses from the heater core • Heater housing-to-cowl nut, located in the engine compartment 5. Remove the instrument panel by removing or disconnecting the following: • Front seats • Front and rear consoles

1-28

ACURA

9 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX . the wiring harness clip from the • Lower dashboard-to-instrument heater housing panel screws and the lower dash¬ • Heater housing-to-chassis nuts and board, located on the driver’s side the heater housing • Knee bolster • Glove box 7. Remove the damper arm cover-toheater housing screw and the cover. • 4 glove box frame-to-instrument panel bolts and the frame 8. Remove or disconnect the following: • Clock • Damper arm link; then, remove the • Moon roof switch damper arm-to-heater housing screw and the arm • Stereo radio/cassette • Lower steering column cover clamps and the cover • Wrap a shop towel around the steering column to prevent damage to the column. • Steering column-to-instrument panel nuts/bolts and lower the steering column • SRS module-to-instrument panel

• • • • • •

nuts (located on the driver's side); then, carefully, remove the SRS module and disconnect the electri¬ cal connector Air mix control cable and electrical connectors, located at the center of the instrument panel Antenna lead Electrical connectors, located at the under-dash fuse/relay box Pry out the access panels, from both sides of the instrument panel Instrument panel-to-chassis bolts and remove the instrument panel Wiring harness clips; then, remove the 4 heater housing-to-blower motor duct screws and the duct, (models not equipped with air con¬ ditioning only)

To install:

•InstHeater to the heater housing all or core conn t the follthe • Pipe clamp ecscrew and owinclamp g: • Heater core cover and the 2 coverto-heater housing screws • Damper arm-to-heater housing screw and the arm; then, connect the damper arm link • Damper arm cover and the coverto-heater housing screw

• 2 heater core cover-to-heater hous¬ ing screws and the cover • Pipe clamp screw and the clamp • Heater core from the heater housing

• Heater housing and the heater housing-to-chassis nuts • Mode control motor connector and

▲ : Bolt, nut locations BA : Nut. 2

A A : Bolt, 2 8x1 .25 mm

8 x 1.25 mm

22 Nm (2.2 kgf-m, 16 Ibf-ft)

13 N m (1.3 kgf-m, 9 Ibf-ft) Replace.

STEERING

COLUMN

or rem hou the eva rem ptor f sin ovi dis ove heato oll g ng con o the air con¬ ne•c Discharge randwinrecover tinditioning systemg: refrigerant g • Refrigerant lines from the evapora¬ tor core, discard the O-rings and plug the openings to prevent con¬ tamination • Cut the insulation pad (at the fire¬ wall) at the lower evaporator housing-to-chassis location • Thermostat electrical connector, located at the evaporator housing • Wiring harness clips from the evaporator housing • Evaporator housing-to-chassis screws, the nut and bolt • Drain hose • Evaporator housing, carefully • 2 SRS support beam bolts, nut and the SRS beam, located at the pas¬ senger’s side • Mode control motor connector and

93112GP5

View of the steering column and related components — Integra

ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

1

the wiring harness clip to the heater 0 housing . SRS support beam, nut and the 2 SRS beam bolts on the passengers side

install the evaporator housing by installing or connIfecetqiung the following: ipped with air conditioni • Evaporator housing ng, • Drain hose

▲ : Nut locations, 4

1.00 «

£5*

• 4 evaporator housing-to-chassis screws, the nut and bolt • Wiring harness clips to the evapo¬ rator housing • Thermostat electrical connector at the evaporator housing O-rings • Refrigerant lines to the evaporator core making sure to use new • Heater housing-to-blower motor duct and the 4 duct screws; then, connect the wiring harness clips ditioning only) (models not equipped with air con¬

FRONT AIRBAG PASSENGER'S

11. Install the instrument panel by installing or connecting the following: • instrument panel and the instru¬ ment panel-to-chassis bolts • Access panels on both sides of the instrument panel • Electrical connectors at the underdash fuse/relay box • Antenna lead • Air mix control cable and electrical connectors at the center of the instrument panel • SRS module electrical connector HARNESS

(located on the passenger's side) and torque the SRS module-toinstrument panel nuts to 84 inch lbs. (9.8 Nm)

93112GP6

View of the passenger’s side SRS module and related components— Integra

• Steering column and torque the

T : Bolt locations. 6

• ••

steering column-to-instrument panel nuts to 108 ft. lbs. (13 Nm) and the bolts to 16 ft. lbs. (22 Nm) Lower steering column cover and the cover clamps Stereo radio/cassette Clock Moon roof switch

• • •

Glove box frame and the 4 frameto-instrument panel bolts Glove box Knee bolster

•

PROTECTIVE

PROTECTIVE

• Lower dashboard and the lower dashboard-to-instrument panel screws Nm) on the drivers side •• Front Front and seatsrear consoles • Heater housing-to-cowl nut (located in the engine compart¬ ment) and torque to 16 ft. lbs. (22 • Heater hoses to the heater core 12. Refill the cooling system. 13. Connect the negative battery cable. 14. Evacuate, charge and leak test the air conditioning system refrigerant. 93112GP7

View of the instrument panel fastener locations— Integra

15. Operate the engine to normal operat¬ ing temperatures; then, check the climate control operation and check for leaks.

1-30

ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX HEATER

CORE

COVER

steering wheel by removing or disconnect¬ ing the following: • Access panel-to-steering wheel screws and the panel • SRS module electrical connector • SRS module-to-steering wheel cov¬ ers wheelfrom both sides of the steering • Both SRS module-to-steering wheel bolts, using a T30 Torx®bit • SRS module from the steering wheel • Electrical connectors from the steering wheel • Steering wheel from the steering column 7. Remove the steering column by removing or disconnecting the following: • Coin pocket, the lower instrument panel-to-dash screw and the lower instrument panel from the driver’s side • Electrical connector and the air hose at the knee bolster; then, remove the knee bolster-to-dash bolts and the knee bolster • Steering column cover screws and the covers

93112GP6

Exploded view of the heater core, heater housing and related components — Integra

• Combination switch-to-steering column screws, disconnect the electrical connectors and remove the combination switch • Ignition switch connectors • Clamps, clips and the steering joint cover

3.2CL AIRBAG

^•Be sure to acquire the anti-theft code for the radio; then, write down the fre¬ quencies for the preset buttons.

DRIVER'S

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable.

•' CAUTION After disconnecting the negative bat¬ tery cable, wait for at least 3 minutes for the SRS module to deplete its energy.

3. Drain the cooling system into a clean container for reuse. 4. Remove or disconnect the following: • Heater hoses from the heater core • 2 heater housing-to-cowl nuts, located in the engine compartment 5. Place the front wheel in the straight¬ ahead position. 6. Remove the SRS module and the

93112GP0

Removing the driver’s side SRS module-to-steering wheel bolts — 3.2CL

ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX B ►, 8

A ►, 2

6 x 1.0mm 0 °

9.8 N-m, (1.0 kgf-m. 7.2 Ibf-ft)

B S

CK

1

8

>: AO,Clip 8 locations

BO, 2

1.Q1 ■

O

I

CO, 4

1

V

.

• Steering joint from the steering col¬ umn shaft • Steering column-to-instrument panel nuts/bolts and the steering column 8. Remove the passenger’s side SRS module by removing or disconnecting the following: • SRS module electrical connector • 5 SRS module-to-instrument panel nuts and carefully remove the SRS module 9. Remove the instrument panel by removing or disconnecting the following: • Front and rear consoles

• Cruise control master switch and the panel brightness controller; then, disconnect the electrical con¬ nectors • Instrument cluster-to-instrument panel screws and pry out the instrument cluster and disconnect the electrical connectors • Glove box-to-damper screw • 2 glove box-to-dash screws and the glove box • Audio unit-to-instrument panel fas¬ teners and the audio unit

side); then, carefully pry out the dashboard panel and the climate control unit as an assembly • Side defogger trim from both sides of the instrument panel • Instrument panel electrical connec¬ tors, the recirculation control motor connector and the resistor connec¬ tor • Instrument panel-to-chassis bolts and the instrument panel • Steering hanger beam-to-chassis nuts, bolts and the beam

• 3 passenger’s dashboard panel screws (located on the passengers er

g

tem

rig

ref

sys

nin

tio

1-32

ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

STEERING

1 1 . Remove the evaporator housing by removing or disconnecting the following: • Refrigerant lines from the evapora¬ tor core. Discard the 0-rings and

WHEEL

plug the openings to prevent con¬ tamination. • Thermostat electrical connector at the evaporator housing • Wiring harness clips from the evaporator housing • Evaporator housing-to-chassis the nut and bolt • screws, Drain hose • Evaporator housing 12. Remove or disconnect the following: • Wiring harness clip; then, discon¬ nect the mode control motor and the air mix control motor connectors • Heater housing-to-chassis bolt and the heater housing • Vent/defroster duct-to-heater hous¬ ing screws and the duct • Heater core pipe clamp-to-heater housing screw and the clamp • Heater core clamp-to-heater hous¬ ing screw and the heater core

To install:

13. Install or connect the following: • Heater core clamp and the heater core-to-heater housing screw

93112GQ1

Exploded view of the steering wheel and related components — 3.2CL UPPER

RETAINING NOTE:

COLUMN

COVER

COLLAR

COMBINATION

Take care not to let the

SWITCH

ASSEMBLY

retaining collar fall out of position during installation.

STEERING

STEERING

JOINT

JOINT

BOLTS

23 N m (2.3 kgf-rn, 17 Ibf ft) LOWER

CLAMPS

COLUMN

COVER

SCREWS STEERING

JOINT

COVER 93112GQ4

Exploded view of the steering wheel column and related components — 3.2CL

ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

• Heater core pipe clamp and the clamp-to-heater housing screw • Vent/defroster duct and the duct-toheater housing screws • Heater housing and the heater housing-to-chassis bolt • Wiring harness clip; then, con¬ nect the mode control motor and the air mix control motor connec¬ tors 14. Install the evaporator housing by installing or connecting the following: • Evaporator housing • Drain hose

FRONT PASSENGER AIRBAG

1 oq ■

OU

S

• Evaporator housing-to-chassis screws, the nut and bolt • Wiring harness clips to the evapo¬ rator housing • Thermostat electrical connector, at the evaporator housing • Refrigerant lines to the evaporator core, make sure to use new O-rings • Steering hanger beam and the beam-to-chassis nuts and bolts 15. Install the instrument panel by installing or connecting the following: • Instrument panel and the instru¬ ment panel-to-chassis bolts • Instrument panel electrical connec-

MOUNTING

NUTS 93112GQ2

Exploded view of the passenger's side SRS module— 3. 2CL

► : Bolt locations, 6

PANEL

View of the dashboard bolt locations— 3. 2CL

931I2GQ3

1-34

ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

ment cluster-to-instrument panel screws; then, connect the electrical connectors • Cruise control master switch and the panel brightness controller; then, connect the electrical connectors • Front and rear consoles

8 x 1.25 mm 22 N-m (2.2 kgf-m, 16 Ibf-ft)

16. Install the passenger’s side SRS mod¬ ule by installing or connecting the following: • SRS module and the 5 SRS module-to-instrument panel nuts and torque to 84 inch lbs. (9.8 Nm) • SRS module electrical connector 17. Install the steering column by installing or connecting the following: • Steering column and the steering column-to-instrument panel nuts/bolts

8 x 1.25 mm 8 x 1.25 mm

22 N-m (2.2 kgf-m, 16 Ibf-ft)

• Steering joint to the steering col¬ umn shaft • Clamps, clips and the steering joint cover

22 N-m (2.2 kgf-m, 16 Ibf-ft)

• Ignition switch connectors • Combination switch, connect the electrical connectors and install the combination switch-to-steering column screws • Steering column covers and the cover screws • Knee bolster and the knee bolsterto-dash bolts; then, connect the electrical connector and the air hose. • Lower instrument panel, the lower instrument panel-to-dash screw and the coin pocket 18. Install the SRS module and the steering wheel by installing or connecting the following: • Steering wheel to the steering col¬ umn and torque the nut to 28 ft. lbs. (38 Nm) • Electrical connectors to the steering wheel

8 x 1.25 mm 22 N-m (2.2 kgf-m, 16 Ibf-ft)

93112GQ5

View of the steering hanger beam and related components— 3. 2CL

tors, the recirculation control motor connector and the resistor connec¬ tor Side defogger trim at both sides of the instrument panel Dashboard panel and the climate control unit as an assembly; then, install the 3 passenger's dashboard

panel screws at the passenger’s side Audio unit and the audio unit-toinstrument panel fasteners Glove box and the 2 glove box-to dash screws Glove box-to-damper screw Instrument cluster and the instru¬

• SRS module to the steering wheel • Both SRS module-to-steering wheel bolts and torque to 84 inch lbs. (9.8 Nm) using a T30 Torx bit • SRS module-to-steering wheel cov¬ ers • SRS module electrical connector • Access panel-to-steering wheel screws and the panel. • 2 heater housing-to-cowl nuts located in the engine compartment • Heater hoses to the heater core 19. Refill the cooling system. 20. Connect the negative battery cable. 21 . Evacuate, charge and leak test the air conditioning system. 22. Operate the engine to normal operat¬ ing temperatures; then, check the climate control operation and check for leaks.

ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

VENT/DEFROSTER

DUCT

1 oc ■

ww

screw; then, remove the damper from the glove box • Glove box stop located at each side while holding the glove box • Both glove box-to-instrument panel screws and the glove box • Clips and remove the dashboard side cover located at the passen¬ ger’s side • Glove box cover-to-instrument panel connectors screws, disconnect the elec¬ trical and remove the glove box cover • Rear console and the front console cover • 4 audio unit-to-instrument panel screws, disconnect the electrical connectors and remove the audio unit • Pry out the front pillar trim at both sides • Bolts at the rear vent duct, discon¬ nect the clips and the OBD-II con¬ nector; then, detach the tabs and remove the rear vent duct • Steering column cover screws and the covers • tors Steering column electrical connec¬ • Steering joint cover clamp, screws and the cover • Steering column-to-instrument panel nuts/bolts and lower the steering column • Instrument nectors and panel’s clips electrical con¬ • Instrument panel-to-chassis bolts and the instrument panel

93112G06

Exploded view of the heater core, heater housing and related components— 3. 2CL

3.2TL c»Be sure to acquire the anti-theft code for the radio; then, write down the frequencies for the preset buttons.

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable.

K CAUTION After disconnecting the negative bat¬ tery cable, wait for at least 3 minutes for the SRS module to deplete its energy.

3. Drain the cooling system into a clean container for reuse. 4. Disconnect the heater hoses from the heater core. 5. In the engine compartment, remove the heater housing-to-cowl nut. 6. Remove the instrument panel by removing or disconnecting the following: • Clips and remove the dashboard located cover at the screw, driver’s side • side Lowercover, dashboard detach the clips and remove the lower dashboard cover • Console panel screws and the con¬ sole panel • Glove box-to-instrument panel

7. Discharge and recover the air condi¬ tioning system refrigerant. 8. Remove the evaporator housing by removing or disconnecting the following: • Refrigerant lines from the evapora¬ tor core. Discard the O-rings and plug the openings to prevent con¬ tamination. • Electrical connectors from the evaporator housing • Evaporator housing-to-chassis screws, nut and bolts; then, remove the evaporator housing 9. Remove or disconnect the following: • Heater housing-to-chassis bolts and the heater housing • Mode control motor-to-heater housing screws, the linkage and the motor • Bracket-to-heater housing screws and the brackets • Upper-to-lower heater housing and separate the housings • screws Heater core

1-36

ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

Fastener Locations £>: Clip, 10

► : Screw, 4

To install:

rator housing-to-chassis screws, nut and bolts

10. Install or connect the following: • Heater core

• Electrical connectors to the evapo¬ rator housing • Refrigerant lines to the evaporator O-rings core, make sure to use new

fol the

con or

g

:

ing

low

g

tin

nec

• Instrument panel and the instru¬ ment panel-to-chassis bolts • nectors Instrument and panel’s clips electrical con¬

lin

tal

ins

• Upper-to-lower heater housing and install the heater housing screws • Brackets and the bracket-to-heater housing screws • Mode control motor, the linkage and the motor-to-heater housing screws • Heater housing and the heater housing-to-chassis bolts 11. Install the evaporator housing by installing or connecting the following: • Evaporator housing and the evapo¬

• Steering column and torque the

steering column-to-instrument panel nuts to 12 ft. lbs. (16 Nm) and bolts to 17 ft. lbs. (23 Nm) • Steering joint cover and the cover clamp and screws • Steering column electrical connec¬ tors • Steering column covers and the cover screws • Rear vent duct, connect the clips and the OBD-II connector, attach the tabs and install the bolts • Front pillar trim. On both sides. • Audio unit, connect the electrical

Inst t ins atlhle

1

3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX Fastener Locations A [> : Screw, 2

B [> : Screw, 5

C t> : Screw, 4

D [>: Clip, 8

E [> : Clip, 4

SHOP TOWEL

CLIP DRIVER S SEAT HEATER SWITCH CONSOLE

CLIP

PANEL TRAY SEAT HEATER

ACCESSORY SOCKET CONNECTOR

SWITCH

PASSENGER'S HEATER SWITCHSEAT

HOOKS

HOOKS

PASSENGER'S FRONT CONSOLE COVER

SHIFT INDICATOR TRIM RING

DRIVER'S FRONT CONSOLE COVER

SEAT HEATER CONNECTORS

CONSOLE

PANEL

931 12GQ8

Exploded view of the console panel and related components— 3.21

connectors and install the 4 audio unit-to-instrument panel screws • Rear console and the front console cover • Glove box cover, connect the elec¬ trical connectors and install the glove box cover-to-instrument panel screws • Dashboard side cover and attach

the clips at the passenger’s side • Both glove box and the glove boxto-instrument panel screws • Glove box stop (located at each side), while holding the glove box • Damper to the glove box and the glove box-to-instrument panel screw • Console panel and the console panel screws • Lower dashboard cover, attach the

93112GQ9

Exploded view of the steering column and related components— 3. 2TL

1-38

ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

Fastener Locations B ► : Bolt, 6

C ► : Bolt, 3

D ► : Bolt, 1

E ► : Bolt, 3

F ► : Bolt, 1 8 x 1.25 mm 22 N m (2.2 kgf m,

16 Ibf-ft)

H

H

G

clips and install the lower dash¬ board cover screw • Dashboard side cover and attach clipshousing-to-cowl at the driver's side • the Heater nut located in the engine compartment • Heater hoses to the heater core 13. Refill the cooling system. 14. Connect the negative battery cable. 15. Evacuate, charge and leak test the air conditioning system. 16. Operate the engine to normal operat¬ ing temperatures; then, check the climate control operation and check for leaks. 3.5RL •Be sure to acquire the anti-theft code for the radio; then, write down the frequencies for the preset buttons.

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable.

■:* CAUTION

A A

A 93112GR1

Exploded view of the heater core, heater housing and related components— 3. 2TL

After disconnecting the negative bat¬ tery cable, wait for at least 3 minutes energy. for the SRS module to deplete its

ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

8 3. Drain the cooling system into a clean • Both SRS module-to-steering container for reuse. . wheel bolts using a T30 Torx bit 4. Disconnect the heater hoses from the • SRS module from the steering wheel heater core. 5. Place the front wheel in the • Electrical connectors from the steering wheel 7straight-ahead position. 6. Remove the SRS module and the • Steering wheel from the steering column . steering wheel by removing or disconnect¬ ing the following: mo by remo o d the • Access panel-to-steering wheel ving r isconnec foldluole ting screws and the panel wing: • SRS module electrical connector • RS module electrical connector • SRS module-to-steering wheel cov¬ Remo • 2 SRS module-to-instrument panel ve nuts ers, located at both sides of the the pand carefully remove the SRS module assen steering wheel ger’s side SRS ► : Bolt, screw locations A ►, 2

B ►, 4

CP-,2

!> : Clip locations A >, 4 BO,4

1 on ■

Oil

Store the SRS module in a safe place with the front facing upward.

removin or disconn t f ect g he ollowing: R•egmConsole ove th panel inand the rear console e str • Center airinvent umusing ent pana suitable el by • 4 climate control unit/audio assembly-to-instrument panel bolts; then, prytool disconnect the electrical connectors and remove the climate control unit/audio assembly

C t>, 2

6 x 1.0 mm 9.8 Nm (1.0 kgf-m, 7.2 Ibf ft)

A/T GEAR POSITION INDICATOR TRIM

SEAT HEATER SWITCH

93112GR2

Exploded view of the console panel, rear console and related components— 3. 5RL

ACURA

1-40

3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX HORN

SWITCH

WIRES

STEERING

WHEEL

WHEEL HORN

LOWER

COVER

SWITCH

RADIO

REMOTE

RADIO

SWITCH

REMOTE

COVER

SWITCH

ACCESS

CRUISE CONTROL SET/RESUME/CANCEL SWITCH

STEERING

CRUISE

PANEL

CONTROL

SET/RESUME/CANCEL SWITCH COVER

DAMPER

SPRINGS STEERING

WHEEL

SLIDE SCREWS

WHEEL

LOWER

COVER

CAP

HORN

PLATE

COVER HORN

RADIO

PLATE

REMOTE

SWITCH

CRUISE

CONTROL

ACCESS

PANEL

SET/RESUME/CANCEL SWITCH 93112GR3

Exploded view of the SRS module, the steering wheel and related components — 3.5RL

;

1-41 ACURA

3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

• Lower instrument panel cover at the passenger’s side • The stop located at each side of the glove box • Damper clip and the electrical con¬ nector while holding the glove box • Glove box-to-instrument panel bolts and the glove box • 3 glove box back cover screws, disconnect the clips and remove 9 the cover • Lower carpet at both sides of the . console • Lower instrument panel cover and the kick panel at the driver’s side • Steering column cover screws and the covers • Combination switch-to-steering column screws, the combination switch and disconnect the electrical connectors • Steering joint cover clamp, screws and the cover • Steering column-to-instrument panel nuts and bolts; then, lower the steering column

• Instrument panel wiring harness connectors, the clip and the air hose • Instrument panel-to-chassis bolts, the screws and the instrument • Steering beam-to-chassis bolts at the panelleft side • Steering beam-to-chassis nuts, the bolt and the steering hanger beam at the right side

heater housing bolt and the cruise control unit. 12. Remove or disconnect the following: • Mode control motor and the air mix control motor connectors • Wiring harness clips and the wiring harness • Heater housing-to-chassis nuts, the bolt andingthe heater housing • Vent/defroster duct-to-heater hous¬ ing screws and the duct • Heater core-to-heater housing pipe clamp screws and the clamps • Heater core-to-heater housing clamp screws and the clamp • Heater core from the heater hous¬

tioni syste refrig ng erant. m 10. Remove the evaporator/blower hous¬ ing by removing or disconnecting the fol¬ lowing: • Refrigerant lines from the evapora¬ tor core Disch arg•e Electrical connectors from the and evaporator/blower housing recov er th e air co housing-to• Evaporator/blower ndi¬the evapora¬ chassis fasteners and tor/blower housing • Clips and the floor heater duct 1 1 . At the left side of the heater hous¬ ing, remove the cruise control unit -toUPPER COLUMN

Exploded view of the steering column and related components— 3. 5RL

To install: 13. Install or connect the following: • Heater core to the heater housing • Heater core-to-heater housing clamp and the clamp screws • Heater core-to-heater housing pipe clamps and the clamp screws • Vent/defroster duct and the duct-toheater housing screws COVER

1-42

ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX ► : Bolt locations

DASHBOARD PROTECTIVE PLATE

PROTECTIVE TAPE

ACCESS

ACCESS

CAP

CAP

IN-CAR TEMPERATURE SENSOR

DASHBOARD WIRE HARNESS AIR HOSE SELF-TAPPING SCREW

CONNECTORS

I

i 93112GR5

Nm)

View of the instrument panel bolt locations— 3. 5RL

• Heater housing and the heater housing-to-chassis nuts and bolt • Wiring harness and the wiring har¬ ness clips • Mode control motor and the air mix control motor connectors • Cruise control unit and the cruise control unit-to-heater housing bolt at the left side of the heater housing • Floor heater duct and the clips 14. Install the evaporator/blower housing by installing or connecting the following: • Evaporator/blower housing and the evaporator/blower housing-tochassis fasteners

• Electrical connectors to the evapo¬ rator/blower housing • Refrigerant lines to the evaporator core using new 0-rings • Steering beam and the steering hanger beam-to-chassis nuts • Steering beam-to-chassis bolts 15. Install the instrument panel by installing or connecting the following: • Instrument panel and the instru¬ ment panel-to-chassis bolts and the screws • Instrument panel wiring harness connectors, the clip and the air hose

• Lower the steering column and torque the steering column-toinstrument panel nuts to 12 ft. lbs. (16 Nm) and bolts to 16 ft. lbs. (22 • Steering joint cover and the cover clamp and screws • Combination switch, the combina¬ tion switch-to-steering column screws and connect the electrical connectors • Steering column covers and the cover screws • Lower instrument panel cover and the kick panel at the driver’s side

1-43 ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX VENT/DEFROSTER

DUCT

Exploded view of the heater core, heater housing and related components— 3. 5RL

• Lower carpet at both sides of the console • Glove box back cover, connect the clips and install the 3 cover screws • Glove box and the glove box-toinstrument panel bolts • Damper clip and the electrical connector while holding the glove box • The stop at each side of the glove box • Lower instrument panel cover • Climate control unit/audio assem¬ bly; then, connect the electrical connectors and install the 4 climate

control unit/audio assembly-toinstrument panel bolts • Center air vent.

• Steering wheel to the steering col¬ umn and torque the nut to 36 ft. lbs. (49 Nm)

• Console panel and the rear console

• Electrical connectors to the steering wheel • SRS module to the steering wheel • Both SRS module-to-steering wheel bolts and torque to 84 inch lbs. (9.8 Nm) using a T30 Torx bit • SRS module-to-steering wheel cov¬ ers • SRS module electrical connector • Access panel-to-steering wheel screws and the panel

16. Install the passenger’s side SRS module lowing: by installing or connecting the fol¬ Nm) • SRS module and the 2 SRS module-to-instrument panel nuts; then, torque the nuts to 84 inch lbs. (9.8 • SRS module electrical connector 17. Install the SRS module and the steering wheel by installing or connecting the following:

1-44

ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

18. Connect the heater hoses to the heater core. 19. Refill the cooling system. 20. Connect the negative battery cable. 21 . Evacuate, charge and leak test the air conditioning system. 22. Operate the engine to normal operat¬ ing temperatures; then, check the climate control operation and check for leaks. NSX

:: CAUTION Before starting service procedures on components, especially under the instrument panel and/or near the steering column, disable the SRS system. In addition, the vehicle may be equipped with a radio anti-theft code (5 digits). Get this code from the customer before disconnecting the battery.

1 . Before servicing the vehicle, refer to

• Reconnect the battery. When the word “CODE” appears, re-enter the 5-digit code in the radio, if

the precautions in the beginning of this sec¬ tion. 2. If equipped with SRS or an anti-theft radio, perform the following procedures: • Disconnect the negative battery cable, then disconnect the positive battery cable. • Remove the access panel beneath the air bag on the under-side of the steering wheel center housing. • Disconnect the connector between the air bag and the cable reel and install the short connector (red) that is provided. Install this con¬ nector on the air bag side of the connector. • The system is now disabled. When repairs are complete, unplug the red short connector, reconnect the air bag and cable reel connector and replace the access panel.

HEATER

equipped. • When the ignition is turned to the II position, the SRS light on the instrument cluster should come ON for about 6 seconds, then go out. If so, the system is okay.

i: WARNING Do not use electrically powered test equipment on this system or related circuits. All SRS wiring is covered with a special yellow cable housing for identification.

K* CAUTION All SRS wiring harnesses are covered with yellow outer insulation. Before disconnecting any part of the SRS PIPE CLAMP

CORE

HEATER EXPANSION

Exploded view of the heater core/evaporator assembly — NSX

VALVE

CORE

COVER

1-45 ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX wire harness, install short connection to prevent accidental discharge of the air bag system. If the SRS harness assembly should have an open circuit or damaged wiring, replace the entire affected harness.

3. Disconnect the negative battery cable. 4. Properly drain the cooling system. Properly discharge the air conditioning sys¬ tem using an approved refrigerant recover/recycling system. 5. Remove or disconnect the following: • Blower assembly • Refrigerant lines from their connec¬ tion at the firewall. Cap all opening immediately to keep dirt and mois¬ ture from contaminating the sys¬ tem.

6. Remove the dashboard by removing or disconnecting the following:

• Front seats

• Knee bolster, pad, dashboard stay and center armrest • Clock, center air vent and center console panel • Heater/air conditioning control panel and the radio assembly • Right dashboard lower panel. Remove the glove box • Lower the steering column • Instrument cluster bezel and the instrument cluster • Air vents from both ends of the dashboard • U-plate at the foot of the center console, rearward of the parking brake • Defrost outlet grille, remove the mounting bolts and lift out the dashboard. Note the position of the center guide pin for reinstallation.

ing: 7. Remove or disconnec t the follow¬ • Heater duct

• Connectors from the control u nit and from the evaporator tempera¬ ture sensor, then remove the con¬ trol unit and bracket • Sound system speaker • Connectors from the control unit and from the evaporator tempera¬ ture sensor, then remove the con¬ trol unit and bracket • Sound system speaker • Actuator connectors and sensor connectors from the heater-evapo¬ rator unit • 2 under-dash mounting bolts and remove the heater-evaporator unit

door passen the now throug 8. The unith can beger’s disasse mbled and the heater core removed.

RETRACTOR SWITCH/DASH BRIGHTNESS CONTROLLER

L. DASH SENSOR

CABLE REEL and MAIN HARNESS

DASHBOARD PANEL

LOWER

KNEE 80LSTER PAD 93112G06

Exploded view of the dashboard and related components— NSX

1-46

ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

To install:

removal procedures . 10. Add 0.3 oz. of extra refrigerant oil if the evaporator core was replaced. 9. 1 1 . Adjust the heater valve cable, if needed. Installation is the reve rse of tand 12. Refill the cooling system he bleed the system by performing the following pro¬ cedure:

.

:: WARNING Failure to properly bleed the air from the cooling system could cause engine damage.

24. Turn the engine OFF, check and adjust the coolant to the MAX line if needed. 25. Install the coolant tank cap securely and install the car’s undercover. 26. Evacuate, charge and leak test the air conditioning system. 27. Connect the negative battery cable.

Cylinder Head REMOVAL & INSTALLATION 1.8L Engines

2. Before removing the cylinder head, be sure the engine temperature is below 100°F (38°C); a fully cooled engine is best. 3. Disconnect the negative battery cable. 4. Be sure the crankshaft is at TDC on No. 1 cylinder by aligning the white mark on the crankshaft pulley with the pointer on the lower timing belt cover. 5. Drain the engine coolant. 6. Properly relieve the fuel system 7. Remove or disconnect the following: pressure. •• Cylinder cover Crankshafthead pulley

• Middle and lower timing belt cov¬ ers • Timing belt 13. Turn the ignition switch ON and of this sec¬ in the begi t p slowly set the climate control temperature tihoen. recaut nnin i g ons knob to 90. This will allow the coolant in the heater to drain out with the rest of the system. 14. Open the hood, rear hatch and the 1 B engine cover. efor e se 15. Remove the cover protecting the rvic ing under¬ the on cables the shift and water pipes vehi side of the car. cle, refer 16. Carefully loosen the coolant reserve to tank cap. Loosen the drain plug at the bot¬ tom of the radiator. Remove the 2 drain bolts from the water pipes. Install rubber hoses to the drain bolts at the front and rear of the engine under the cylinder bank and loosen the drain bolts to drain the coolant. 17. Coolant will drain more quickly if all the air bleed bolts, plug and cap are opened. Be sure the coolant reserve tank 7923BG07 has drained completely before opening the air bleed bolts. Cylinder head torque sequence— 1.8L (B18B1) engine 18. Using new washers on the water pipe drain bolts, install the drain bolts and radia¬ CYLINDER HEAD BOLT tor drain plug. TORQUE SEQUENCE 19. Open all 4 air bleeder bolts (radiator, heater pipe, water pipe and engine thermo¬ 11 X 1.5 mm stat cover). 81 N m 18.3 kgf-m. 60 Ibf ft) 20. Using approved coolant in a 50/50 mixture, fill the coolant reserve tank. Tighten the bleeders in sequence; thermo¬ stat cover bleed bolt, radiator bleed plug, heater pipe bleed cap, and water pipe bleed bolt as coolant runs out in a steady stream with no bubbles. 21 . After tightening all the bleed bolts, fill the coolant tank to the MAX line. Loosen the thermostat bleed bolt to remove any remaining air. 22. When bleeding is complete, tighten the thermostat bolt and fill the coolant reserve tank to the MAX line again. Install the tank cap to the 1st detent. 23. Start the engine and run it to normal operating temperatures (thermostat opens and radiator cooling fan runs).

7923BG08

Cylinder head torque sequence — 1.8L (B18C1, B18C5) engines

1-47 3.2TL * 3.2CL • 3.5RL • INTEGRA • RSX • NSX

• • • •

Camshaft pulleys Back cover Exhaust manifold cover Exhaust manifold and bracket 8. Loosen the locknuts and adjusting screws, then remove the camshaft holder bolts. Remove the camshaft holders, camshafts and rocker arms. 9. Remove the cylinder head bolts, then remove the cylinder head. To prevent warpage, unscrew the bolts in the reverse of the torque sequence, Vz turn at a time. Repeat the sequence until all bolts are loos¬ ened. To install: 10. Install the cylinder head with a new gasket. Be sure to pay attention to the fol¬ lowing points: • Be sure the No. 1 cylinder is at top dead center and the camshaft pul¬ ley UP mark is on the top before positioning the head in place. • The cylinder head dowel pins and oil control orifice must be cleaned and aligned. • Replace the washer if damaged or deteriorated. • Apply engine oil to the cylinder head bolts and the washers. • Use the longer cylinder head bolts at the No. 1 and No. 2 positions. 11. Tighten the cylinder head bolts in 2 steps. In the first step tighten all bolts in sequence to 22 ft. lbs. (29 Nm), then in the second step tighten all bolts in the same sequence to 63 ft. lbs. (85 Nm). 12. Install or connect the following: • Intake manifold with a new gasket and torque the bolts in a criss-cross pattern to 17 ft. lbs. (24 Nm) • Intake manifold bracket and torque the bolts to 17 ft. lbs. (24 Nm) • Exhaust manifold and tighten the new self-locking nuts in a criss¬ cross pattern in to 23 ft. lbs. (31 Nm)

• Exhaust pipe with a new gasket and tighten the new nuts to 40 ft. lbs. (54 Nm) 13. Be sure that the keyways on the camshafts are facing up and that the rocker arms are in their original position. The valve locknuts should be loosened and the adjusting screw backed off before installa¬ tion. 14. Place the rocker arms on the pivot bolts and the valve stems. 15. Install the camshafts, then install the camshaft seals with the open side facing in. Install the rubber cap with liquid gasket applied. If the rubber cap has 2 horizontal

marks, align the marks with the cylinder head upper surface. 16. Apply liquid gasket to the cylinder head mating surfaces of the No. 1 and No. 6 intake and exhaust camshaft holders and install them, along with No. 2, 3, 4 and 5. Be sure to pay attention to the following

22. Install or connect the following: • Rear timing belt cover and torque the bolts to 84 inch lbs. (9.5 Nm) • Camshaft pulleys and tighten the retaining bolts to 27 ft. lbs. (37 Nm) (B18B1 engine) or 41 ft. lbs. engines) (56 Nm) (B18C1 and B18C5

points: 17. Do not apply oil to the holder mating surface of camshaft seals.

• Timing belt and adjust the tension • Timing belt cover(s) and torque the bolts to 84 inch lbs. (9.5 Nm) 23. Adjust the valve clearance. • Cylinder head cover and torque the nuts to 86 inch lbs. (9.8 Nm) • Engine side mount and torque the mounting bolts to 38 ft. lbs. (52 Nm) (74 and Nm) the through bolt to 54 ft. lbs.

'•■I or E marks are stamped on the camshaft holders. 18. The arrows marked on the camshaft holders should point to the timing belt. 19. Tighten the camshaft holders tem¬ porarily. Be sure that the rocker arms are properly positioned on the valve stems. 20. Tighten each bolt in 2 steps to ensure that the rockers do not bind on the valves. Tighten the 6mm bolts to 86 inch lbs. (9.8 Nm) and the 8mm bolts to 20 ft. lbs. (27 Nm) working from the middle out¬ ward. 21. Install the keys into the camshaft grooves. To set the No. 1 piston at TDC, align the holes on the camshaft with the holes in the No. 1 camshaft holders and insert 5.0mm pin punches into the holes.

• Crankshaft pulley and torque the bolt to 130 ft. lbs. (177 Nm) 24. Connect the negative battery cable and enter the radio security code. 25. After installation, check to see that all hoses and wires are installed correctly. 26. Fill and bleed the air from the cool¬ ing27. system. Attach the negative battery cable. 28. Enter the radio security code.

OO

o o

(D

o

O -®: 8 X 1.25 mm 27 N m (2.8 kgfm, 20 Ibfft)

-(E): 6 x 1.0 mm 9.8 N m (1.0 kgf m, 7.2 Ibf ft)

7923BG09

Camshaft plate torque sequence— 1.8L engines

1-48

ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

1 2.0L5 Engines .

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable. 3. Drain the coolant. 4. Relieve the fuel system pressure. 5. Remove or disconnect the following: • Fuel feed hose, K20A3 engine only • Drive belt • Intake manifold • Water bypass hose • Exhaust manifold • Timing chain 6. Disconnect the following engine wire harness connectors and wire harness clamps from the cylinder head: • Fuel injector connectors, K20A3 engine • Engine Coolant Temperature (ECT) sensor connector • Exhaust and intake Camshaft Posi¬ tion (CMP) sensor connectors 7. Remove or disconnect the following: • Upper radiator hose and heater hose • Harness holder from the bracket • Connecting pipe mounting bolt and water bypass line mounting bolts • Water bypass hose • Rocker arm assembly • Cylinder head bolts, loosening in sequence, 'A turn at a time until removed • Cylinder head To install: 8. Clean and inspect the cylinder head and mating surfaces. 9. Install a new cylinder head gasket and dowel pins on the cylinder block 10. Set the crankshaft to Top Dead Cen¬ ter (TDC). Align the TDC mark on the crank¬ shaft sprocket with the pointer on the cylinder block. 11. Measure the diameter of each cylin¬ der head bolt at point A and point B, as shown in the illustration. If either specifica¬ tion is less than 0.42 in. (10.6mm), you must replace the cylinder head bolt. 12. Carefully position the cylinder heads on the engine. 13. Lubricate the cylinder head bolts with clean engine oil. 14. Tighten the cylinder head bolts in 3 steps. Be sure to follow the tightening torque sequence: a. Step 1: 29 ft. lbs. (39 Nm). b. Step 2: 90 degrees. c. Step 3: 90 degrees. d. Step 4 (new bolts only): 90 degrees.

• • • • •

• Rocker arm assembly •InstWater hose all or bypass connect the following:bolt and • Connecting pipe mounting water bypass line mounting bolts • Harness holder on the bracket

Upper radiator hose and heater hose Water bypass hose Intake manifold Exhaust manifold Timing chain

• Fuel feed hose, K20A3 engine only

®

(D 42356-INTE-G06

Cylinder head bolt loosening sequence— 2. OL engines

B 50 mm

(2.0 in.)

A 45 mm

(1.8 in.)

Align the TDC mark on the crankshaft

Measure the diameter of the head bolts to

sprocket (A) with the pointer (B) on the

determine if they are reusable — 2.0L

cylinder block— 2. OL engines

engine

Adjust the valve clearance. • Drive belt • Negative battery cable and enter the radio security code. 17. After installation, check to see that all hoses and wires are installed correctly. 18. Fill and bleed the air from the cool¬ ing system. 19. Attach the negative battery cable. 20. Enter the radio security code.

3.0L, 3.2L and 3.5L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

2. Disconnect the negati ve battery cable. 3. Drain the coolant. 4. Relieve the fuel syste m pressure. 5. Remove or disco nnect the following: • Engine covers • Strut brace • Water bypass hose • Traction Control System (TCS) control valve from the throttle body (if equipped) • Evaporative Emissions (EVAP) can¬ ister hose from the throttle body • Intake air duct • Upper engine covers • Accelerator and cruise control cables from the throttle body > Fuel feed and return hoses • Brake booster vacuum hose 1 PCV hose 1 Intake Manifold Runner Control (IMRC) actuator Wire harness holder Side engine mount bracket Accessory drive belts Power steering pump without dis¬ connecting the lines Ground cable from the engine Alternator Spark plug wires Distributor Intake Air Temperature (IAT) sensor connector Idle Air Control (IAC) valve con¬ nector Throttle Position (TPS) sensor con¬ nector Manifold Absolute Pressure (MAP) sensor connector Engine Coolant Temperature (ECT) sensor connector Radiator fan switch connectors Crankshaft Position (CKP) sensor connector Top Dead Center (TDC) sensor connector

engine

Loosen the cylinder head bolts in the sequence shown— 3. 5L engine

Cylinder head torque sequence— 3. OL engine

1-50

ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

1

• Exhaust Gas Recirculation (EGR) 9 . valve connector

) .

• Engine oil pressure switch connec¬ tor • Ignition coils • Intake manifold • Fuel injector connectors • Fuel rails • Intake Air Bypass (IAB) control valve vacuum hoses • Heater hoses • Upper and lower radiator hoses • Exhaust manifolds • Water passage assembly • Crankshaft pulley • Front timing belt cover 6. Set the engine to TDC by aligning the marks on the crankshaft and camshaft pulleys. • Timing belt • Camshaft pulleys • Rear timing belt covers 7. Loosen each cylinder head bolt 14$ turn at a time in the reverse order of the tightening sequence. 8. Remove the cylinder heads and the oil control orifices. To install: 9. Install the oil control orifices (A) using new 0-rings (B). 10. If removed, install the dowel pins 11. Position new cylinder head gaskets (D) on the cylinder block. 12. If moved, set the crankshaft and camshaft pulleys to TDC by aligning the marks on the pulley and oil pump. 13. Carefully position the cylinder heads on the engine. 14. Lubricate the cylinder head bolts with clean engine oil. 15. Tighten the cylinder head bolts in 3 steps. Be sure to follow the tightening torque sequence: a. Step 1:29 ft. lbs. (39 Nm). b. Step 2: 51 ft. lbs. (69 Nm). c. Step 3: 72 ft. lbs. (98 Nm). 16. Install or connect the following: • Exhaust manifolds with new gas¬ kets and torque the nuts to 23 ft. lbs. (31 Nm) • Rear timing belt covers and torque the bolts to 16 ft. lbs. (22 Nm) 17. Install the camshaft pulleys and torque to: a. 3.0L and 3.2L engines: 67 ft. lbs. (90 Nm). b. 3.5L engines: 23 ft. lbs. (31 Nm. 18. Install or connect the following: • Timing belt • Front timing belt cover and torque the bolts to 108 inch lbs. (12 Nm)

and 0-rings and tighten the bolts to 16 ft. lbs. (22 Nm)

ance.

• Cylinder head cover and tighten the bolts to 108 inch lbs. (12 Nm)

•CheCrankshaft ckNm)an adjupulley and torque the st lbs. the (245 bolt tod 181 ft. valve Nm) clear¬ • Water passage assembly and torque the bolts to 16 ft. lbs. (22

• Ignition coils and torque the bolts to 108 inch lbs. (12 Nm) • Exhaust manifolds and torque the bolts to 23 ft. lbs. (31 Nm)

• Intake manifold with new gaskets

3

5

CYLINDER

HEAD

17

BOLTS

Apply engine oil to the bolt threads. 7923BG12

Cylinder head torque sequence— 3. 2L engine

CYLINDER

HEAD BOLTS TORQUE

SEQUENCE

®

-

rTyHrTl' V ry—»Tag each rocker arm set to assure installation in their original locations. 7. Inspect the rocker arm pistons. If they do not move smoothly, replace the rocker arm assembly. 8. Remove the lost motion assembly from the cylinder head. Inspect the lost motion assembly by pushing the plunger with your finger. Replace the lost motion assembly if it does not move smoothly. To install: 9. Install the lost motion assembly to the cylinder head. 10. Apply engine oil to the rocker arm pistons, then bundle the rocker arms with a rubber band. Apply a light coat of clean engine oil to the rocker arms. 11. Position the rocker arms in their original locations, if they are being reused. If new assembles are being used place them in the cylinder head. 12. Lightly coat the rocker arm shafts

ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX with clean engine oil, then install the rocker arm shafts into the cylinder head. A 12mm bolt can be installed into the end of the rocker arm shafts to aid in their installation. Be sure to install the shafts in the proper positions. Remove the 12mm bolts from the rocker arm shafts. 13. Clean and install the rocker arm

1_CO ■ OO

A

shaft orifices with new 0-rings. If the holes in the rocker arm shafts are not aligned screw a 12mm bolt into the end of the shaft to position the it. 14. Install the sealing bolts with new washers and tighten them to 47 ft. lbs. (64 Nm). 15. Install the cylinder head into the vehicle. Loosen the rocker arm adjusting screws (A)— 2.0L engines

2.0L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Cylinder head from the vehicle • Loosen the rocker arm adjusting screws • Camshaft holder bolts, 2 turns at a time in a criss-cross pattern • Timing chain guide B, camshaft holders and camshafts 3. Insert the bolts into the rocker shaft holder, then remove the rocker arm assembly. 4. Disassemble the rocker shafts as necessary. To install: 5. Clean and dry the No. 5 rocker shaft holder mating surface. 6. Apply liquid gasket part No. 08718-0009 evenly to the cylinder head mating surface of the No. 5 rocker shaft holder and install within 5 minutes. 7. Reassemble the rocker arm assembly. 8. Insert the bolts into the rocker shaft holder, then install the rocker arm assembly on the cylinder head. Remove the bolts from the rocker shaft holder. 9. Make sure the punch marks on the VTC actuator and exhaust camshaft sprocket are facing up, then set the camshafts in the holder. 10. Set the camshaft holders and timing chain guide B in place. 11. Tighten the bolts, in sequence, to the following specifications: • 8mm bolts: 16 ft. lbs. (22 Nm) • 6mm bolts (nos. 21 , 22 & 23): 8.7 ft. lbs. (12 Nm) 12. Install or connect the following: • Timing chain, then adjust the valve clearance

Camshaft holder bolt loosening sequence— 2. OL engines

42356-INTE-G12

Insert the bolts (A) into the rocker shaft holder, then remove the rocker arm assembly (B)— 2.0L engines

1-54

ACURA 3.2TL • 3.2CL • 3.5RL • rINTEGRA • RSX • NSX \ -A.

A"V

o

o

EXHAUST

ROCKER

SHAFT EXHAUST

ROCKER

ARM

WASHER

No. 1 CAMSHAFT HOLDER

No. 5 CAMSHAFT HOLDER

RUBBER BAND

«e;

No. 2 CAMSHAFT HOLDER

k

No. 3 CAMSHAFT HOLDER

lA.

No. 4 CAMSHAFT HOLDER

INTAKE ROCKER ARM ASSEMBLY

INTAKE

ROCKER

SHAFT 42356-INTE-G13

Rocker arm disassembly— 2. OL (K20A3) engine

• Cylinder head • Negative battery cable 13. Check for proper engine and valve NSX)operation. train 3.0L, 3.2L and 3.5L Engines (except 1. Before servicing the vehicle, refer to

42356-INTE-G15

Rocker arm assembly tightening sequence — 2.0L engines

the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable. 3. Remove the cylinder head from the vehicle. 4. Loosen the rocker shaft holder bolts 1 turn at a time in the opposite of the instal-

1-55 ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

■'IT

CT

EXHAUST

-TV

r\

ROCKER

SHAFT EXHAUST ROCKER ARM ASSEMBLY

RUBBER BAND

r m

—

.

i n

y~\

—

n

-—

(

d

[

n

[j 1 ;

-—

1 i

No. 1 CAMSHAFT HOLDER

No. 5 CAMSHAFT HOLDER

RUBBER BAND No. 2 CAMSHAFT HOLDER

No. 3 CAMSHAFT HOLDER

No. 4 CAMSHAFT HOLDER

o

INTAKE ROCKER ARM ASSEMBLY

o INTAKE

ROCKER

SHAFT 42356-INTE-G14

Rocker arm disassembly— 2. OL (K20A2) engine

lation sequence. Following this procedure will prevent the camshafts and rocker assemblies from warping. 5. After all bolts are loose, remove the rocker arm shafts as an assembly with the bolts still in the holders. 6. If the rocker shafts are to be disas¬ sembled, note that each rocker arm has a letter A or B stamped into the side. Before disassembling the rocker arms, make a note of the position of each letter so the arms can be reassembled the same way. 7. For 3.2L and 3.5L engines, do not remove the hydraulic tappets from the rocker arms unless they are to be replaced. Handle the rocker arms carefully so the oil does not drain out of the tappets.

8. Lift the camshafts from the cylinder head, wipe them clean and inspect the lift ramps. Replace the camshafts and rockers if the lobes are pitted, scored, or excessively worn. To install: 9. Lubricate the camshaft and its jour¬ nals with fresh engine oil. 10. Place a new camshaft seal on the end of the camshaft. The spring side of the seal must face in. Lubricate the journals and set the camshaft in place on the head. 1 1 . Install the camshaft onto the cylinder head with the keyway pointed up. 12. Apply liquid gasket to the mounting surfaces of the camshaft end holders. 13. Set the rocker arm assemblies in

place and start all the cam holder bolts. Be sure the rocker arms are properly posi¬ tioned and turn each bolt in sequence 2 turns at a time until the holders are seated on the head. Follow this procedure to avoid damaging the camshaft and rocker assem¬ blies. 14. When all the camshaft and rocker holders are seated, tighten the bolts in the same sequence. Tighten the 8mm bolts to 16 ft. lbs. (22 Nm) and the 6mm bolts to 104 inch lbs. (12 Nm). 315. Install or connect the following: • Cylinder head • Negative battery cable 16. Check for proper engine and valve train operation.

1-56

ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

INTAKE INTAKE ROCKER ARM SPRING

INTAKE ROCKER SHAFT B

INTAKE ROCKER SHAFT C

ARM

ROCKER

B

INTAKE ROCKER

(3 places)

(2 places)

SHAFT

INTAKE ROCKER ARM A

A

(2 places)

(3 places) WAVE

WASHER

(4 places)

EXHAUST ROCKER ARM SPRING (2 places)

CAMSHAFT HOLDER L-5 is similar

CAMSHAFT HOLDER L-2 is similar

CAMSHAFT HOLDER L-1 is similar

CAMSHAFT HOLDER L-3 is similar

to R-4

to R-3

to R-5

HT

rTn

.

CAMSHAFT HOLDER L-4 is similar

EXHAUST ROCKER

\

Q, — 0

EXHAUST SHAFT

n

pi

ROCKER

ARM

A

to R-1 EXHAUST ROCKER ARM B (3 places)

to R-2

ROCKER

O-RING

ARM

(3 places)Do not remove NOTE: 'V the hydraulic tappet from the rocker arm except when replacing.

Replace.

HYDRAULIC TAPPET INTAKE

ROCKER

ARM

Letter "A” is stamped on rocker arm.

A

INTAKE

ROCKER

ARM

B

Letter "B" is stamped on rocker arm.

EXHAUST

ROCKER

ARM

Letter "A" is stamped on rocker arm.

A

EXHAUST

ROCKER

ARM

B

Letter "B” is stamped on rocker arm.

L: Left R: Right 7923BG83

Exploded view of the rocker arms and related components — 3.5L engine

1-57 3.2TL*3.2CL*3.5RL«

INTAKE ARMS

INTAKE ROCKER SHAFT B

INTAKE ROCKER SHAFT C

CAMSHAFT

L-1 similar

HOLDER

R-7

EXHAUST

ROCKER

WAVE

WASHER

(12 places)

A

camshaftV HOLDER

CAMSHAFT W HOLDER ® SHAFT L-4 HOLDER similar R-4

R-6

(3 places)

CAM SHA FT L-7 sim ila r

ROCKER

similar

INTAKE ROCKER SHAFT

B

-2LDER ®LHO jjCAMSHAI

INTAKE ROCKER ARM A

ROCKER

(3 places)

12 places)

ACURA

INTEGRA • RSX • NSX

\ R-1 EXHAUST ROCKER ARM

HOLDER

®

(3 places)

SHAFT

EXHAUST ROCKER ARM

®

ROCKER

O-RING

ARM

(3 places)

NOTE: Do not remove the hydraulic tappet from rocker arm except when replacing.

Replace.

HYDRAULIC TAPPET

INTAKE

ROCKER

ARM

Letter "A" is stamped on rocker arm.

A

INTAKE

ROCKER

ARM

B

Letter “B" is stamped on rocker arm.

EXHAUST

ROCKER

ARM

Letter "A” is stamped on rocker arm.

A

EXHAUST

ROCKER

ARM

B

Letter "B" is stampe d on rocker arm.

L: Left R: Right 7923BG84

Exploded view of the rocker arms and related components— 3. 2L engine

1-58

ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX

Nm)

removal procedure, while using the follow¬ ing torque values: • Intake manifold nuts:17 ft. lbs. (23 • ft. Manifold lbs. (23support Nm) bracket bolts: 17 • Strut brace nuts: 17 ft. lbs. (23 Nm) 2.0L (K20A3) Engines

Be sure to loosen the rocker arm shaft bolts in the correct order as shown — 3.0L engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system into a sealable container. 3. Remove or disconnect the following: • Negative battery cable • Intake manifold cover • Intake Air Temperature (IAT) sensor connector • Breather hose • Air cleaner housing • Throttle cover. Fully open the throttle link and cruise control link by hand, then remove the throttle cable and cruise control cable from the links • Locknut, loosen only, then the cables from the bracket • Evaporative emission (EVAP) canis¬ ter hose and brake booster vacuum hose

• Water bypass hoses, then plug them • Intake Manifold Runner Control (IMRC) valve actuator control sole¬ noid valve connector • Positive Crankcase Ventilation Tighten the bolts 2 turns at a time in the sequence shown— 3. OL engine

Intake Manifold REMOVAL & INSTALLATION 1.8L (B18B1, B18C1 and B18C5) Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable. 3. Drain the cooling system into a sealable container. 4. Remove the strut brace (if equipped). 5. Properly relieve the fuel pressure. 6. Remove or disconnect the following: • Intake air duct • Fuel feed and return hoses • PCVhose • Brake booster vacuum hose

• Throttle cable from the throttle body, take great care not to kink or damage the cable 7. Label and disconnect all the emis¬ sion vacuum hoses from the intake mani¬ fold. 8. Label and disconnect the wiring con¬ nected to the intake manifold. Disconnect sensors as needed; release wiring retainers and clips. 9. Remove or disconnect the following: • Water bypass hoses from the mani¬ fold • Attaching the intake manifold to the support bracket • Nuts attaching the intake manifold to the cylinder head in a crisscross pattern, beginning from the center and moving out to both ends • Intake manifold To install:

hose control solenoid valve • (PCV) IMRC valve mounting bolt • Front bumper • Hood switch connector • A/C line bracket mounting bolt • Intake airduct mounting bolt and harness clamps • Upper bracket and cushion mount¬ ing bolts, then the bulkhead • Idle Air Control (IAC) valve con¬ nector • Throttle Position (TP) sensor con¬ nector • Manifold Absolute Pressure (MAP) sensor connector • Evaporative Emission (EVAP) can¬ ister purge valve connector • Intake Manifold Runner Control (IMRC) nector valve position sensor con¬ • Intake manifold and O-rings To install: 4. Install or connect the following: • Intake manifold, with new O-rings.

1-59 ACURA 3.2TL • 3.2CL • 3.5RL • INTEGRA • RSX • NSX INTAKE MANIFOLD Replace if cracked or if mating surface is damaged.

8 x 1.25 mm 22 N m 000

Liters (cc) 1.6(1595)

1.6 (1590)

Engine

Main Brg.

Main Brg. Oil

Shaft

Thrust

Journal

ID/VIN

Journal Dia.

Clearance

End-play

on No.

Diameter

B16A2

2.1644- © 2.1354

D16Y5 2.1654 2.1644-

1.6 (1590)

D16Y7

D16Y8

2.3 (2254)

0.018

0.0007- ©

0.0040.018

0.0016 0.0007- ©

2.1654 2.16442.0(1997)

0.0020

0.0007- © 2.1654 2.1644-

1.6 (1590)

0.0009- ©

0.0016

0.0016

F20C1 F23A1

2.1654 2.1644©

0.0016 070.00 ©

0.004-

3

3

0.004-

2.3 (2254)

2.2(2157)

3.0 (2997)

F23A4

©

©

F23A5

©

©

H22A4

©

©

1.7 (1668)

D17A1

2.16442.1654 1.7 (1668)

D17A2

0.0014

F23A1

©

0.0016 0.0007©

F23A4

©

©

2.3 (2254)

F23A5

©

©

3.0 (2997)

H22A4

©

D17A1 2.1654 2.1644-

1.7(1668)

2.0(1997)

2.3 (2254)

©

J30A1 2.8346 2.8337-

1.7(1668)

D17A2

0.0020 0.00080.0007- © 0.0014 0.0007- ©

2.1654 2.1644-

0.0014

2.1654 2.1644©

0.0016 070.00 ©

F20C1

F23A1

0.0040.018

0.0040.014 0.0040.014

0.014

1.7717 1.77071.8898 1.8888-

4

0.0040.018 0.0040.014 0.004-

1.8888-

2.3 (2254)

F23A4

©

0.0024 0.00080.0020

0.0016 0.00060.0016 0.006 0.0006-

2.0857-

0.0008-

1.7717

0.0017

0.0016

1.7707-

0.00090.0017

0.0006-

0.00090.0020

0.00060.0016

0.00120.0024

0.00060.0016

1.7707-

1.88881.7717

0.018

0.0016

4

1.7707-

0.0008-

1.7717 4

0.0024

0.006 0.00060.018

1.7707-

0.00080.0024

0.0016

1.7717 4

3

4

4

4

0.014 0.004-

4

0.004-

0.0008-

0.00110.0020

1.8898

0.014 0.004-

0.0040.018

0.0024

2.0866

1.7717

0.018 ©

0.006 0.00060.018

1.8898

0.0040.018

0.0040.018

0.0008-

1.7717 1.7707-

4

0.0016 0.0006-

0.0020

1.7707-

4

4

0.00060.0016

0.00060.0016

1.7707-

4

0.0008-

0.00060.0016

0.00120.0024

4

4

0.0008-

0.0017

0.0016

1.7717 1.7717

0.0040.018

0.0040.018

0.0006-

3

0.0040.018

0.004-

2.3 (2254)

2.2 (2157)

2002

0.0014

F20C1 2.1654 2.1644-

2.3 (2254)

0.0020 0.00080.0007- ©

0.0007- © 2.1654 2.1644-

2.0(1997)

0.0040.018

0.00130.0017

0.0017

3

J30A1 2.8346 2.8337-

2001

0.0040.018

1.7707-

1.7717 1.7707-

4

Clearance 0.0016

0.0008-

4

Side

0.0022

1.7707-

0.018 0.0040.014

Clearance

3

0.018

0.004-

Oil

1.7717 1.7717

0.018 2.3 (2254)

3-9

4

1.77071.8898 1.8888-

0.00080.0020

0.00060.0016 0.006 0.00060.018

2.0866

0.00110.0020

2.0857-

0.0008-

1.7717

0.0017 0.0009-

0.0016

1.77071.7717

0.0017

1.77071.8898

0.00060.0016

0.0009-

1.8888-

0.0012-

1.7717

0.0024

1.7707-

0.0020

1.7717

0.00080.0024

1.7707-

0.0008-

0.00060.0016

0.00060.0016 0.006

0.00060.018 43256-ACCO-C06

3-10

HONDA ACCORD • CIVIC • PRELUDE • S2000

CRANKSHAFT _

AND CONNECTING

All measurements

Engine _ Displacement Engine Main Brg. Year_ Liters (cc)

2002

2.3 (2254)

ID/VIN F23A5

Journal Dia. ©

are given in inches. _

Crankshaft _ Main Brg. Oil Shaft Clearance

2003-04

3.0 (2997)

J30A1

1.7(1668)

D17A1

1.7(1668)

D17A2

2.16442.1654

2.1654 2.16442.0(1997)

2.4 (2254)

3.0 (2997)

K24A4

©

Journal 3: 2.1642 - 2.1651 1,2, 4 and 5

Journal 3: 0.0012-0.0021 1 and 5

Journals 2, 3 and 4: 0.0009 - 0.0019 ©Journals

1,2 and 4: 2.1646 - 2.1655

Journal 3:2.1644 - 2.1654 Journal 5: 2.1650 -2.1660 ©Journals

1, 2 and 4: 0.0008 - 0.0020

Journal 3: 0.0010 - 0.0022 Journal 5: 0.0004 - 0.0016

0.0014 0.0007- © 0.0014 0.0016 0.0007©

J30A4

_ Connecting Rod Journal Oil

on No.

0.0020 0.0008-

Diameter

Clearance

Side Clearance

4 1.7717

0.0024

0.0016

0.0040.018

3

1.77072.0866

0.004-

4

2.0857-

0.0008-

1.7717 1.7707-

0.0017

0.0016

0.00090.0017

0.00060.0016

0.00090.0020

0.00060.0016

0.014 0.0040.014 0.004-

4

1.7717 4

0.0040.014

1.77071.8898

0.014

0.0042.83372.8346

1,2, 4 and 5

0.0020 0.00080.0007- ®

F20C1 2.1654 2.1644-

©Journals

Thrust

0.018 2.8346 2.8337-

©Journals

End-play

©

(cont.)

©Journals

ROD SPECIFICATIONS

4

1.88881.8898

3

© Journals 0.004-1 and 2: 1 .9676 - 1 .9685

2.0857-

0.006 0.018 0.0006-

0.00120.0006

0.0006-

0.00020.0020

0.006 0.00060.018

1.88882.0866

0.018

0.00080.0020

0.0016

0.0008-

Journal 3: 1.9674-1.9683 Journal 4: 1.9679 - 1.9688 Journal 5:1.9680- 1.9690 ©Journals

1 and 2: 0.0008 - 0.0020

Journal 3: 0.0010 - 0.0022 Journal 4: 0.0005 - 0.0020 Journal 5: 0.0004 - 0.0016 ©Journals

1, 2 4 and 5: 2.1648 - 2.1657

Journal 3: 2.1644 - 2.1654 ©Journals

1, 2 4 and 5: 0.0007-0.0016

Journal 3: 0.0010-0.0019 43256- ACCO-C07

Top

HONDA

3-11

ACCORD • CIVIC • PRELUDE • S2000 Top

PISTON AND RING SPECIFICATIONS All measurements

are Ring givenGapin inches.

Engine

2000

Displacement

Engine

1.6(1595)

B16A2

Piston 0.008 0.0020 0.0004-

1.6(1590)

D16Y7 0.0020 0.0004-

1.6(1590)

D16Y8 0.00040.0020

2.0(1997)

F20C1 0.00020.0011

2.3 (2254)

F23A1 0.00080.0020

2.3 (2254)

F23A4 0.00080.0020

2.3 (2254)

F23A5 0.00080.0020

2.2 (2157)

H22A4 0.00020.0020

3.0 (2997)

J30A1 0.00060.0030

2001

1.7(1668)

D17A1 0.00040.0016

1.7(1668)

D17A2 0.00040.0016

2.0(1997)

F20C1 0.00020.0011

2.3 (2254)

2.3 (2254)

2.3 (2254)

F23A1

1.7(1668)

F23A5

H22A4

J30A1 D17A1

D17A2 0.00040.0016

2.0(1997)

2.3 (2254) 2.3 (2254)

0.028

0.024 0.0060.024 0.0060.024 0.0100.024 0.0080.024 0.0080.024 0.0080.024 0.0100.024 0.0080.024 0.0060.024 0.0060.024 0.010-

0.024 0.008-

0.00040.0016 1.7(1668)

0.024 0.006-

0.0020 0.0008-

F23A4

0.00060.0030 2002

0.028

0.024 0.008-

0.00020.0020 3.0 (2997)

0.024

0.00080.0020

0.00080.0020 2.2 (2157)

0.016

F20C1

0.024 0.0080.024 0.0100.024 0.0080.024 0.0060.024 0.006-

0.00020.0011

0.024 0.010-

0.0020 0.0008-

0.024 0.008-

F23A1

F23A4 0.00080.0020

0.024 0.008-

0.0120.028 0.0120.028 0.0120.035 0.024-

Ring Side Clearance Bottom

Oil 0.008 0.028

D16Y5 0.00040.0020

1.6(1590)

Bottom

0.031 0.0080.031 0.0080.031 0.0080.031

Oil N/A

0.0050 0.0018-

0.0050

0.0050

0.00160.0050

0.00140.0050

0.0012-

0.00140.0050

0.0012-

0.00140.0035

0.0050

0.0050

N/A N/A

N/A

N/A

0.00120.0028

N/A

0.028

0.0080.031

0.00180.0050

0.00160.0050

0.0160.028

0.0080.031

0.00140.0050

0.00120.0050

N/A

0.00120.0050

N/A N/A

0.0160.028 0.0160.035 0.0240.028 0.0160.024

0.0080.031 0.0080.031 0.0080.031 0.0080.031

0.0120.024 0.0120.035

0.0080.031 0.0080.031

0.0240.028

0.0080.031

0.0160.028

0.0080.031

0.016-

0.008-

0.028

0.031

0.0160.035 0.0240.028 0.016-

0.00140.0050 0.00140.0050 0.00220.0050

0.00120.0050 0.00160.0050

0.00140.0024 0.00140.0024 0.00140.0035 0.00180.0050 0.00140.0050 0.00140.0050

0.0012-

0.00120.0022

N/A N/A

0.00120.0028

N/A

0.00160.0050 0.00120.0050 0.00120.0050

0.031

0.00120.0050

0.0080.031

0.00220.0050

0.00160.0050

0.008-

0.0014-

0.0012-

0.024

0.031

0.0024

0.0022

0.012-

0.0080.031

0.0014-

0.024 0.0120.035 0.024-

0.0080.031

0.0024 0.00140.0035

0.00120.0022 0.00120.0028

0.0080.031

0.00180.0050

0.0016-

0.0080.031

0.0012-

0.028

0.00140.0050

0.016-

0.008-

0.0014-

0.028 0.016-

N/A

0.0022

0.00140.0050

0.008-

N/A

0.0050

N/A

N/A

N/A

N/A N/A

N/A N/A

N/A N/A

0.0050 0.0012-

43256-ACCO-C08

HONDA

3-12

ACCORD • CIVIC • PRELUDE • S2000 T

PISTON ANDop RING SPECIFICATIONS All measurements

Year

Engine Piston Displacement Engine Liters (cc) Clearance ID/VIN

2002

2.3 (2254)

0.0020 0.0008J30A1 0.0030 0.0006-

2003-04

1.7(1668)

D17A1 0.00040.0016

1.7(1668)

D17A2 0.0016 0.0004-

2.0 (1997)

F20C1 0.00020.0011

2.4 (2354)

3.0 (2997)

NA: Not Available

Compression

Ring Gap _ Ring Side Clearance Oil Bottom Top Bottom Control Oil Control N/A Compression Compression Compression

F23A5

(cont.) 3.0 (2997)

_

are given in inches.

K24A4

0.0050

0.024 0.008-

0.028

0.031

0.0050

0.016-

0.008-

0.024 0.008-

0.028

0.031

0.00140.0050

0.00120.0050

0.0080.031

0.00140.0024

0.00120.0022

0.0080.031

0.0014-

0.0012-

0.0080.031

0.00140.0035 0.0018-

0.016-

0.024 0.006-

0.024

0.024 0.006-

0.024 0.0120.035

0.024 0.010-

0.0016 0.0008-

0.0014 0.008-

0.0030 0.0006-

0.024 0.008-

J30A4

0.012-

0.0240.022

0.0080.028

0.0024

0.0028 0.0018-

0.028

0.0080.031

0.016-

0.008-

0.0014-

0.016-

0.0050

N/A

N/A N/A

0.0022 0.00120.0028

N/A

0.00160.0030

N/A

0.00200.0050

N/A

0.001243256-ACC0-C09

3-13 HONDA

ACCORD • CIVIC • PRELUDE • S2000 Ste

VALVE SPECIFICATIONS

Year 2000

Engine Disnlacement Enaine

Seat Anale

Stem-to-Guide Spring Clearance Face Spring Test Installed Anqle Pressure Height (in.)

Liters (cc)

ID/VIN

45 (deg.)

(deg.) (lbs. @ in.)

1.6(1595)

B16A2

45 45

1.6(1590)

D16Y5

45

(in.) NA NA

NA

45 1.6(1590)

NA

D16Y7 45

1.6(1590)

45

NA NA

D16Y8 45

2.0(1997)

F20C1

2.3 (2254)

2.3 (2254)

NA

H22A4

3.0 (2997)

J30A1

1.7(1668) 1.7(1668)

F20C1

NA

F23A4

2.3 (2254)

NA

NA

NA

45 2.2 (2157)

45

H22A4 45

3.0 (2997)

2002

1.7 (1668) 1.7 (1668)

J30A1 D17A1 D17A2

45 45

F20C1

F23A4

0.0018 0.0008-

0.0031

0.00080.0020

0.0030

0.0010-

0.0018 0.0008-

NA

0.00080.0020

0.00080.0020

0.0008-

45

NA

NA NA

0.0020-

0.0020

0.0020 0.0010-

NA

0.0031

0.0008-

NA

NA

0.0022-

0.0031 0.0020-

0.0022 0.00100.0018

NA

45

F23A1 45

2.3 (2254)

0.0020-

NA

NA

45 45

0.0010-

0.0020

0.0018 0.00080.0018 0.0008-

0.21590.2163

0.0031 0.00220.0031

NA

45

0.0031 0.0022-

0.00080.0022

0.0018 0.0008-

NA 45

2.3 (2254)

NA

NA

45 2.0(1997)

NA

NA

45

0.0008-

0.0018 0.0008-

45

F23A5

0.2146- (in 0.2150

0.21460.2150

NA

45

0.21460.2150

0.21590.2163

0.0018

NA

45

0.21570.2161

0.21460.2150

45 2.3 (2254)

0.2150 0.2146-

0.2163

NA 45

F23A1

0.21570.2161

0.0031 0.0022-

NA

45 2.3 (2254)

0.0030

0.0018 0.0008-

NA NA

45

0.0020-

0.0020 0.0010-

0.2157-

45 2.0 (1997)

0.0010-

0.0020-

NA

45

D17A2

0.21460.2150

0.0010-

NA 45

0.21560.2161

0.21570.2162

NA

D17A1

0.0030

0.0030

NA

45 45

0.0020

0.0018

45

45

0.2150

0.0020-

NA 45

0.2159

0.0010-

45 2.2 (2157)

0.0031 0.0020-

0.0020

NA NA

45

0.0022 0.0010-

NA

NA

F23A4

F23A5

Exhaust

0.00200.0030

NA

45 45

Intake

0.0020

NA

F23A1 45

2.3 (2254)

45

Exhaust

NA

45 45

Intake

Diam eter

NA

45

2001

m

0.0020-

0.0031 0.0022-

0.0031 0.0022-

0.0031 0.00220.0031 0.0020-

0.0031 0.0022-

0.21460.2150

0.21590.2159

0.21460.2159

0.21560.2163

0.21560.2150

0.21590.2161

0.2150 0.2146-

0.21570.2161

0.21460.2150

0.21570.2162

0.21460.2150

0.21570.2163

0.21460.2150

0.21590.2163

0.21590.2163 0.21590.2159 0.21560.2163

0.21460.2150

0.21460.2150

0.21460.2159 0.21560.2150

0.21590.2161

0.21460.2150

0.21570.2161

0.21460.2150

0.00200.0030

0.21570.2162

0.21460.2150

0.0020-

0.21570.2163

0.0031 0.00200.0031

0.0031 0.00220.0031 0.0022-

0.21590.2163 0.2159-

0.21460.2150

0.2150 0.214643256-ACC0-C1

0.2146-

3-14

HONDA ACCORD • CIVIC • PRELUDE • S2000

VALVE SPECIFICATIONS Spring Engine Year

Displacement Liters (cc)

Engine ID/VIN

2002

2.3 (2254)

F23A5

(cont.)

Seat Angle (deg.) 45

1.7(1668)

Height

(deg.) 45

(lbs. @ in.)

(in.)

45

D17A1

NA

NA

45

D17A2

NA 45

2.0(1997)

F20C1

NA: Not Available

J30A4

Exhaust

(in.) Intake Exhaust

NA

0.2163 0.21590.2163

0.2150 0.21460.2150

0.0031

0.2161

NA

0.0020 0.0008-

0.0020-

0.21570.2161

0.21460.2150 0.21460.2150

NA NA

45

0.0031

NA

NA

45 3.0 (2997)

(in.) Intake

0.0031 0.0022-

NA

45 K24A4

Diameter

0.0018 0.0008-

45

45 2.4 (2354)

Clearance

0.0022NA

45 45

1.7(1668)

Stem

0.0018 0.0008-

NA

J30A1 45

2003-04

Angle

Spring Test Pressure

Stem-to-Guide

NA 45

3.0 (2997)

Face

Installed

NA

0.2159-

0.0020

0.0031

0.0008-

0.0020-

0.0020 0.0010-

0.0030

0.21570.2162

0.0020-

0.2157-

0.0022 0.0012-

0.0031

0.2159

0.0018

0.00220.0031

0.21560.2163

0.0008-

0.0022-

0.2159-

0.2150 0.2146-

0.21460.2150 0.21460.2150 0.214643256-ACC0-C12

3-15 HONDA ACCORD • CIVIC • PRELUDE • S2000

TORQUE SPECIFICATIONS All readings

Engine Displacement

Engine

Main Bearing

Cylinder Head

in ft. lbs.

Bearing Rod

Crankshaft Damper

23 Manifold

Flywheel 76

13 Spark 13

2000

B16A2

©

©

1.6 (1590)

D16Y5

©

©

1.6 (1590)

D16Y7

©

©

23 30 23

1.6(1590)

D16Y8

©

©

23

2.0 (1997)

F20C1

©

©

®

181

2.2(2157)

H22A4

©

2.3 (2254)

F23A1

©

® 54

©

181 181

87 © 94 ©

2.3 (2254)

F23A4

©

®

© 34

181

2.3 (2254)

F23A5

3.0 (2997) 2001

1.7 (1668)

J30A1 D17A1

1.7(1668)

D17A2

2.0(1997) 2.2 (2157)

F20C1 H22A4

2.3 (2254)

F23A1

2.3 (2254) 2.3 (2254) 2002

2003-04

©Step

©Step

©Step

©Step

©

87

©

©

23 23 23

13 13 13

23

13

80

23

13

80

23

13 13

80

23

13 13

80

23 23 23 23

13

80

©

© ® 24

©

® 54

©

®

© 34 ©

©

®

©

©

©

©

2.3 (2254)

F23A1

©

®

©

2.3 (2254)

F23A4 F23A5

©

®

©

®

©

©

©

©

1.7 (1668)

J30A1 D17A1

1.7(1668)

D17A2

©

©

2.0 (1997)

F20C1

©

©

2.4 (2354)

K24A4

3.0 (2997)

J30A4

Step 3: Rotate 90 degrees Step 4: If new bolt rotate

80

24

©

1:22 ft. lbs.

80 80 80

©

F20C1

Step 2: Rotate 90 degrees

13

©

2.0 (1997)

Step 2: 38 ft. lbs.

13 13 13 13

24 ® 24

1:18 ft. lbs.

23 23 23 23

©

to 49 ft. lbs.

© 16 16 16

©

Step 4: Bolts 1-2, retorque

80

©

D17A2

Step 3: 49 ft. lbs.

13

©

1.7(1668)

1:14 ft. lbs.

23

16

©

Step 2: 36 ft. lbs.

13

©

©

Step 2: 54 ft. lbs.

80

181

D17A1

1:18 ft. lbs.

80

23 23 23

181

©

@ ©

© ©

80

®

1.7(1668)

1:22 ft. lbs.

16 16 16

13

©

©

Step 2: 61 ft. lbs.

87

13

23

®

J30A1

3.0 (2997)

87

17 16 17 17

23

80

©

©

F23A4 F23A5

134 134 134

13

80

23

3.0 (2997)

2.3 (2254)

©Step

17

130

1.6(1585)

Lug

©Step

1:18 ft. lbs.

Step 2: Plus 90 degrees ©Step

1:29 ft. lbs.

Step 2: 51 ft. lbs. Step 3: 72.3 ft. lbs. ©Automatic

transaxle: 54 ft. lbs.

Manual transaxle: 76 ft. lbs. ® Step 1 : 1 1mm bolts, 29 ft. lbs. Step 2: 1 1mm Step 3: 6mm ©Step

87 ©

181

©

181

94 ©

181

©

87 87

© 181

©

181 181

©

©

181

©

24 24 ®

16 16 16

16 16 16 16

© 94 ©

©

16

©

181

16 16 16 16

23 23

80 80 80 80

80 13 13 13

80 80 80 80

©

23

13

80

©

23

13 13 13

80

87

181

16

©

©

181

Step 2: Bearing cap bolts plus 60 degrees bolts to 16 ft. lbs.

181

181 ©

Step 1 : Bearing cap bolts to 22 ft. lbs.

Step 3: 8mm

181

16 16 16

87 © 94 ©

16 16 16

23

23

80 80

33 13

80

© Step 1 : Cap bolts, 56 ft. lbs. Step 2: Side bolts, 36 ft. lbs. ©Step 1:29 ft. lbs. Step 2: Rotate 90 degrees Step 3: Rotate 90 degrees Step 4: If new bolt rotate additional 90 degrees ©Step 1:22 ft. lbs. Step 2: Rotate 56 degrees ©Step

1:36 ft. lbs.

Step 2: Rotate 90 degrees

bolts, 58 ft. lbs. bolts, 8.7 ft. lbs.

1:14 ft. lbs.

Step 2: Rotate 90 degrees

additional 90 degrees 43256- ACCO-C 18

3-16

HONDA ACCORD • CIVIC • PRELUDE • S2000 Steering

WHEEL ALIGNMENT Caster Range

Setting Preferred

Range 1.00

2000

Accord Civic Prelude

F

—

—

F

—

R

— 1.00

+1.66 —

F

Accord Civic Prelude S2000

2002

Accord Civic S2000

2003-04

Accord Civic S2000

0.50 — — 1.00

+2.66 1.00

-0.50

-1.00 +0.06 -0.45 -0 0 .50 -1.50 0 -0.50

+6.00

— 1.00

— +2.80

R

—

0.50

F

—

— +1.66

—

-0 5 -0.4 0 .50

R

— 1.00

— 1.00

-1.50

F

— +2.66

R

—

—

1.00

0 -0.50

F

0.75

+6.00

R

— 1.00

— +2.80

R

—

F

—

— +1.66

F F

F

—

0.50 0.50 1.00

0.50 0.50 1.00 0.50 —

R

—

F

0.75

— +6.00

R

— 1.00

— +2.80

0.50 1.00

R

—

F

— +1.66

0.50

—

R

—

F

0.75

— +6.00

— 0.50

R

—

—

0.50

F

—

-1.00 +0.06

Inclination Toe-in

-

0 +/- 0.03

_

0.03 +/- 0.03 0.03 0.03

—

'

-

—

0 +/- 0.03 0.03 +/- 0.03 0 +/- 0.03 0.1 2+/- 0.03 0 +/- 0.03 0.03 0.03 +/- 0.03 0.03

—

_ _ —

_ —

0 +/- 0.03

_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

0.12+/- 0.03

—

0 +/- 0.03 0.03+/- 0.03 0 +/- 0.03

-1.00 +0.06 -0.50

0.12+/- 0.03 0+/-0.03

-1.50 0 -0.50

0.03 +/- 0.03 0.03 0.03 0 +/- 0.03

0.50

—

Axis

Setting Preferred

— 0.75

R 2001

+2.80

R

R S2000

1.00

Camber

-1.00 +0.06 -0.50

0.12+/- 0.03 0 +/- 0.03

-1.50 0

0.03 0.03 +/- 0.03 0.03

43256-ACC0-C13

3-17 HONDA ACCORD • CIVIC • PRELUDE • S2000 WHEEL

Camber

Caster Range rear 2000

Accord

Prelude

1.00

F

S2000 Accord Civic

—

+1.66

R

—

—

—

F

0.75 —

Accord

Civic S2000

Civic S2000

1.00

+6.00 —

+2.80 —

F

_

+1.66

—

—

F

0.75

R

—

1.00

F

+2.66 —

+6.00 —

+2.80

R

—

F

_

+1.66

R

—

—

F

0.75

R Accord

—

—

—

—

F

1.00

—

+6.00 —

+2.80

R

—

—

F

—

+1.66

R

—

—

F R

!

0.75 -

—

1.00

R

1.00

0.50

+2.66

1.00

F

1.00

—

F

R S2000

—

1.00

F

Setting Preferred -0.50

Axis

-1.00 +0.06

Toe-in 0 +/- 0.03

— —

F

R Prelude

+2.80

—

R

2003-04

Range

Inclination

R

R

2002

Setting Preferred

moaei

Civic

2001

Steering

ALIGNMENT

+6.00 —

-00.45 -0.50

0.03+/- 0.03 0.03

-10.50

0.03 0 +/- 0.03

-0.50

0.03 +/- 0.03 0 +/- 0.03

—

-1.00 +0.06

0.12+/- 0.03 0+/-0.03

—

0.50 —

—

1.00 1.00

0 -0.45 -0.50 -1.50 0

0.50

—

0.03 +/- 0.03 0.03 0.03 0 +/- 0.03

—

-1.00 +0.06

0.12+/- 0.03 0 +/- 0.03

—

-0.50 0

—

—

0.03 +/- 0.03 0.03

— —

-0.50 LOo -1.00 +0.06 -0.50

0.03 0+/-0.03

-1 0.50

— —

1

—

—

—

0.50

—

—

—

—

0.50

—

0.03+/- 0.03 0 +/- 0.03

—

0.50 1.00

—

-0.50

0.50 0.50 1.00

—

—

0.50 0.50 1.00

—

0.12+/- 0.03 0 +/- 0.03

— —

0.03 +/- 0.03

—

0.03 0.03

—

0.50

0+/-0.03

0.50

0.12+/- 0.03

—

—

3-18

HONDA ACCORD • CIVIC • PRELUDE • S2000

BRAKE SPECIFICATIONS

Lining

All measurements in inches unless noted Brake Disc Year

Original Thickness

Model

2000

Accord Civic

Prelude

S2000 2001

Accord

Civic Prelude

S2000

2002

Accord

Civic

S2000

2003-04

Accord Civic

S2000

F

Minimum

Maximum

Original Inside

Thickness

Runout

Diameter

0.830

0.004

R

0.910 0.358

0.310

F

0.840

0.750 —

0.004 0.004

—

Max. Wear Limit —

Maximum Machine Diameter —

Thickness Front 0.060

8.66

8.70

—

—

—

7.91

7.91

—

—

0.060

—

—

—

8.70

—

0.060 —

R

—

F

0.910

0.830

R

0.390

0.320

0.004

—

F

0.990

0.910

0.004

—

—

—

0.060

R

0.476

0.390

0.004

—

—

—

—

F

0.910

0.830

—

—

R

0.358

F

0.840

0.310 0.750

0.004 0.004

—

R

—

F

0.910

0.830

R

0.390

0.320

F

0.990

0.910

R

0.476

0.390

0.910

0.830

0.004 0.004

F

—

—

0.004

0.004 —

8.66 —

7.87

8.70 —

7.91

—

0.080 © —

Bolts

(ft. lbs.)

(ft. lbs.)

—

©

—

— 83 —

© 17

—

0.080

0.060

8.70

0.060 —

0.060 —

0.080 ©

—

0.060 —

—

©

—

7.91

—

0.080

—

17

80

24

41

17

—

©

—

17

— 83

©

—

—

©

—

—

—

0.004

—

—

—

0.060 —

0.060

— 41

17

0.004

—

—

—

0.060

—

80

24

—

—

—

—

—

—

— 0.060

—

© 17 17

0.358

0.310

0.004

F

0.840

0.750

R

—

—

0.004 —

F

0.990

0.910

R

0.476

R

—

—

—

7.87

7.91

7.91

— 0.060

0.080

—

0.390

0.004

—

—

—

—

0.910 0.400

0.830

0.004

—

—

—

0.060

0.840

0.750

—

—

—

F

0.990

0.910

R

0.476

0.390

—

0.060

—

F

— 0.080 ©

8.70 —

—

R

0.060

8.70 —

—

0.004 0.004

—

8.66 —

0.004

0.310

Rear

Bracket Bolts

0.004

R

F

7.87 —

Mounting Brake Caliper

Minimum

Brake Drum Diameter

8.66 —

7.87

8.70 —

7.91

8.70

—

—

0.060 —

—

0.004

—

—

—

0.060

0.004

—

—

—

—

80 41

17

—

©

—

17

—

©

—

41

—

80

24

0.080 ©

—

—

7.91

0.060

0.080 —

24 © —

17

0.060

NA: Not Available F: Front R: Rear ©

Calipers with long pins beyond bolt threads, 54 ft. lbs. Calipers with no pin beyond threads, 20 ft. lbs.

©With

rear disc: 0.060 43256-ACCO-C15

3-19 HONDA ACCORD • CIVIC • PRELUDE • S2000

SCHEDULED

INTERVALS

MAINTENANCE

Honda — Civic, Accord, Prelude & S2000 VEHICLE 15

TYPE OF SERVICE

7.5

Engine oil & filter

R

✓

y

Front brake pads

S/I

✓

Rotate tires

S/I

V V

Cooling system, hoses &

rnnnprtions Driveshaft boots Exhaust system Front brake discs & calipers Front wheel alignment

S/I S/I S/I S/I S/I

Front & rear wheel alignment

rPrfihirip w/4WSI

S/I

Fuel pipes, hoses & connections

S/I

Parking brake adjustment Power steering system

S/I S/I

Rear brake discs, calipers &

narls

S/I

Suspension components

S/I

Suspension mounting bolts Tie rods, steering gear box & boots

S/I

Parking brake Air cleaner element

30

y y y

y y y

S/I

52.5

60

✓

y y y

y y

✓

(xIOOO) 67.5

75

82.5

90

97.5

/

✓

✓

y

y y

y y

y y y

y y

y

✓

y

y

y

V

y

y y

y y

y y

y y

y y

y

y

y

y

y

y

V

y

y

y

y

y

y

y

y

y

y

y

V

y

y

y

y

y

y y

y y

y y

y y

y y

y y

y

y

y

y

y

y

V y

y y

y y

y y

y y

y y

y

y

y

y

y

y

y

y

y

y

y

y

S/I S/I R

INTERVAL

V

Valve clearance (Accord L4, Civic & Prelude non-VTEC)

V y y

37.5

S/I

Valve clearance (Prelude VTECt ©

22.5

MILEAGE 45

y

V'

TO BE SERVICED

y

y

y

y y

y y

y y

Transmission fluid (Civic CVT)

R

y

Transmission fluid (A/T or

R

y

y

y

y

y y

y

M/T) (except as noted below) Transmission fluid (Prelude L4)

R

Brake fluid (including ABS)

R

y y

y

y

(Anrorri V6) Brake fluid (including ABS)

y

y

R

(Accord L4, Civic, & Prelude) Spark plugs (non-VTEC) Spark plugs (VTEC)© ABS operation

R

Alternator drive belt Power steering pump belt

S/I

Rear brake drums, wheel PrplnHpt

Engine coolant

y y y

y

y

y

R S/I S/I

cylinders & linings (except

y y y

y y y y y

y

S/I R

y

y

y 43256-ACC0-C16

3-20

HONDA ACCORD • CIVIC • PRELUDE • S2000

SCHEDULED

MAINTENANCE

INTERVALS

Honda — Civic, Accord, Prelude & S2000 VEHICLE TO BE SERVICED

TYPE OF SERVICE

Fuel filter

R

Timing belt

R

Timing balancer belt

R

S/I

Ignition wires

S/I

PCV valve

S/I

converter heat shield

Water pump R: Replace

30

S/I

Idle speed

TWC

15

22.5

R

ABS high pressure hose

Distributor, ignition cap & rotor

7.5

S/I

37.5

MILEAGE 45

INTERVAL

52.5

60

(xIOOO) 67.5

75

82.5

90

97.5

✓ V V S V V V S S

S/I

S

S/I: Service or Inspect

©S2000: 105,000 miles

FREQUENT OPERATION MAINTENANCE (SEVERE SERVICE) It a vehicle is operated under any of the following conditions it is considered severe service: - Extremely dusty areas.

- 50% or more of the vehicle operation is in 32°C (90°F) or higher temperatures, or constant operation in temperatures below 0°C (32°F). - Prolonged Idling (vehicle operation in stop and go traffic).

- Frequent short running periods (engine does not warm to normal operating temperatures).

- Police, taxi, delivery usage or trailer towing usage. Oil & oil filter: change every 3750 miles. Driveshaft boots: service or inspect every 7500 miles.

Front brake discs & calipers, & rear brake discs, calipers & pads: service or inspect every 7500 miles. Power steering system: service or inspect every 7500 miles. Suspension components: service or inspect every 7500 miles.

Tie rods, steering gear box & boots: service or inspect every 7500 miles.

Air cleaner element: service or inspect every 15,000 miles. Transmission fluid (Accord V6 & Civic CVT): replace every 15,000 miles. Transmission fluid (Accord L4, Civic, & Prelude): replace every 30,000 miles. Timing balancer belt: replace eveiy 60,000 miles. Timing belt: replace every 60,000 miles. Water pump: service or inspect every 60,000 miles. 43256-ACC0-C17

HONDA ACCORD • CIVIC • PRELUDE • S2000

O.Oi ■

&

PRECAUTIONS Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: • Never open, service or drain the radia¬ tor or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. • Observe all applicable safety precau¬ tions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. • Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. • Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If

eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance. • The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas as soon as possible after expo¬ sure to used engine oil. Soap and water, or waterless hand cleaner should be used. • All new vehicles are now equipped with

proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in con¬ tact with a painted surface; it will damage

an air bag system. The system must be dis¬ abled before performing service on or around system components, steering col¬ umn, instrument panel components, wiring and sensors. Failure to follow safety and dis¬ abling procedures could result in accidental air bag deployment, possible personal injury, and unnecessary system repairs. • Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a nondeployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section. • Clean, high quality brake fluid from a sealed container is essential to the safe and

important! Many models utilize an interfer¬ ence-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing poten¬ tially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this section for the recommended replace¬ ment interval for the timing belt, and to the timing belt procedure in this section for belt replacement and inspection. • Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer sys¬ tem^) and may require the computer to undergo a relearning process once the neg¬ ative battery cable is reconnected. • When servicing drum brakes, only dis¬ assemble and assemble one side at a time,

the paint. • Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine damage. • Timing belt maintenance is extremely

leaving the remaining side intact for refer¬ ence.

ENGINE REPAIR ^Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board com¬ puter systems and may require the computer to undergo a relearning pro¬ cess, once the negative battery cable is reconnected.

Distributor REMOVAL f^The radio may contain a coded theft protection circuit. Always obtain the code number before disconnecting the battery. If the vehicle is equipped with 4WS, the steering control unit is shut down when the battery is disconnected. After connecting the battery, turn the steering wheel lock-to-lock to reset the steering control unit.

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Rotate the crankshaft to bring No. 1 cylinder to TDC, and align the white mark on the crankshaft pulley with the pointer on the timing belt cover. 4. Remove or disconnect the following: • Distributor cap with the ignition wires attached • Electrical connectors from the dis¬ tributor 5. Mark the direction the ignition rotor is pointing on the distributor housing to aid in installation. 6. Matchmark the distributor housing with the cylinder head to aid in installation. • Distributor mounting bolts and remove the distributor • O-ring from the distributor hous¬ ing, then discard the O-ring

DISTRIBUTOR END

CAMSHAFT END

7923FG01

Distributor components — 1.6L engines

3-22

HONDA ACCORD

• CIVIC • PRELUDE

• S2000

INSTALLATION

2.0L Engine

1. Coat a new 0-ring with clean engine oil and install it to the distributor housing. 2. Align the ignition rotor with the mark made on the distributor housing. The drive lugs are offset so the distributor cannot be installed incorrectly. Fit the distributor into place and turn the rotor until the drive lugs engage and the distributor seats in the cylinder head.

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Accessory drive belt • 4P connector and battery terminal wire • Alternator bolts • Alternator

'■►The lugs on the end of the distributor and their mating grooves in the camshaft end, are offset to eliminate the possibility of installing the distribu¬ tor 180° out of time.

3. Align the matchmark on the distribu¬ tor housing and the cylinder head and install the mounting bolts snugly. 4. Install or connect the following: • Distributor cap with the ignition wires • Distributor electrical connectors • Negative battery cable and enter the radio security code. 5. If equipped with 4-Wheel Steering (4WS), start the engine and turn the steering wheel lock-to-lock to reset the 4WS control unit. 6. Adjust the ignition timing. 7. Tighten the distributor mounting bolts to 16 ft. lbs. (22 Nm)

To install:

• Alternator and tighten the bolts to 33 ft. lbs. (44 Nm) • 4P connector and battery terminal wire. Tighten the battery terminal wire nut to 108 inch lbs. (12 Nm). • Accessory drive belt • Negative battery cable

• Cruise control actuator but do not remove the cable 3. Loosen the through bolt and then loosen adjusting bolt. • Alternator belt • Adjusting bolt • Through bolt and then the alterna¬ tor To install:

4. Installation is the reverse of removal. 5. Adjust the alternator belt tension. 2.3L Engines

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Note the radio security code and the radio presets. 3. Remove or disconnect the following: • Negative battery cable, then the

2.2L Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable, then the • Powe r steering pump positive

• 4P connector and battery terminal wire from the alternator positive • Adjusting bolt, locknut and the mounting bolt • Alternator belt • Alternator from the bracket To install:

4. Installation is the reverse of removal. THROUGH

BOLT

45 N*m (4.5 kg-m, 33 Ib-ft)

Alternator REMOVAL & INSTALLATION 1.6L and 1.7L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Accessory drive belts • Power steering pump • 4P connector and battery terminal wire • Alternator bolts • Alternator To install:

• Alternator and tighten the bolts to 33 ft. lbs. (44 Nm) • 4P connector and battery terminal wire. Tighten the battery terminal wire nut to 108 inch lbs. (12 Nm). • Power steering pump • Accessory drive belts • Negative battery cable

BOLT 91182G24

Alternator mounting bolt locations

3-23 HONDA ACCORD

5. Adjust the alternator belt tension. 6. Enter the anti-theft code for the radio. 2.4L Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Note the radio security code and the radio presets. 3. Remove or disconnect the following: • Negative battery cable, then the • • • •

positive Drive belt Auto-tensioner Connectors from the alternator 3 alternator mounting bolts and the alternator

• CIVIC • PRELUDE

• S2000

• Alternator mounting bolts • Wiring harness clamp • Alternator assembly To install:

4. Alternator installation is the reverse of the removal procedure. 5. Connect the positive battery cable, then the negative battery cable. Enter the radio security code and station presets.

WARNING Be sure to adjust the alternator belt to the proper tension or alternator bearing failure may occur.

Relieve the belt tension by pulling back on the tensioner — 3.0L engine 6 x 1.0 mm 9.8 N-m (1.0 kgf-m, 7.2 Ibf-ft)

Alternator mounting — 2.4L engine

To install:

• Alternator and 3 mounting bolts. Torque the bolts to 16 ft. lbs. (22 Nm). • Electrical connectors • Auto-tensioner • Drive belt • Positive, then negative battery cables

Remove the condenser tan — 3.0L engine 6 x 1.0 mm

set

s

3.0L Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Note the radio security code and the radio presets. 3. Remove or disconnect the following: • Negative battery cable, then the positive • Alternator belt tension by pulling back on the adjuster and then remove the belt • Condenser fan motor connector from the shroud • Condenser fan assembly • Four prong connector from the rear of the alternator

10 x 1.25 mm 44 N-m (4.5 kgf-m, 33 Ibf-ft) 91182G23

Torque the alternator bolts to the specs shown— 3. OL engine

3-24

HONDA ACCORD

• CIVIC • PRELUDE

• S2000

Ignition Timing ADJUSTMENT

9 1.6L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Set the parking brake and block the front wheels. 3. Connect a timing light to the No. 1 spark plug wire. . 4. Start the engine and allow it to warm up. 5. Pull out the service check connector located behind the right kick panel. On the 2-P connector, connect the WHT/BGN or BRN and BLK terminals with service con¬ nector 07PAZ-0010100, or equivalent. Don’t connect a jumper wire to the 3-P DLC. PGM

FI ECU

SERVICE

CHECK

CONNECTOR

A 22 N m (2.2 kgfm, 16 Ibf ft)

Typical crankshaft pulley timing mark location

6. Shift the transaxle to neutral. All electrical accessories must be off. If equipped with DRL’s, turn them off by engaging the parking brake lever. 7. Connect a test tachometer to the test tachometer connector located on the left shock tower. Check the idle speed. 8. While the engine idles, point the tim¬ ing light at the mark on the timing belt cover. 9. Timing specifications: B16A2 engines • Manual transmission: 16° Before Top Dead Center (BTDC) at 650-750 (USA) and 700-800 (Canada) 10. Timing specifications: D16Y5 engine • Manual transmission: 10-14° BTDC at 620-720 rpm (USA only) • Automatic transmission and CVT: 10-14° BTDC at 650-750 rpm (USA only) 11. Timing specifications: D16Y7 and D16Y8 engines

Distributor hold-down bolt locations— 2. 3L (F23A1 and F23A4) engine

• Manual transmission: 10-14° BTDC at 620-730 rpm (USA) or 700-800 rpm (Canada) • Automatic transmission: 10-14° BTDC at 650-750 rpm (USA) or 700-800 rpm (Canada) 12. If adjustment is needed, loosen the distributor adjusting bolts and turn the dis¬ tributor counterclockwise to advance the timing or clockwise to retard the timing. 13. Tighten the distributor adjusting bolts to 16 ft. lbs. (22 Nm) and recheck the timing and the idle. 14. After everything has been rechecked, remove the service connector from the ser¬ vice check connector. Tuck the service check connector back behind the kick panel. 1.7L and 2.0L Engines

Service check connector— 1.6L engines

7923FG04

A 22 N m (2.2 kgfm, 16 Ibfft)

7923FG05

Distributor hold-down bolt locations — 2.3L (F23A5) engine

These engines are equipped with Distrib¬ utorless Ignition Systems (DIS). No adjust¬ ment is necessary.

lbs. (22 Nm). Recheck the timing after the bolt is tight to confirm the correct timing.

2.2L and 2.3L Engines

2.4L and 3.0L Engines

D 1 . Before servicing the vehicle, refer to isco The ignition timing is only adjustable by nnthe Powertrain Control Module (PCM), but ect the precautions in the beginning of this sec¬ hP tion. the eignition base timing can be checked by GM t performing the following: e 2. Connect a PGM tester (scan tool) to ste r . 1 . Before servicing the vehicle, refer to the the Data Link Connector (DLC). precautions in the beginning of this section. 3. Connect a timing light to the No. 1 2. Connect a PGM tester (scan tool) to ignition cable. the data link connector. 4. Start the engine and allow it to warm 3. Connect a timing light to the No. 1 up until the electric fan comes on. 5. Be sure to turn off all accessories. ignition cable. 4. Start the engine and allow it to warm 6. Verify the idle speed is 650-750 rpm. up until the electric fan comes on. 7. Point the light at the timing belt cover 5. Be sure to turn off all accessories. near the crankshaft pulley and read the tim¬ 6. Verify that the idle speed is 630-730 ing. Correct timing is 10-14° Before Top Dead Center (BTDC) for both automatic and 7. Point the light at the timing belt cover manual transmissions. If necessary, loosen rpm. the distributor hold-down bolt and rotate the near the crankshaft pulley and read the tim¬ distributor slightly to adjust the timing. Turn ing. Correct timing is 8-12° Before Top Dead Center (BTDC). If the ignition timing it counterclockwise to advance and clock¬ is different from the specification, replace wise to retard the timing. the PCM. 8. Tighten the hold-down bolt to 16 ft.

3-25 HONDA ACCORD

Engine Assembly REMOVAL & INSTALLATION p»The original radio contains a coded anti-theft circuit. Obtain the security code number before disconnecting the battery cables. Civic

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative and positive battery cables. Wait at least 3 minutes before working around the air bags. (■♦The engine and transaxle are removed from the vehicle as 1 unit.

3. Support the hood as far open as possible. If the hood is to be removed, first matchmark the hinge plates with a felttipped marker. 4. Remove the battery from the vehicle. Unbolt and remove the battery tray. 5. Disconnect the battery and alternator cables from the underhood fuse and relay box on the right shock tower. 6. Remove the lower right kick panel to expose the Powertrain Control Module (PCM). 7. Label and disconnect the 5 wiring harness connections from the PCM. 8. Unbolt the main wiring harness retainer from the rear of the fuse and relay box on the right side of the bulkhead. Care¬ fully pull the grommet out of its bulkhead opening. Next, pull the PCM harness and connectors through the opening. Be careful not to damage the wiring, insulation, or connectors. 9. Relieve the fuel pressure: a. Loosen the fuel filler cap. b. Use a box-end wrench and a flare nut wrench to hold the fuel filter banjo fitting.

c. Place a shop towel over the fuel fil¬ ter to catch the fuel spray. d. Slowly loosen the fuel filter service bolt 1 full turn. e. Clean up any spilled fuel. 10. Remove or disconnect the following: • Intake air duct and air cleaner • Intake Air Temperature (IAT) sensor connector from the air cleaner case, if equipped • Fuel feed hose from the fuel filter • Fuel return hose from the fuel rail • Intake manifold/throttle body vac¬ uum hoses • Brake booster vacuum hose

• CIVIC • PRELUDE

• Evaporative emissions (EVAP) can¬ ister vacuum hose • Power Steering Pressure (PSP) switch and detach its clamp from the bracket below the brake booster • Transaxle ground cable • Radiator hose bracket 11. Loosen the throttle cable locknut, then disconnect the cable from the throttle Move the cable aside without body linkage. kinking it. 12. Loosen the power steering pump mounting bolts. Slip power steering belt off its pulleys. Unbolt the steering pump and move it out of the work area. Don’t discon¬ nect the hydraulic hoses. ^Label the connectors before detach¬ ing them.

13. Remove or disconnect the following: • Engine wiring harness connectors at the leftside of the engine com¬ partment 14. Drain the coolant from the radiator and engine block. 15. Remove or disconnect the following: • Upper and lower radiator hoses • Heater hoses from the cylinder head 16. If equipped with a CVT transaxle, loosen the shift cable locknut. Remove the spring clip and washers and disconnect the shift cable from its linkage. Be careful not to kink the cable or damage its boot. 17. Remove or disconnect the following: • Hydraulic line brackets from the top of the transaxle case, if equipped with a manual transaxle 18. Attach a chain hoist to the engine to lift brackets. lifting the engine yet. Don't raise the hoist 19. Raise the vehicle and support it safely. Remove the front wheels. 20. Remove or disconnect the following: • Engine splash shield 21. Drain the engine oil. 22. Drain the fluid from the transaxle. 23. Remove or disconnect the following: • Left front engine mount bracket from the shock tower, if equipped with air conditioning 24. Loosen the compressor idler pulley and adjusting bolt. Slip the belt around the engine mount stud to remove it. 25. Remove or disconnect the following:

• Compressor mounting bolts to sep¬ arate the compressor from its plate. Move the compres¬ mounting out of the work area. Do not sor disconnect the air conditioning refrigerant lines. 26. Remove or disconnect the following: • ATF cooler lines, if equipped. Plug

• S2000

the cooler lines to prevent fluid leakage and contamination • Slave cylinder from the transaxle case without disconnecting its hydraulic line, if equipped with manual transaxle • Front exhaust pipe from the exhaust manifold and catalytic con¬ verter. Unbolt its hanger bracket and remove the exhaust pipe. • Shift cable from the transaxle con¬ if equipped with auto¬ trol maticshaft, transaxle • Shift rod and extension rod from the transaxle, if equipped with manual transaxle • Strut damper fork • Steering knuckle ball joint from the lower control arm using a. ball joint separator 27. Pry the inboard CV-joints from the transaxle. Then, move the halfshafts away from the transaxle and wire them to the undercarriage of the vehicle. Tie plastic bags over the inboard CV-joints to prevent damage to the boots and splined shafts. bly.28. Raise the hoist slightly to take up the weight of the engine and transaxle assem¬ 29. Disconnect the engine mounts in the following order: a. Unbolt and remove the left front engine mount. b. Unbolt and remove the right front engine mount and bracket assembly. c. Remove the rear engine mount through-bolt. Then, unbolt the rear mount bracket from the engine block. 30. If necessary, lower the vehicle slightly to gain access to the side engine and transaxle mounts. Do not release the tension on the chain hoist. The engine must be securely supported. 31. Unbolt the side engine mount bracket from the engine block bracket and mount damper. 32. Unbolt the transaxle mount bracket from the transaxle case. Then, unbolt the mount from the shock tower. 33. Raise the chain hoist to lift the engine a few inches off of its mounts. 34. Verify that all electrical, vacuum, and fuel lines have been disconnected. 35. Raise the engine and transaxle assembly and remove it from the vehicle. To install:

•Use new self-locking nuts and gas¬ kets when installing the front exhaust pipe and when assembling the front suspension. Use new set rings on the inboard CV-joint splined shafts.

3-26

HONDA ACCORD

• CIVIC • PRELUDE

36. Lower the engine and transaxle assembly into the vehicle. 37. Install and connect the engine and transaxle mounts and brackets. Use new self-locking nuts and color-coded bolts. At this point, only tighten the mounting nuts and bolts by hand. 38. Before installing the left front engine mount, fit the air conditioning compressor back into place and install the compressor belt. Tighten the compressor bolts to 17 ft. lbs. (24 Nm). ^Failure to tighten the bolts in the proper sequence can cause excessive noise and vibration and reduce bushing life. Be sure to check that the bushings are not twisted or offset.

39. The engine and transaxle mount and bracket fasteners must be tightened in the proper sequence with the weight of the engine resting upon them. This step is important for engine mount pre-loading. Tighten the engine mount bolts in the fol¬ lowing sequence: a. Transaxle mount bolts: 47 ft. lbs. (64 Nm); or 28 ft. lbs. (38 Nm) for CVTequipped vehicles. b. Side engine mount bracket nuts: 54 ft. lbs. (74 Nm). c. Rear mount bracket bolts: 61 ft. lbs. (83 Nm); or 43 ft. lbs. (59 Nm) for CVT-equipped vehicles. d. Rear mount through-bolt: 43 ft. lbs. (59 Nm). e. Transaxle mount bracket nuts or bolts: 47 ft. lbs. (64 Nm). f. Transaxle mount through-bolt: 54 ft. lbs. (74 Nm). g. Right front mount bracket bolts: 33 ft. lbs. (44 Nm). h. Right front mount carrier bolts: 33 ft. lbs. (44 Nm). i. Left front mount: stud: 61 ft. lbs. (85 Nm); carrier bolts: 33 ft. lbs. (44 Nm); nut: 43 ft. lbs. (59 Nm). 40. Remove the chain hoist from the engine lifting hooks. 41 . Install or connect the following: • New set rings on the inboard splined shafts of each halfshaft. Check that the set ring on each inboard CV-joint clicks into place when the halfshafts are installed into the transaxle. • Damper fork and reconnect the lower ball joint. When the weight of the vehicle is resting on its suspension, tighten the pinch bolt to 32 ft. lbs. (44 Nm) and the fork bolt to 47 ft. lbs. (65 Nm). Tighten the ball joint castle nut to 36-43 ft. lbs. (50-60

• S2000

Nm). Next, tighten the castle nut only enough to install a new cotter pin. • Slave cylinder, if equipped. Tighten the slave cylinder mounting bolts to 16 ft. lbs. (22 Nm). If the clutch hydraulic line was disconnected, air must be bled from the system. • Transaxle shift and extension rods to the linkage at the transaxle case, if equipped. Install a new 8mm spring pin into the shift rod link¬ age. Then, install the retainer clip and boot. Tighten the extension rod bolt to 16 ft. lbs. (22 Nm). • Shift cable to the control shaft, if equipped with an automatic trans¬ axle. Use a new lockwasher and tighten the lockbolt to 10 ft. lbs. (14 Nm). Tighten the shift cable cover bolts to 16 ft. lbs. (22 Nm). Install the shift cable cover and tighten its bolts to 16 ft. lbs. (22 Nm). 42. Install the front exhaust pipe using new self-locking nuts: a. If equipped with the D16Y8 engine, tighten the converter flange nuts to 16 ft. lbs. (22 Nm) b. Tighten the exhaust manifold nuts to 40 ft. lbs. (55 Nm). c. If equipped with the D16Y5 or D16Y7 engine, tighten the converter flange nuts to 25 ft. lbs. (33 Nm). 43. Install or connect the following: • Tighten the exhaust flange bolts to 16 ft. lbs. (22 Nm). • ATF cooler lines. If the rubber cooler lines are cracked or stressed, they must be replaced. • Engine splash shield 44. Refill the engine with fresh oil. 45. Refill the transaxle with the proper fluid. 46. Lower the vehicle. 47. If equipped, fit the clutch hydraulic line brackets back into place. Tighten the 8mm bolts to 17 ft. lbs. (24 Nm). Tighten the 6mm bolts to 96 inch lbs. (11 Nm). 48. If equipped with a CVT transaxle, reconnect the shift cable to the linkage. Use new plastic washers and a new spring clip. Tighten the locknut to 22 ft. lbs. (29 Nm). 49. Adjust the alternator and air condi¬ tioning compressor belt tensions. 50. Install or connect the following: • Upper and lower radiator hoses and the heater hoses • Power steering pump into its mounts. Adjust the pump belt ten¬ sion, then tighten the mounting bolts to 17 ft. lbs. (24 Nm). • PSP switch connector and attach its harness clamp

• Intake manifold/throttle body vac¬ uum hoses • Brake booster vacuum hose • EVAP canister vacuum hose • Fuel line fittings to the fuel filter and fuel rail. Use new sealing washers. Tighten the banjo fittings to 25 ft. lbs. (33 Nm), and the ser¬ vice bolts to 11 ft. lbs. (15 Nm). Don’t overtighten the fittings • Throttle cable and adjust its deflec¬ tion to 10-12mm (0.39-0.47 in.). 51. Feed the PCM harness through the hole in the bulkhead. Apply sealant to the grommet, then install the retainer. 52. Install or connect the following: • Engine wiring harness and ground cables that were disconnected dur¬ ing removal. Be sure the grounds are free of corrosion to ensure good contact. • Fuse and relay box back into posi¬ tion • Battery and alternator cables • Air cleaner case and air intake duct • IAT connector

• 5 PCM connectors and kick panel • Battery tray and the battery 53. Verify that all wiring harnesses and grounds, vacuum lines, fuel lines have been reconnected. 54. Refill the radiator with fresh coolant. 55. If it was removed, install the hood. Reconnect the windshield washer tubing. After installation, check to be sure that the hood, fender, and grille panel gaps are equal. 56. Reconnect the positive and negative battery cables. 57. Turn the ignition switch to the ON position, but don’t start the engine. Then, turn the ignition OFF. Repeat this procedure 2 or 3 times and check for fuel leaks. 58. Start the engine and allow it to warm up to its normal operating temperature. 59. Bleed the air from the cooling sys¬ tem with the heater valve open. 60. Check the throttle cable deflection and operation. 61. Check and adjust the ignition timing. 62. Shut the engine off and check the drive belt adjustments. 63. Check all fluid levels and top up as necessary. 64. Check and adjust the front wheel alignment. 65. Road test the vehicle. Prelude

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

3-27 HONDA ACCORD

2. Secure the hood as far open as pos¬ sible. 3. Remove or disconnect the following: • Negative battery cable, then the positive battery cable • Radiator cap 4. Raise and safely support the vehicle. Remove the front wheels and the engine splash shield. 5. Drain the engine coolant into a sealable container. 6. Drain the transaxle fluid into a sealable container. Install the drain plug with a new gasket. 7. Lower the vehicle to a working level. 8. Remove or disconnect the following: • Air intake duct and the air cleaner case • PAIR vacuum tank and bracket • Battery and the battery base • Battery cable and starter cable har¬ nesses from the body 9. Relieve the pressure from the fuel system.

C CAUTION The fuel injection system remains under pressure after the engine has been turned OFF. Properly relieve fuel pressure before disconnecting any fuel lines. Failure to do so may result in fire or personal injury.

• Fuel feed hose from the fuel rail and the fuel return line from the fuel pressure regulator

• Injector resistor connector on the left side of the engine compartment • Throttle cable by loosening the locknut, then slip the cable end out of the throttle linkage. Take care not to bend the cable when removing it. Always replace any kinked cable with a new one. • Engine wiring harness connectors, terminal, and clamps on the right side of the engine . Power cable from the under-hood fuse/relay box • Brake booster vacuum hose and emissions control vacuum tubes from the intake manifold • Cruise control actuator electrical connector and vacuum tube, then the actuator • Engine ground cable from the body side • Power steering pump drive belt, then the pump

• Air conditioning condenser fan,

• CIVIC • PRELUDE

then install a protector plate on the radiator • Alternator mounting bolt, nut, and adjusting nut, then the alternator drive belt

• Air conditioning compressor elec¬ trical connector • Compressor without disconnecting the air conditioning hoses. Support the compressor with a strong wire out of the way. • Upper and lower radiator hoses, and the heater hoses from the engine • Transaxle ground cable • Cooler hoses, if equipped with an automatic transaxle 1 1 . If equipped with a manual transaxle perform the following: a. Disconnect the shift cable and the select cable from the transaxle. Do not bend the cables when removing them. Replace any kinked cable with a new one. b. Remove the clutch slave cylinder and the pipe/hose assembly. Do not depress the clutch pedal once the slave v cylinder has been removed. bly.c. Remove the clutch damper assem¬ 12. Remove or disconnect the following: • Vehicle Speed/Power Steering Speed (VSS/PSS) sensor assembly. Do not disconnect the hoses • Nuts attaching the exhaust pipe to the exhaust manifold and the cat¬ alytic converter • Bolts from the exhaust pipe hanger, then the exhaust pipe and discard the gaskets 13. If equipped with an automatic transaxle, remove the shift cable cover, then disconnect the shift cable. Do not bend the cable and replace the cable if it becomes kinked. 14. Remove or disconnect the following: • Left and the right side damper forks • Lower ball joints from the lower control arms 15. Pry the halfshafts from the transaxle. Cover the inner CV-joints with plastic bags to protect them. 16. Swing the halfshafts under the fender out of the way. 17. Attach an engine hoist to the engine lifting points and raise the hoist to remove all slack from the chain. 18. Remove or disconnect the following: • Rear engine mount bracket • Front engine mount bracket • Left side engine mount • Transaxle mount and the mount bracket

• S2000

19. Check that the engine is completely free of vacuum hoses, fuel and coolant hoses, and electrical wiring. 20. Slowly raise the engine approxi¬ mately 6 in. (150mm). Check once again that all hoses and wires have been discon¬ nected from the engine. 21 . Raise the engine all the way and remove it from the vehicle. 22. Remove the transaxle. 23. If equipped with a manual transaxle, remove the clutch cover (pressure plate) and clutch disc. 24. Mount the engine on an engine stand, making sure the mounting bolts are tight. If an engine stand is not available, support the engine in an upright position with blocks. Never leave an engine hanging from a lift or hoist. To install:

25. Install or connect the following: • Clutch disc and pressure plate to the flywheel for manual transaxle vehicles • Transaxle

• Engine into position and lower it into the car, aligning the mounts and bushings. i^When installing the engine mounts and vibration dampers in the following steps, they must be tightened to the correct tension in the correct order if they are to damp vibration properly.

Nm) • Side engine mount and the through-bolt. Do not tighten the through-bolt at this time • Nut and bolt attaching the side mount to the engine: 40 ft. lbs. (55

• Transaxle mount and through-bolt. the through-bolt at Do not timetighten this • Rear engine mount and new bolts g the attachin Nm) to the engine: (55 mount ft. lbs. 40 rearft.engine New 47 • bolt: lbs. (65mount Nm) through

• Front mount and the 3 bolts attach¬ ing the mount to the engine assem¬ bly, only snug the bolts in place . New through-bolt to the front mount: 47 ft. lbs. (65 Nm) • Nuts to the transaxle mount: 28 ft. lbs. (39 Nm)

26. Tighten the side engine mount through-bolt to 47 ft. lbs. (65 Nm). throughTighte bolt27.to 47 ft. nlbs.the(65transa Nm).xle mount Nm). 28. Tighten the 3 bolts attaching the front mount to the engine to 28 ft. lbs. (39

3-28

HONDA ACCORD

• CIVIC • PRELUDE

29. Remove the hoist equipment from the engine. 30. Install or connect the following: • New spring clips to the inner CVjoints • Halfshafts into the transaxle. Be sure that the inner joint spring clips click into place • Lower ball joints to the lower con¬ trol arms. Tighten the nuts to 36-43 ft. lbs. (50-60 Nm). Install a new cotter pin to the ball joint stud. 31. Using new self-locking bolts, attach the damper forks to the struts and tighten to 32 ft. lbs. (44 Nm). Tighten the new nut and bolt attaching the damper fork to the lower control arm to 47 ft. lbs. (65 Nm). 32. If equipped with an automatic trans¬ axle, connect the shift cable to the transaxle. Install a new lockwasher and tighten the attaching bolt to 84 inch lbs. (10 Nm). Install the shift cable cover. Tighten the shift cable cover attaching bolts to 13 ft. lbs. (18 Nm). 33. Install or connect the following: • Exhaust pipe with new gaskets • New nuts attaching the exhaust pipe to the exhaust manifold: 40 ft. lbs. (55 Nm) • New nuts attaching the exhaust pipe to the catalytic converter: 25 ft. lbs. (34 Nm) • New attaching bolts to the exhaust pipe hanger: 13 ft. lbs. (18 Nm) • VSS/PSS, connect the electrical connector, and tighten the mount¬ ing bolt to 13 ft. lbs. (18 Nm) 34. If equipped with a manual transaxle perform the following: a. Install the clutch damper assembly and tighten the attaching bolts to 16 ft. lbs. (22 Nm). b. Install the clutch slave cylinder and the pipe/hose assembly and tighten the slave cylinder mounting bolts to 16 ft. lbs. (22 Nm). c. Connect the shift cable and the select cable to the transaxle. Adjust the shift cable and select cable. 35. Install or connect the following: • Cooler hoses, if equipped with an automatic transaxle • Transaxle ground cable • Upper and lower radiator hoses and heater hoses to the engine • Air conditioning compressor, con¬ nect the electrical connector. Tighten the mounting bolts to 16 ft. lbs. (22 Nm). • Alternator drive belt, then adjust 36. Remove the protector plate from the radiator and install the air conditioning con¬ denser fan.

• S2000

37. Install or connect the following: • Power steering pump and drive belt. Adjust the drive belt tension, then tighten the attaching nuts and bolts to 16 ft. lbs. (22 Nm). • Engine ground cable to the body • Cruise control actuator, electrical connector and vacuum tube. Tighten the mounting bolts to 84 inch lbs. (10 Nm) • Brake booster vacuum hose and the emissions control vacuum tubes to the intake manifold • Engine wiring harness connectors, terminal, and clamps • Throttle cable, then adjust • Injector resistor connector on the left side of the engine compartment • Fuel return hose to the regulator • Fuel feed hose to the fuel rail with new washers. Tighten the cap nut tobody 16 ft. ibs. (22 Nm) • Battery and starter cables to the • Battery base and the battery. Tighten the battery base attaching bolts to 16 ft. Ibs. (22 Nm) • PAIR vacuum tank and bracket. Tighten the mounting bolts to 96 inch Ibs. (10 Nm) • Air cleaner duct and housing • Engine splash shield and the front wheels 38. Lower the vehicle. 39. Fill the engine with oil and the transaxle with fluid. 40. Fill and bleed the air from the cool¬ ing system. 41. Connect the positive, then the nega¬ tive battery cable and enter the radio secu¬ rity code. 42. Switch the ignition ON but do not engage the starter. The fuel pump should run for approximately 2 seconds, building pressure within the lines. Switch the igni¬ tion OFF, then ON 2 or 3 more times to build full system pressure. Check for fuel leaks. 43. Start the engine, allowing it to idle. Check the hoses and lines carefully for any sign of leakage. 44. Check the timing and idle speed. 45. After the engine has warmed up fully and the fan(s) have come on at least once, recheck the engine for fluid leaks. Switch the engine OFF. 46. Adjust the belts and throttle cable as necessary. 47. If equipped with 4WS, start the engine and turn the steering wheel lock-tolock to reset the 4WS control unit. 48. Road test the vehicle, then loosen

and retighten the 3 bolts attaching the front engine mount to the engine. Tighten the bolts to 28 ft. Ibs. (39 Nm). Accord

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Obtain the anti-theft code for the radio, then disconnect the battery cables. Be sure to disconnect the negative cable first. 3. Remove the air intake duct. 4. Secure the hood in the open position with a long prop rod such as P/N 74145S84-A00. 5. Remove or disconnect the following: • Both battery cables and the con¬ body from the underhood relay nector box • Battery and tray, on the 3.0L engine • Bolt securing the relay box to the • Accelerator and cruise control cables from the throttle body and bracket 6. Properly relieve the fuel system • Fuel hoses from the fuel rail pressure. • Brake booster vacuum and evapo¬ rative emissions (EVAP) canister hoses • Vacuum hose from the canister • Hose securing the power steering hose on the engine • Power steering pump belt, then remove the pump and position it sary. out of the way. Use wire if neces¬

• Powertrain Control Module (PCM) connectors from the control mod¬ ule. Remove the grommet and pull the connectors through. 0

B

7923FG06

Starter cable, clamp, ground cable and back-up light switch connector locations — Accord with 2.3L engine

3-29 HONDA ACCORD

• CIVIC • PRELUDE

• S2000

• Wiring harness connectors at the right side of the engine compart¬ ment for 2.3L and 2.4L engines and on the left side for the 3.0L engine. 7. On the 2.3L and 2.4L engine, remove the starter cable (A) and clamp (B). Remove the ground cable (C) and back-up light switch connectors (D). On the 3.0L engine, remove the starter wiring from the engine compartment attaching points. 8. On vehicles with a manual transaxle, disconnect the shift and select cables from the transaxle. Remove the slave cylinder mounting bolts and position the cylinder out of the way. Be sure not to bend the line. 9. Remove or disconnect the following: • Rear engine mount through-bolt and stiffener

• Front engine mount bracket mount¬ ing bolts and loosen the throughbolt • Radiator cap 10. Raise and safely support the vehicle. 1 1 . Remove or disconnect the following: • Front tires • Engine under cover 12. Loosen the radiator drain plug and drain the coolant. 13. Drain the transaxle oil or fluid, then reinstall the plug using a new washer. 14. Drain the engine oil, then reinstall the plug using a new washer. 15. Lower the vehicle and remove the upper and lower radiator hoses and heater hoses from the engine. 16. On vehicles with an automatic transaxle, disconnect the ATF fluid cooler lines. 17. Remove the air conditioning com¬ pressor from the engine and position it to the side without disconnecting the hoses. 18. Raise the vehicle and remove the front exhaust pipe.

7923FG08

removing the Be sure to mark the location of the front beams (A) on the rear beams (B) before subframe — 2.3L Accord

c

7923FG07

Automatic transaxle linkage compo¬ nents — 2.3L Accord

3.0L Accord

3-30

HONDA ACCORD

• CIVIC • PRELUDE

19. On vehicles with automatic transaxle, remove the 2 bolts (A) for the shift cable holder (B), then remove the shift cable cover (C). To prevent damage to the linkage, be sure to remove the shift cable holder before removing the bolts for the cover. 20. Remove or disconnect the following: • Lockbolt (D) from the control lever (E), then the shift cable (F) with the control lever • Through-bolt securing the bottom of the shock absorber to the control arm • Halfshafts • Rear engine mounting bracket • 2 flange bolts from each of the radius rods 21 . Mark the location of the front beams (A) on the rear beams (B). Remove the 4 bolts and the subframe. 22. Lower the vehicle about half way and attach a chain hoist to the engine lifting points as shown. Apply slight upward pres¬ sure to the engine/transaxle assembly. 23. Remove the remaining engine and transaxle mounting brackets.

• S2000

24. Lower the engine about 6 in. (150mm) and check that the engine/transaxle is free of any hoses, cables or wiring. 25. Lower the assembly completely and remove it from under the vehicle.

29. Install the sub-frame in its original position, and tighten the retainers as fol¬ lows: a. On the 2.3L and 2.4L engines, Nm). tighten the rear bolts to 47 ft. lbs. (64 Nm) and the front bolts to 76 ft. lbs. (103

To install:

26. Lift the engine into position and install the engine mounting brackets. Tighten the retainers as follows: a. On the 2.3L and 2.4L engines, tighten the engine mounting bolts and nuts to 40 ft. lbs. (54 Nm). b. On the 3.0L, tighten the bolts to 28 ft. lbs. (38 Nm). 27. On the 3.0L engine, install the air conditioning compressor. Tighten the bolts to 16 ft. lbs. (22 Nm). 28. Install the transaxle mounting bracket, and tighten the retainers as follows: a. On the 2.3L and 2.4L engines, tighten the nuts to 28 ft. lbs. (38 Nm) Nm).the through-bolt to 40 ft. lbs. (54 and

b. On the 3.0L engine, tighten the rear bolts to 40 ft. lbs. (54 Nm), front bolts to Nm) 76 ft. lbs. (103 Nm) and the nuts to 28 ft. Nm) lbs. (38 Nm). 30. On the 2.3L and 2.4L engines, install or connect the following: • Radius rod bolts: 119 ft. lbs. (162

• Rear mount bracket: 40 ft. lbs. (54 • Stiffener. Tighten the through-bolt to 47 ft. lbs. (64 Nm) for manual transaxles or the nut and bolt to 28 ft. lbs. (38 Nm) for automatic transaxles. • 3 front mounting bracket bolts: 28 ft. lbs. (38 Nm). Then, tighten the Nm) through-bolt to 47 ft. lbs. (64 Nm). • Air conditioning compressor: 16 ft. lbs. (22 Nm)

b. On the 3.0L engine, tighten the bolts to 28 ft. lbs. (38 Nm).

31. On the 3.0L engine, install or con¬ nect the following: • Radius rod bolts: 119 ft. lbs. (162

• Front mounting bracket support nut: 40 ft. lbs. (54 Nm) • Rear mounting bracket nut and bolt. Tighten the nut to 40 ft. lbs. (54 Nm) and the bolt to 28 ft. lbs. (38 Nm). • Side mounting bracket. Tighten the bolts to 40 ft. lbs. (54 Nm) and the through-bolt • Exhaust systetom 40 ft. lbs. (54 Nm). • Shift linkage, if equipped with an automatic transaxle 32. The remainder of the installation is the reverse of the removal. 33. Refill and bleed the cooling system.

h WARNING Operating the engine without the proper amount and type of engine oil will result in severe engine damage.

34. Fill the engine with the correct amount of oil. 35. Install the battery if removed. Start the engine and check for leaks. S2000 7923FG09

Engine lifting points— 2.3L Accord shown, 2.4L similar

1 . Before servicing the vehicle, refer to 7923FG11

Engine lifting points— 3. OL Accord

the precautions in the beginning of this sec¬ tion.

ACCORD

• CIVIC • PRELUDE

A ND00 HO * S20

OO-I ** 1 V

2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: • Battery • Front wheels • Transmission

• Engine Control Module (ECM) con¬ nectors and the main wire harness connector. Pass the connectors through the cowl panel. • Vacuum tank • Throttle cable • Electrical Power Steering (EPS) control unit

• Battery cable at the main under¬ hood fuse/relay box • Battery cable at the auxiliary fuse box • Ground cable and harness clamps • Fuel lines • Brake booster vacuum line • Evaporative Emissions (EVAP) can¬ ister hose • Front motor mount and bracket • Heater hoses • Radiator hoses • Left motor mount • Right motor mount bracket 5. Carefully raise the engine out of the vehicle. To install:

6. Installation is the reverse of the removal procedure, while using the follow¬ ing torgue values: • Right motor mount bracket bolts: 28 ft. lbs. (38 Nm) • Nm) Motor mount nuts: 40 ft. lbs. (54 • Front motor mount bolts: 16 ft. lbs. (22 Nm)

Water Pump REMOVAL & INSTALLATION 1.6L, 2.2L and 2.3L Engines ^The original radio contains a coded anti-thett circuit. Obtain the security code number before disconnecting the battery cables.

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable 3. Drain the cooling system. 4. Remove or disconnect the following: • Accessory drive belts, the valve cover, and the upper timing belt cover

7923FG12

Water pump — 2.2L and 2.3L engines

5. Set the timing at Top Dead Center (TDC)/compression for No. 1 piston. 6. Remove or disconnect the following: • Crankshaft pulley and lower timing belt cover • Timing belt. Replace the timing belt if it is contaminated with oil or coolant or shows any signs of wear and damage. • Crankshaft Speed Fluctuation (CKF) sensor bracket and move the sensor out of the way, if equipped. Cover the sensor with a shop towel to keep coolant off of it. • Water pump from the engine block. On 1.6L engines, the top right water pump mounting bolt also secures the alternator adjusting bracket. Leave the bracket attached to the alternator.

plug is closed. Refill and bleed the cooling 10. Connect the negative battery cable system. and enter the radio security code. 11. Start the engine, allow it to reach normal operating temperature, and check for coolant leaks. 12. If equipped with 4WS, and turn the steering wheel lock-to-lock to reset the 4WS control unit. 2.0L Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Remove or disconnect the following: • Negative battery cable • Accessory drive belt • Water pump pump pulley

To install:

7. Clean the water pump and 0-ring mating surfaces before installation. 8. Install or connect the following:

• Water pump with a new O-ring. Coat only the bolt threads with liq¬ uid gasket and tighten them to 108 inch lbs. (12 Nm). On 1 .6L engines, tighten the bracket bolt to 33 ft. lbs. (44 Nm). • Timing belt. Be sure it is fitted and adjusted properly. • CKF sensor, if equipped, and tighten the bracket bolts to 108 inch lbs. (12 Nm). • Lower belt cover and crankshaft pulley • Upper timing belt cover, the valve cover, and the accessory drive belts 9. Be sure the cooling system drain

To install:

4. Install or connect the following: • Water pump with a new 0 ring seal. Tighten the 8mm bolts to 16 ft. lbs. to 33 (22lbs.Nm)(44and Nm).the 10mm bolt ft.

• Water pump pulley and tighten the bolts to 10 ft. lbs. (14 Nm) • Accessory drive belt • Negative battery cable 5. Fill the cooling system. 6. Start the engine and check for leaks. 2.4L Engine

1 . Before servicing the vehicle, refer to

the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system.

3-32

HONDA ACCORD

• CIVIC • PRELUDE

• S2000

Heater Core REMOVAL & INSTALLATION

. Accord

'■••Make sure to acquire the anti-theft code form the radio and write down the frequencies for the radio’s preset but¬ tons.

!'* CAUTION 1 Di disconnecting the negative bat¬ After sconn ect wait tery cable, the nefor at least 3 minutes gative to deplete its for the air bag module batt energy before working theeryoncablthe e. instrument panel or steering wheel.

6 x 1.0 mm 12 N-m (1.2 kgf-m, 8.7 Ibf ft) 43256-ACCO-G02

Water pump mounting— 2. 4L engine

3. Remove or disconnect the follow¬ ing: • Crankshaft pulley • 6 water pump mounting bolts, then the pump and O-ring seal 4. Clean the seal groove and mating surfaces. 5. Install or connect the following: • Water pump, with a new seal. Tighten the bolts to 104 inch lbs. (12 Nm). • Crankshaft pulley 6. Fill the cooling system. 7. Start the engine and check for leaks. 3.0L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the follow¬ ing: • Timing belt. • Timing belt tensioner • 5 water pump mounting bolts, then remove the pump and seal To install:

3. Clean the seal groove and mating surfaces. 4. Install or connect the following: • Water pump, with a new seal. Tighten the bolts to 104 inch lbs. (12 Nm).

• Timing belt tensioner • Timing belt. 5. Refill the cooling system. 6. Start the engine and check for leaks. 7. Top off the cooling system if neces¬ sary after the engine has cooled.

2. Drain the cooling system into a clean container for reuse. 3. In the engine compartment, open the heater valve cable clamp and disconnect the cable from the heater valve arm. Then, turn the heater valve to the fully opened position. 4. Remove or disconnect the following: • Heater hoses from the heater core • Heater housing-to-chassis nut '•■When removing the heater housing nut, be careful not to damage or bend the fuel lines, the brake lines or etc.

• Center console

3-33 ACCORD

5. Remove the instrument panel by removing or disconnecting the following: • Center lower cover • Passenger’s side lower cover • Lower glove box screws • Hooks at the top inner side of the glove box by placing a flat tipped screwdriver in the cap notch and pry out the cap • 4 glove box screws, release the hooks and remove the glove box • Front door opening trim and the front door pillar trim at both sides • Combination switch, the ignition switch and the air bag connectors

• CIVIC • PRELUDE

• Steering column-to-instrument panel nuts and lower the steering column • Side wiring harness connectors, cabin wire harness and door wire harness from the fuse box at the driver’s side • Instrument panel wiring harness connector • Wiring harness, the steering hanger beam wiring harness and the brake switch connectors under the dash • Clutch switch connectors, if equipped with a manual transmis¬ sion

HONDA

• S2000

• Pull back the carpet at the passen¬ ger’s wiring side harness, the • SRS ECM/PCM, the air mix control motor, the evaporator temperature sensor and the antenna lead • ECM/PCM and the antenna lead harness clips • Ground bolt using a Torx®bit T30 • Parking brake switch positive (+) terminal and harness clips at the driver’s side • Parking pin shift and the shift lock solenoid connectors, if equipped with an automatic transmission

Fastener Locations ► : Screw, 8

A [> : Clip, 4

B > : Clip, 2

SHIFT INDICATOR

TRIM RING (A/T)

C > : Clip, 2

CABLES Exploded view of the center console and related components— Accord

D >

:Clip, 7

93112GJ7

3-34

HONDA ACCORD

• CIVIC • PRELUDE

• S2000

• Side wiring harness, the cabin wiring harness, the roof wiring har¬ ness and the door wiring harness from the passenger’s fuse box at the passenger’s side • Instrument panel wiring harness • Instrument pane harness, the blower motor and the recirculation control motor connectors under the passenger’s side • Harness, the harness holder and the connector clips • Instrument panel-to-chassis cap and bolts • Instrument panel from the guide pins and remove it 6. If not equipped with air conditioning, remove the blower motor-to-heater housing duct screws and the duct. 7. If equipped with air conditioning, remove the evaporator housing by removing or disconnecting the following: • Discharge and recover the air con¬ ditioning system refrigerant • Refrigerant lines-to-evaporator housing bolts, located in the engine compartment • Separate the lines, discard the 0rings and plug the openings to pre¬ vent contamination

Exploded view of the heater core and housing— Accord

Fastener Locations B ► : Bolt, 6

C ► : Bolt, 4

D ► : Bolt, 3

E ► : Bolt, 1 8 x 1.25 mm 22 N mft)(2.2 kgf m, 16 Ibf

G

G

F

G

93112GJ8

View of the instrument panel bolt locations— Accord

3-35 HONDA ACCORD • CIVIC

PRELUDE

• S2000

.

2 g and related components View of the heater housing, evaporator housin

fol the

low

ing

:

g

ing

ect

n con or

. Instrument panel to the guide pins . Instrument panel-to-chassis cap and clipsbolts . Harness holder and the connector

lin

tal

ins lby

ne epnat rum nst

9. Install or connect the following: • Heater core to the heater housing

• Refrigerant lines-to-evaporator housing bolts, located in the engine compartment

i lhe talt

To install:

• Heater core-to-heater housing bracket and the bracket screws • Heater housing and the heater housing-to-chassis bolts 10. If not equipped with air conditioning, install the blower motor-to-heater housing duct and the duct screws. 1 1 . If equipped with air conditioning, install the evaporator housing by installing or connecting the following: . Evaporator housing and the evapo¬ rator housing-to-chassis nut/bolts housing’s temperature • Evaporrator senso connector . Refrigerant lines using new O-rings Ins

temperature housin Evaporator • sensor tor g’s connec • Evaporator housing-to-chassis nut/bolts and remove the evapora¬ tor housing 8. Remove or disconnect the following: • Heater housing-to-chassis bolts and the heater housing • Heater core-to-heater housing bracket screws and the brackets ing • Heater core from the heater hous¬

Accord

• Instrument pane harness, the blower motor and the recirculation control motor connectors under the

wiring harness • Instrument panel passenger’s side

3-36

HONDA ACCORD

• CIVIC • PRELUDE

• Side wiring harness, the cabin wiring harness, the roof wiring har¬ ness and the door wiring harness

•

•

• • •

• •

to the passenger’s fuse box at the passenger’s side Parking pin shift and the shift lock solenoid connectors, if equipped with an automatic transmission Parking brake switch positive (+) terminal and harness clips a the driver’s side Ground bolt using a Torx bit T30 ECM/PCM and the antenna lead harness clips SRS wiring harness, the ECM/PCM, the air mix control motor, the evaporator temperature sensor and the antenna lead Move back the carpet. Clutch switch connectors, if equipped with a manual transmis¬ sion

• Wiring harness, the steering hanger

• S2000

beam wiring harness and the brake switch connectors, located under the dash • Instrument panel wiring harness connector • Side wiring harness connectors, cabin wire harness and door wire harness from the fuse box, located at the driver’s side • Steering column and the steering column-to-instrument panel nuts • Combination switch, the ignition switch and the air bag connectors • Front door pillar trim and the front door opening trim on both sides • Glove box and the 4 glove box screws

(■••When installing the heater housing nut, be careful not to damage or bend the fuel lines, the brake lines or etc.

13. Install or connect the following: • Heater housing-to-chassis nut • Heater hoses to the heater core 14. Refill the cooling system. 15. Connect the negative battery cable. 16. Evacuate, charge and leak test the air conditioning system refrigerant. 17. Operate the engine to normal operat¬ ing temperatures; then, check the climate control operation and check for leaks. Civic

1 . Disconnect the negative battery cable. i' CAUTION

• Cap at the top inner side of the • • • •

glove box Lower glove box screws Passenger’s side lower cover Center lower cover Center console

Wait at least 3 minutes for the SRS to deplete its energy before working on the steering wheel or instrument

panel.

BLOWER

UNIT

93112GI0

View of the heater housing, evaporator housing and related components— Civic

HONDA ACCORD

2. In the engine compartment, remove the heater valve cable clamp; then, discon¬ nect the heater valve cable and rotate the heater valve to the fully open position. 3. Drain the engine coolant into a clean container for reuse. 4. Remove or disconnect the following: • Heater hoses from the heater unit • Heater housing-to-chassis nut • Instrument panel. 5. If not equipped with air conditioning, remove the wiring harness from the heater duct; then, remove the 2 screws and the heater duct. 6. If equipped with air conditioning, remove or disconnect the following:

• Discharge and recover the air con¬ ditioning system refrigerant • Refrigerant lines-to-evaporator bolts. Disconnect the lines. Discard the O-rings. Plug the openings to prevent contamination • Thermostat electrical connector and

from the evapo¬ the ratorwiring harness • 4 evaporator housing screws, the bolt and nut hose and remove the evapo¬ Drain housing • rator 7. On 2000-01 models, disconnect the electrical connectors from the blower motor, the power transistor, the blower high relay and the recirculation con¬ motormotor. trol ing: 8. Remove or disconnect the follow¬ • Electrical connectors from the mode control motor and the air mix control motor (for 2000-01); then, remove the electrical harness clips housing wiring harness from the heater and • Heater duct clip

• 2 heater housing-to-chassis nuts and the heater housing

• Heater core cover-to-heater hous¬ BLOWER

UNIT

• CIVIC • PRELUDE

O

* S2000

^

1

ing screws, the cover, the clamp and the heater core To install:

9. Install or connect the following: • Heater core, the clamp, the cover and the heater core cover-to-heater housing screws • Heater housing and the 2 heater nuts • housing-to-chassis Heater duct clip • Electrical connectors to the mode control motor and the air mix con¬ trol motor (for 2000-01); then, install the electrical harness clips housing and wiring harness to the heater

10. On 2000-01 models, connect the electrical connectors to the blower motor, the power transistor, the blower motor high relay and the recirculation control motor. 11. If not equipped with air conditioning, install the heater duct, the 2 screws and the wiring harness to the heater duct. RECIRCULATION

93112GJ1

nts— Civic View of the heater housing, evaporator housing and related compone

07

3-38

HONDA

ACCORD • CIVIC • PRELUDE • S2000 1

. HEATER

CORE COVER

frequencies for the radio’s preset but¬ tons.

cable. Disconne ct

the negati ve battery

CAUTION

Wait at least 3 minutes for the SRS to deplete its energy before working on the steering wheel or instrument

2. In the engine compartment, remove panel. the heater valve cable clamp; then, discon¬ nect the heater valve cable and rotate the heater valve to the fully open position. 3. Drain the engine coolant into a clean container for reuse. 4. Remove or disconnect the following: • Heater hoses from the heater unit • Heater housing-to-chassis nuts • Instrument panel • Steering hanger beam mounting bolts and the steering hanger beam 5. Discharge and recover the air condi¬ tioning system refrigerant 6. Remove the evaporator housing by removing or disconnecting the following: • Refrigerant lines. Discard the 0rings. Plug the openings to prevent contamination. • Thermostat electrical connector • Drain hose and remove the evapo¬ rator housing. 7. Remove or disconnect the following: • Electrical connector from the mode control motor • Wiring harness clips from the heater housing • Heater housing-to-chassis nuts and the heater housing • Heater housing screws and sepa¬ rate the housings • Heater core from the heater housing To install: Exploded view of the heater core— Civic

12. If equipped with air conditioning, • Heater housing-to-chassis nut • Heater hoses to the heater unit install or connect the following: 14. Refill the cooling system. • Drain hose and install the evapora¬ tor housing 15. In the engine compartment, install the heater valve cable clamp and connect • 4 evaporator housing screws, the bolt and nut the heater valve cable. • Thermostat electrical connector and 16. Connect the negative battery cable. the wiring harness to the evaporator 17. Operate the engine to normal operat¬ ing temperatures; then, check the climate • Refrigerant lines-to-evaporator bolts, connect the lines using new control operation and check for leaks. O-rings Prelude • Evacuate, charge and leak test the air conditioning system refrigerant. '■►Make sure to acquire the anti-theft 13. Install or connect the following: code form the radio and write down the • Instrument panel

8. Install or connect the following: • Heater core to the heater housing • Assemble the housings and install the heater housing screws • Heater housing and the heater housing-to-chassis nuts housing • Wiring harness clips to the heater • Electrical connector to the mode control motor 9. Install the evaporator housing: • Evaporator housing and connect the drain hose • Evaporator housing-to-chassis screws, the bolt and nuts • Thermostat electrical connector and the wiring harness to the evaporator

3-39 HONDA ACCORD

related components View of the heater housing, evaporator housing and

BERING

HANGER

BEAM

• CIVIC • PRELUDE

» S2000

Prelude

HANGER

BEAM

8 x 1.25 mm

22 Nm

(2.2 kgf-m, 16 Ibf-ft)

8 x 1.25 mm

22 N m (2.2 kgf-m, 16 Ibf-ft) 8x1.25

1

22 Nm

(2.2 kgf-m, 16 Ibf-ft)

mm

93112GI8

nents View of the steering hanger beam and related compo

Prelude

3-40

HONDA ACCORD • CIVIC • PRELUDE • S2000

^

LOWER

4

HOUSING

4

4

i

4 93112GI9

Exploded view of the heater core, the heater housing and related components— Prelude

steering wheel lock-to-lock to reset the steering control unit.

e mat cli ks. lea the or f ck che heck c n, the and

ion; ratres opeatu per tem ol tr ing con

rma

ono inet

eng tehe rat

Ope

• Refrigerant lines using new 0-rings • Evacuate, charge and leak test the air conditioning system refrigerant 10. Install or connect the following: • Steering hanger beam and the steering hanger beam mounting bolts • Instrument panel • Heater housing-to-chassis nuts • Heater hoses to the heater unit 11. Refill the cooling system. 12. In the engine compartment, Install the heater valve cable clamp; then, connect the heater valve cable. 13. Connect the negative battery cable.

Cylinder Head

REMOVAL & INSTALLATION '■•The radio may contain a coded theft protection circuit. Always obtain the code number before disconnecting the battery, if the vehicle is equipped with 4WS, the steering control unit is shut down when the battery is disconnected After connecting the battery, turn the

1.6L (D16Y5, D16Y7, D16Y8) and 1.7L (D17A1, D17A2) Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Be sure the cylinder head is cool to the touch before beginning the removal pro¬ cedure. The coolant temperature must be below3. 100°F(38°C). Remove or disconnect the following: • Negative battery cable 4. Drain the cooling system.

HONDA ACCORD

5. Remove or disconnect the following: ^Label the wires before disconnecting them.

• Ignition wires • Air intake duct and the air cleaner assembly 6. Relieve the fuel pressure. 7. Clean up any fuel that may have spilled on the engine or intake manifold. 8. Remove or disconnect the following: • Upper radiator hose from the coolant inlet • Coolant bypass hoses and the heater hose from the intake manifold • Power steering pump belt • Power steering pump from its mounting bracket and lift the power steering reservoir from its mount. Move the pump and reservoir out of the work area and secure them. Don’t disconnect the hydraulic lines. 9. Place a block of wood on the pad of a floor jack. Place the floor jack under the engine for support. 10. Remove or disconnect the following: • Left-front engine mount bracket, if equipped with air conditioning ’-•■Slip the air conditioning compressor belt around the engine mount to remove it.

• Air conditioning compressor belt • Alternator belt 1 1 . Be sure the engine is supported with the padded floor jack. Loosen the nuts from left side engine mount. Remove the engine mount bracket. 12. Remove or disconnect the following: • Valve cover and the upper timing belt cover • Crankshaft pulley and the lower timing belt cover • Dipstick tube from its catches on the timing cover • Timing belt. 13. With the timing belt removed, inspect the water pump and replace it if necessary. 14. Remove or disconnect the following: • Distributor, if equipped • Camshaft sprocket • Fuel lines from the intake manifold fuel rail. Immediately plug the lines to prevent fuel leakage and contam¬ ination • Throttle cable from the linkage by first loosening its locknut, then slipping it out of its holder. ’"label the electrical connectors, before disconnecting them.

• CIVIC • PRELUDE

• Fuel injector wiring harness con¬ nectors • VTEC solenoid valve and pressure switch connectors, if equipped • Idle Air Control (IAC) valve con¬ nector • Throttle Position (TP) sensor con¬ nector • Exhaust Gas Recirculation (EGR) valve lift sensor connectors, if • • • •

equipped Engine Coolant Temperature (ECT) sensor, switch, and gauge sender connectors Manifold Absolute Pressure (MAP) sensor connector Primary and secondary Pleated Oxygen Sensor (HO2S) connectors Vacuum hoses and Positive Crankcase Ventilation (PCV) hose from the intake manifold and throttle body

• EVAP and breather hoses from the intake manifold • Intake manifold together with the throttle body and plenum • Exhaust manifold • Power steering pump bracket 15. Loosen the cylinder head bolts in a 3-step crisscross pattern in the reverse order of the tightening sequence. Start with the outermost bolts and work toward the middle of the cylinder head. Loosen the bolts in the reverse order of installation. 16. Remove the cylinder head. If the head sticks to the engine block, tap it with a plastic or wooden mallet. 17. Inspect the cylinder head for warpage and cracking. Repair, machine, or replace as necessary. The warpage limit is 0.002 in. (0.05mm). Standard cylinder head height is 3.659-3.663 in. (92.95-93.05mm). 18. Remove the old cylinder head gasket and thoroughly clean the mating surfaces. 19. Cover the engine block with a sheet of plastic to keep out dust and foreign objects. To install:

’"Use new O-ring, seals, and gaskets when installing the cylinder head and its components.

20. Be sure the cylinder head and the engine block surfaces are clean, level, and straight. 21. Be sure the cylinder head dowel pins and control orifice are aligned. Clean the oil ring. orifice and reinstall it with a new 0control 22. Install or connect the following: • New head gasket onto the engine block

• S2000

Q_^1 O

H

I

• Camshaft, if removed, with the key¬ way facing up so that the engine will remain at Top Dead Center (TDC)/compression for the No. 1 • cylinder New lubricated camshaft seal i^Use new cylinder head bolts and washers. Used or previously-tightened bolts may be stretched, and therefore they have reduced clamping and seal¬ ing power under compression. Apply clean engine oil to the threads of each head bolt.

• Cylinder head into position • Cylinder head bolts and hand- . tighten the cylinder head bolts to 23. Tighten their final torque specification in 4 steps. Use a crisscross sequence starting with the bolts at the middle of the head and working toward the outer bolts as follows: a. Step 1: Tighten each bolt to 14 ft. lbs. (20 Nm). b. Step 2: Tighten each bolt to 36 ft. lbs. (49 Nm). c. Step 3: Tighten each bolt to 49 ft. lbs. (67 Nm). d. Step 4: Retighten only the 2 center bolts to 49 ft. lbs. (67 Nm). 24. Apply oil to the camshaft sprocket bolt. Install the sprocket with the UP mark and the keyway pointing straight up. Tighten the sprocket bolt to 27 ft. lbs. (37 Nm). 25. Install or connect the following: • Intake manifold with a new gasket, and tighten the nuts in a crisscross pattern in 2 or 3 steps to 17 ft. lbs. (24 Nm) starting with the inner nuts • Bolts that secure the intake manifold to its bracket: 17 ft. lbs. (24 Nm) • Power steering pump bracket: 33 ft. ibs. (44 Nm) • Exhaust manifold with a new gas¬ ket. Apply anti-seize paste to the studs, and tighten the nuts to 23 ft. Ibs. (31 Nm) in a crisscross • sequence. Exhaust manifold to the front Tighten the self-lock¬ exhaust ing nuts pipe. to 25 ft. Ibs. (33 Nm). On Nm). vehicles with the D16Y8 engine, tighten the nuts to 40 ft. Ibs. (55 26. Verify that the engine is at Top Dead Center (TDC)/compression for the No. 1 27. Install or connect the following: cylinder. • Timing belt. After the timing belt has been properly tensioned, tighten the adjusting bolt to 33 ft. Ibs. (44 Nm).

3 AO HONDA "4t

ACCORD

•CIVIC* PRELUDE

• Lower timing belt cover • Crankshaft pulley; tighten its bolt to 134 ft. lbs. (181 Nm) • Dipstick tube back into its catches 28. Adjust the valves. If equipped with a VTEC engine, also check the rocker arms for free and smooth motion.. 29. If equipped with a VTEC engine, remove the VTEC solenoid valve and its fil¬ ter. Install a new filter, then reinstall the VTEC solenoid valve and tighten its bolt to 108 inch lbs. (12 Nm). 30. Install or connect the following: • Distributor, if equipped 31 . Be sure all the spark plug tube seal¬ ing gaskets are fully seated. 32. Install or connect the following: • New gasket onto to the valve cover. Apply liquid gasket to the corner

•

• • • • •

recesses of the gasket. Don't let the sealant cure before installing the valve cover onto the cylinder head. Valve cover. Gently wiggle the valve cover to be sure it is fully seated. Tighten the valve cover bolts in a crisscross pattern to 84 inch lbs. (10 Nm). New spark plugs Ignition wires Upper radiator hose, heater hoses, and intake manifold coolant bypass hoses Intake manifold vacuum lines, PCV, EVAP canister, and breather hoses Fuel lines to the fuel rail. Use new

sealing washers on the banjo fit¬ ting. Carefully tighten the banjo fit¬ ting to 21 ft. lbs. (28 Nm) for the D16Y5 engine, or to 16 ft. lbs. (22 Nm) for all other engines. Tighten the service bolt to 10-11 ft. lbs. (13-15 Nm). • Throttle cable. Adjust its tension so the cable has a deflection of 10-1 2mm (0.39-0.47 in.). 33. Installation of the remaining compo¬ nents is the reverse of removal. 1.6L (B16A2) Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Before beginning the cylinder head removal procedure, be sure the engine tem¬ perature is below 100°F (38°C). To prevent warping, the cylinder head should be removed when the engine is cold. 3. Remove or disconnect the following: • Negative battery cable '■►Label the wires before disconnecting them.

• S2000

• Ignition wires 4. Drain the engine coolant. Remove the radiator cap to speed draining. 5. Remove or disconnect the following: • Strut brace • Intake air duct and the breather hose 6. Relieve the fuel pressure as follows: a. Loosen the fuel filler cap. b. Hold the fuel filter banjo bolt with a back-up wrench. Hold the fuel filter ser¬ vice bolt with a box end wrench. c. Place a shop rag over the fuel filter to absorb fuel spray. d. Slowly loosen the fuel filter service bolt 1 complete turn. 7. Clean up any fuel that may have spilled on the engine or intake manifold. 8. Remove or disconnect the following: • Upper radiator hose from the coolant inlet • Coolant bypass hoses and the heater hose from the intake mani¬ fold • Power steering pump belt • Power steering pump from its mounting bracket and lift the power steering reservoir from its mount Move the pump and reservoir out of the work area and secure them. Don’t disconnect the hydraulic lines. 9. Place a block of wood on the pad of a floor jack. Place the floor jack under the engine for support. 10. Remove or disconnect the following: • Left-front engine mount bracket, if equipped with air conditioning ^Slip the air conditioning compressor belt around the engine mount to remove it.

• Air conditioning compressor drive belt • Alternator belt '■►Be sure the engine is supported with the padded floor jack. Loosen the left side engine mount nuts. Remove the engine mount bracket.

• Valve cover and the upper timing belt cover • Crankshaft pulley and the lower timing belt cover • Timing belt. 11. With the timing belt removed, inspect the water pump and replace it if necessary. 12. Remove or disconnect the following: • Distributor from the cylinder head as an assembly • Fuel lines from the intake manifold

fuel rail. Immediately plug the lines to prevent fuel leakage and contam¬ ination. • Throttle cable from the linkage by first loosening its locknut, then slipping it out of its holder. ►►Label all connectors and vacuum lines before disconnecting them.

• Fuel injector wiring harness con¬ nectors • VTEC solenoid valve and pressure switch connectors • Idle Air Control (IAC) valve con¬ nector • Throttle Position (TP) sensor con¬ nector • Engine Coolant Temperature (ECT) sensor, switch, and gauge sender connectors • Manifold Absolute Pressure (MAP) sensor connector • Primary Heated Oxygen Sensor (HO2S) connector • Vacuum hoses and Positive Crankcase Ventilation (PCV) hose from the intake manifold and throttle body • Evaporative emissions (EVAP) and breather hoses from the intake manifold 13. Loosen the intake manifold nuts in a crisscross sequence. Then, remove the intake manifold together with the throttle body and plenum. 14. Remove or disconnect the following: • Exhaust manifold heat shield • Exhaust manifold nuts in a criss¬ cross sequence • Exhaust manifold ^Be careful not to damage the oxygen sensors when removing the manifold. Cover the front exhaust pipe flange with a shop towel to keep dirt out

• Power steering pump bracket • Camshaft pulleys and back cover • Camshaft holder plate bolts in a crisscross sequence working toward the middle of the cylinder head. 15. Loosen the valve adjusting screws. 16. Remove or disconnect the following: • Camshaft holder plates and holders from the cylinder head. The holder bolts will keep the components together. Note the positions of each camshaft holder for reassembly. • Camshafts from the cylinder head. Mark the exhaust and intake camshafts so that they will not be confused.

3-43 HONDA ACCORD

• CIVIC • PRELUDE

• S2000

21. Tighten the cylinder head bolts to their final torque specification in 2 steps. Use a crisscross sequence starting with the bolts at the middle of the head and working toward the outer bolts: a. Step 1: Tighten each bolt to 22 ft. lbs. (30 Nm). O-ring 2: Tighten each bolt to 61 ft. b. Step lbs. (85 Nm). 22. Install or connect the following: • Dowel pin in the No. 3 cylinder head camshaft holder with a new

7923FG16

Cylinder head bolt loosening sequence— 1.6L (B16A2) engines

• Cylinder head bolts in a 3-step crisscross pattern. Start with the outermost bolts and work toward the middle of the cylinder head. • Cylinder head. If the head sticks to the engine block, tap it with a plas¬ tic-faced or wooden mallet. 17. Inspect the cylinder head for warpage and cracking. Repair, machine, or replace as necessary. The warpage limit is 0.002 in. (0.05mm). Standard cylinder head height is 5.589—5.593 in. (141 .95-1 42.05mm). To install:

^Use new O-ring, seals, and gaskets when installing the cylinder head and its components.

engine block surfaces are clean, level, and straight. 19. Be sure the cylinder head dowel pins and oil control orifice are aligned. Clean the O-ring. control orifice and reinstall it with a new oil 20. Install or connect the following: • New head gasket onto the engine block ^Use new cylinder head bolts and washers. Used or previously-tightened bolts may be stretched; and therefore, they have reduced clamping and seal¬ ing power under compression. Apply clean engine oil to the threads of each head bolt.

18. Be sure the cylinder head and the

• Cylinder head into position. Handtighten all the cylinder head bolts.

23. Thoroughly clean the intake and exhaust camshaft oil control orifices. Rein¬ stall them with new O-rings. 24. Install or connect the following: • Camshafts Nm) • Intake manifold with a new gasket, and tighten the nuts in a crisscross pattern in 2 or 3 steps to 17 ft. lbs. (24 Nm) starting with the inner nuts • Bolts that secure the intake mani¬ fold to its bracket: 17 ft. lbs. (24 • Power steering pump bracket: 33 ft. lbs. (44 Nm) • Exhaust manifold with a new gas¬ ket. Apply anti-seize paste to the studs, and tighten the nuts to 23 ft. lbs. (31 Nm) in a crisscross sequence. Tighten the exhaust manifold bracket bolts to 17 ft. lbs. (24 Nm) • Exhaust manifold to the front self-lock¬ the Nm). exhaust ing nuts pipe. to 40 Tighten ft. lbs. (55 25. Verify that the engine is at Top Dead Center (TDC)/compression for the No. 1

cylinder. • Timing belt. After the timing belt has been properly tensioned, tighten the adjusting bolt to 40 ft. lbs. (55 Nm). • Lower timing belt cover • Crankshaft pulley and tighten its bolt to 130 ft. lbs. (180 Nm) 26. Adjust the valves. 27. Inspect the VTEC rocker arms for free and smooth motion. 28. Remove the VTEC solenoid valve and its filter. Install a new filter, then rein¬ stall the VTEC solenoid valve and tighten its bolts to 108 inch lbs. (12 Nm). or connect the following: 29. • Install Distributor 12 x 1.25 mm

30. Be sure all the spark plug tube seal¬ ing gaskets are fully seated. • New gasket onto to the valve cover.

100 N m (10.0 kg-m, 72 lb ft) Apply clean engine oil to bolt threads and under bolt heads. 7923FG17

Cylinder head torque sequence — 1.6L (B16A2) engine

Apply liquid gasket to the corners of the gasket that meet the camshaft holders. Don’t let the sealant cure

3AA HONDA "44

•

• • • • •

ACCORD*

CIVIC* PRELUDE

before installing the valve cover onto the cylinder head. Valve cover. Gently wiggle the valve cover to be sure it is fully seated. Tighten the valve cover bolts in a crisscross pattern to 84 inch lbs. (10 Nm). New spark plugs Ignition wires Upper radiator hose, heater hoses, and intake manifold coolant bypass hoses Intake manifold vacuum lines, PCV, EVAP canister, and breather hoses Fuel lines to the fuel rail. Use new sealing washers on the banjo fit¬ ting. Carefully tighten the banjo fit¬ ting to 25 ft. lbs. (33 Nm). Tighten the service bolt to 11 ft. lbs. (15 Nm).

• Throttle cable. Adjust its tension so the cable has a deflection of 0.39-0.47 in. (10-1 2mm). 31. Installation of the remaining compo¬ nents is the reverse of removal. 32. After the installation procedure is complete, check that all tubes, hoses, and connectors are installed correctly. 2.0L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: • Negative battery cable • Air cleaner housing • Accessory drive belt • Throttle cable • Fuel lines • Brake booster vacuum hose • Evaporative Emissions (EVAP) can¬ ister hose • Intake manifold bracket and air hose • Water outlet housing • Water bypass hose • Fuel injector connectors • Intake Air Temperature (IAT) sensor connector

• S2000

• VTEC pressure switch connector • Crankshaft Position (CKP) sensor connector • Exhaust manifold cover • Exhaust manifold heat shield • Exhaust manifold • Oil level dipstick • Positive Crankcase Ventilation • • • •

(PCV) valve and hose Ignition coil cover Ignition coils Intake manifold Valve cover

chain auto-tensioner •• Timing Camshafts • Timing chain idler gear • Cylinder head. Loosen the bolts in sequence and in 1/3 turns.

To install:

5. Install the cylinder head with a new gasket. lows: Tighten the bolts in sequence as fol¬ a. Step 1:22 ft. lbs. (29 Nm). b. Step 2: Plus 90 degrees. c. Step 3: Plus 90 degrees. d. Step 4: If using new cylinder head bolts, add an additional 90 degrees. 6. The remainder of the installation is the reverse of the removal procedure.

• Idle Air Control (IAC) valve con¬ nector • Throttle Position (TP) sensor con¬ nector

• Manifold Absolute Pressure (MAP) sensor connector

• Engine Coolant Temperature (ECT) sensor connector • Heated Oxygen (HO2S) sensor con¬ nector • VTEC solenoid valve connector

Cylinder head torque sequence— 2. OL engine

2.2L Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable. 3. Bring the No. 1 cylinder to TDC. 4. Drain the engine coolant into a sealable container. 5. Relieve the fuel system pressure. 6. Remove or disconnect the following: • Vacuum hose, breather hose and air intake duct • Water bypass hose from the cylin¬ der head • Fuel feed and return hose from the fuel rail • Evaporative emissions (EVAP) con¬ trol canister hose from the intake manifold • Brake booster vacuum hose from thebody intake manifold • Vacuum hose mount, on automatic transaxle equipped vehicles • Throttle cable from the throttle • Throttle control cable from the throttle body, on automatic transaxle equipped vehicles

3-45 HONDA ACCORD ^»Be careful not to bend the cable when removing. Do not use pliers to remove the cable from the linkage. Always replace a kinked cable with a new one.

• Ignition coil f»Label the connectors before discon¬ necting them.

• Electrical connectors from the dis¬ tributor and the spark plug wires from the spark plugs i>»Use new self-locking nuts and colorcoded self-locking bolts when installing the engine mounts and suspension components.

• • • • •

i»Do not tighten the engine or transaxle mount fasteners until instructed to do so.

• A/C compressor drive belt • Power steering pump and belt • Cruise control actuator

15. Lower the powertrain into position. 16. Install or connect the following: • Transaxle mount and bracket. Tighten the frame mounting bolts to 47 ft. lbs. (64 Nm). • Upper bracket. Tighten the nuts in sequence to 54 ft. lbs. (74 Nm). • Rear mount bracket through bolt • Right front mount and bracket • Left front mount and bracket

17. Tighten the remaining mount fasten¬ ers as follows: a. Transaxle mount fasteners to 47 ft. lbs. (64 Nm) and the through bolt to 54 ft. lbs. (74 Nm). b. Rear mount bracket through bolt to 43 ft. lbs. (59 Nm). c. Right front mount 12mm bolts to 47 ft. lbs. (64 Nm) and the 10mm bolts to 33 ft. lbs. (44 Nm). d. Left front mount 12mm stud bolt to 61 ft. lbs. (83 Nm), 10mm bolts to 33 ft. lbs. (44 Nm), and 12mm nut to 43 ft. lbs. (59 Nm). e. Right front mount 12mm nut to 43 ft. lbs. (59 Nm). 18. Install or connect the following: • Rear driveshaft, if equipped • A/C compressor • Radiator • A/C hose clamp 19. If equipped with a manual transaxle, install or connect the following: • Shift cables • Transaxle ground cable • Clutch hose bracket • Clutch slave cylinder 20. If equipped with an automatic transaxle, install or connect the following: • Transaxle fluid cooler lines • Transaxle ground cable and hose clamp • Shift cable • Shift cable cover 21. For all vehicles, install or connect the following: • Axle halfshafts • Lower ball joints • Right damper fork • Exhaust front pipe • HO2S connector

• Timing belt • Front cover CR-V

• Heater hoses • Radiator hoses

• Accessory drive belts • Negative battery cable 5. Fill the cooling system. 6. Start the engine and check for leaks.

Splash shield PSP switch Accelerator cable Brake booster vacuum line Fuel lines

2002-03

1 . Before servicing the vehicle, refer to

• Left engine wire harness connec¬ tors • PCM connectors and grommet • Air intake assembly • Battery and tray • Fuse/Relay box battery cables • Negative battery cable

22. Fill the engine crankcase to the cor¬ rect level. 23. Fill the transaxle to the correct level. 24. Fill the cooling system. 25. Start the engine and check for leaks. 26. Check the wheel alignment and adjust as necessary.

tion. the precautions in the beginning of this sec¬ 2. Drain the cooling system. 3. Remove or disconnect the following: • Negative battery cable • Accessory drive belt • Crankshaft pulley • Water pump (6 bolts) Installation is the reverse of removal. Use new 0-rings. Torque the bolts to 104 inch lbs. (12 Nm).

Heater Core REMOVAL & INSTALLATION

Water Pump REMOVAL & INSTALLATION

2000-01

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: • Negative battery cable • Accessory drive belts • Front cover • Timing belt • Water pump

.1 . Disconnect the negative battery cable. 2. Drain the cooling system into a clean container for reuse. 3. In the engine compartment, open the heater valve cable clamp and disconnect the cable from the heater valve arm. Then, turn the heater valve to the fully opened position. 4. Disconnect the heater hoses from the heater core.

5. Remove the heater housing-to-chassis nut. (■►When removing the heater housing nut, be careful not to damage or bend the fuel lines, the brake lines, etc.

To install:

4. Install or connect the following: • Water pump. Use a new O-ring seal and tighten the bolts to 105 inch lbs. (12 Nm).

6. Remove the instrument panel by per¬ forming the following procedure: a. Remove the driver’s side lower instrument panel cover screws, disen¬ gage the clips and remove the lower cover. b. Remove the knee bolster bolts and the knee bolster. c. Remove the glove box stops from each side of the glove box.

d. Remove the glove box-to-instrument panel bolts and the glove box. e. Remove the lower console cover by disengaging the 4 clips and removing the cover. ing 8.7 Ibf-ft)

7924MG10

Exploded view of the water pump mount¬

f. Remove the 6 center pocket-toinstrument panel screws; then, insert a flat tipped screwdriver at the upper right side corner of the center pocket, push down on the top of the hook and remove

4-14

HONDA CR-V

the center pocket/beverage holder chassis screws/nut and remove the evap¬ orator housing. 1 assembly. 8. Disconnect the mode control motor g. Remove9 the center instrument panel lower cover screws and disengage and the air mix control motor electrical con¬ . nectors and remove the wiring harness clips the clips on the upper left side; then, dis¬ connect the electrical connectors and and the wiring harness from the heater housing. remove the cover. h. Gently, push the power window switch from the instrument panel’s lower cover opening by hand. Disconnect the electrical connectors and remove the power window switch. i. Close the driver's side air vent; then, gently, push out the clips and pull out the vent. Disconnect the electrical connectors and remove the vent. j. Gently, push out the driver’s side defogger trim; then, disconnect the elec¬ trical connector and remove the side defogger trim. k. At the base of the steering wheel, remove the access panel and disconnect the air bag electrical connector. l. Remove the steering column cov¬ ers screws and the covers. m. Remove the steering column-toinstrument panel nuts/bolts and lower the steering column. n. Remove the instrument panel side covers. o. Disconnect the wiring harness con¬ nector and remove the nuts. p. Move the under-dash fuse/relay box. q. Disconnect the antenna connector and the harness clips. r. Remove the connector holder from the instrument panel frame. s. Remove the control unit/relay bracket from behind the center of the instrument panel.

9. Remove the heater duct clip, the heater housing-to-chassis heater housing. 10. Remove the heater and the cover. 11. Remove the heater screws and the clamp. 12. Remove the heater heater housing.

nuts and the core cover screws core pipe clamp core from the

To install:

13. Install the heater core in the heater housing. 14. Install the heater core pipe clamp and the clamp screws. 15. Install the heater core cover and the cover screws. 16. Install the heater housing, the heater housing-to-chassis nuts and the heater duct clip. 17. Install the wiring harness clips and the wiring harness to the heater housing and connect the mode control motor and the air mix control motor electrical connec¬ tors. 18. Install the evaporator housing by performing the following procedure: a. Install the evaporator housing and the evaporator housing-to-chassis screws/nut. b. Connect the evaporator housing’s temperature sensor connector.

111mm

100 mm

c. Using new grommets, connect the refrigerant lines. d. In the engine compartment, install the refrigerant lines-to-evaporator hous¬ ing bolts. forming the followin procedur g e: a. Using an assistant, install the I n stall thepanel. instrument instrume nt pan by per¬ b. Install the instrument elpanel-tochassis bolts. c. Connect the connectors and the harness clips.

d. Install the passenger’s side lower instrument panel cover. e. Install the control unit/relay bracket to the center of the instrument panel. f. Install the connector holder to the instrument panel frame. g. Connect the antenna connector and the harness clips. h. Install the under-dash fuse/relay box. i. Connect the wiring harness con¬ nector and install the nuts. j. Install the instrument panel side covers. k. Install the steering column and the column-to-instrument panel nuts/bolts. Torque the nuts to 12 ft. lbs. (16 Nm) and the bolts to 29 ft. lbs. (39 Nm). l. Install the steering column covers and the cover screws. m. At the base of the steering wheel, connect the air bag electrical connector and install the access panel. n. Connect the electrical connector and install the driver’s side defogger trim.

5 mm

t. Remove the passenger’s side lower instrument panel cover. u. Disconnect the connectors and the harness clips. v. Remove the instrument panel-tochassis bolts. w. Using an assistant, remove the instrument panel. pe

pr the fol oc ed the air con¬ or a. Dischargelowiand recover ur mi n g n ditioning system refrigerant. e: g b. In the engine compartment, remove the refrigerant lines-to-evaporator hous¬ ing bolts. c. Separate the lines, discard the grommets and plug the openings to pre¬ vent contamination.

rf

d. Disconnect the evaporator hous¬ ing’s temperature sensor connector. e. Remove the evaporator housing-to-

93113GI2

Exploded view of the steering column and related components

4-15 HONDA

► : Bolt locations AP , 5

. 1

O,

CR-V

1

FRONT PASSENGER'S AIRBAG CONNECTOR

Exploded view of the instrument panel and related components

HEATER

CORE

COVER

o. Connect the electrical connectors and install driver’s side air vent. p. Connect the electrical connectors and install the power window switch to the instrument panel’s lower cover opening. q. Install the center instrument panel lower cover and engage the clips on the the electri¬ connect then,Install left side; and upper cal connectors the cover screws. r. Install the center pocket/beverage holder assembly and the 6 center pocketto-instrument panel screws. s. Install the lower console cover by engaging the 4 clips. t. Install the glove box and the glove box-to-instrument panel bolts. u. Install the glove box stops to each side of the glove box. v. Install the knee bolster and the knee bolster bolts.

w. Install the driver’s side lower instrument panel cover, engage the clips and install the lower cover screws. ~-When installing the heater housing nut, be careful not to damage or bend the fuel lines, the brake lines or etc.

20. Install the heater housing-to-chassis nut. Exploded view of the heater core and housing

4-16

HONDA CR-V

21 . Connect the heater hoses to the heater core. 22. In the engine compartment, connect the cable to the heater valve arm and close the heater valve cable clamp. 23. Refill the cooling system. 24. Connect the negative battery cable. 25. Evacuate and charge and leak test the air conditioning system refrigerant. 26. Run the engine to normal operating temperatures; then, check the climate con¬ trol operation and check for leaks.

Cylinder Head REMOVAL & INSTALLATION 2000-01

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: • Negative battery cable • Air intake assembly • Accessory drive belts • Power steering pump and bracket • Accelerator cable • Fuel lines • Evaporative Emissions (EVAP) con¬ trol canister hose and vacuum hose • Brake booster vacuum line • Intake manifold vacuum line • Positive Crankcase Ventilation (PCV) valve and hose • Upper radiator hose • Heater hose • Bypass hoses • Fuel injector connectors • Engine Coolant Temperature (ECT) sensor connector • Radiator fan switch connector • ECT gauge sending unit connector • Throttle Position (TP) sensor con¬ nector

• Manifold Absolute Pressure (MAP) sensor connector • Heated Oxygen Sensor (HO2S) con¬ nector Cylinder head bolt loosening sequence — 2.0L

• Idle Air Control (IAC) valve con¬ nector

Spark plug wires Distributor Cruise control actuator Engine side mount bracket Front cover Timing belt.

4-17 HONDA • Camshaft sprockets • Rear timing belt cover • Valve cover 5. Loosen the valve adjuster locknuts and screws so that all valves are closed.

B 50 mm

CR-V

(2.0 in.)

p»Keep all valvetrain components in order for assembly.

6. Remove or disconnect the following: • Camshafts • Rocker arms • Exhaust front pipe • Exhaust manifold bracket • Intake manifold 7. Loosen the cylinder head bolts in sequence and 1/3 turns until all bolts are loose. 8. Remove the cylinder head. To install:

9. Install the cylinder head with a new gasket. 10. Apply clean engine oil to the bolt threads and under the bolt heads. 11. Tighten the cylinder head bolts in sequence as follows: a. Step 1:22 ft. lbs. (29 Nm) b. Step 2: 63 ft. lbs. (85 Nm) 12. Install or connect the following: • Intake manifold. Tighten the bolts to 17 ft. lbs. (24 Nm). • Exhaust manifold bracket • Exhaust front pipe • Rocker arms in their original posi¬ tions • Camshafts • Rear timing belt cover • Camshaft sprockets. Tighten the bolts to 27 ft. lbs. (37 Nm). • Timing belt 13. Adjust the valve clearance. 14. Install or connect the following: • Valve cover • Front cover • Engine side mount bracket • Cruise control actuator • Distributor • Spark plug wires • IAC valve connector • HO2S connector • MAP sensor connector • TP sensor connector • ECT gauge sending unit connector • Radiator fan switch connector • ECT sensor connector • Fuel injector connectors • Bypass hoses • Heater hose • Upper radiator hose • PCV valve and hose • Intake manifold vacuum line • Brake booster vacuum line • EVAP control canister hose and vacuum hose

9359MG02

Cylinder head bolt inspection— 2. 4L

• • • • • •

Fuel lines Accelerator cable Power steering pump and bracket Accessory drive belts Air intake assembly Negative battery cable

15. Fill the cooling system. 16. Start the engine and check for leaks. 2002-03

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section.

4-18

HONDA CR-V

2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: • Negative battery cable • Accessory drive belt • Fuel lines • Intake manifold • Bypass hoses • Exhaust manifold • Cam chain • Engine wiring harness connectors • Upper radiator hose • Heater hose • Brake booster vacuum line • Intake manifold vacuum line • Rocker arms 5. Loosen the cylinder head bolts in sequence and % turns until all bolts are loose. 6. Remove the cylinder head. 7. Installation is the reverse of removal. See the accompanying illustration for bolt measurement. For head bolt torque instruc¬ tions, see the Torque Chart.

Rocker Arms/Shafts

/ 1 110-130 (1100-1300, 80-90)

TORQUE

//Vi

: Nm (kgcm, lb-ft)

7923GGA3

Exploded view of the rear strut assembly

To install: 3. Install or connect the following: • Strut assembly and torque the car¬ rier mounting nuts to 66 ft. lbs. (90

eA

40-50 (400-500, 29-35)

Rear suspension

• Upper mounting nuts • Brake hose and wheel speed sensor connectors • Carrier mounting nuts • StruNm) t assembly

• Brake hose and wheel speed sensor connectors

assembly

• Upper mounting nuts and torque the nuts to 22 ft. lbs. (30 Nm) on the Accent and to 37 ft. lbs. (50 Nm) for the Elantra • Wheel house • Rear seatback cover and wheel

2001-03 SONATA AND XG 300 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. •Remove or ldisconnect the following: Rear whee

80-100 (800-1000, 58-7 3)

• Lower mounting bolt • Upper arm and rear carrier bolt • Strut mounting bracket • Strut assembly

7923GGA9

Rear suspension components— Sonata

To install: 3. InstallNm) or connect the following: • Strut assembly and mounting bracket and torque the bolt to 36 ft lbs. (50 Nm)

• Upper arm and rear carrier bolt and torque the bolt to 88 ft. lbs. (120

8-73 HYUNDAI ACCENT • ELANTRA • SONATA • TIBURON « XG 300 6. Install or connect the following: • Upper spring seat and the upper strut mount and torque the nut to 29-36 ft. lbs. (40-50 Nm) • Strut to the vehicle

Self-locking nut 20-25 (200-250, 15-18)

- Washer

©■

Rear upper(A) bushing

7. Check and/or adjust the wheel align¬ ment.

— Collor

SONATA AND XG 300 1 . Before servicing the vehicle, refer to Rear shock absorb mounting bracket

RearCupupper(B) bushing

the precautions in the beginning of this sec¬ tion. 2. Remove the strut from the vehicle and install a Spring Compressor Tool, such as J38402. 3. Compress the coil spring so that the end of the spring comes away from the

spring 4. seat. Remove or disconnect the following: • Self locking nut 5. Install the Compressor Tool, J38402. 6. Remove the bracket, spring pad and coil spring. To install:

Rear spring upper pad

7. Compress the coil spring with Com¬ pressor Tool J38402. 8. Install or connect the following: • Coil spring to the strut • Dust cover, upper spring pad,

Coil spring

bushing and hand tighten the lock nut Shock absorber 9347KG1 7

Exploded view of the rear strut assembly

9. Remove the compressor tool when the coil spring is properly aligned and torque the lock nut to 18 ft. lbs. (25 Nm). 10. Install the strut assembly.

• Lower mounting bolt • Rear wheel 20-30 (200-300, 14-22)

Coil Spring REMOVAL & INSTALLATION Front

ACCENT, ELANTRA AND TIBURON 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the strut from the vehicle and install a spring compressor. 3. Compress the coil spring so that the end of the spring comes away from the spring seat. 4. Remove or disconnect the following: • Upper strut mount • Upper spring seat • Compressed spring from the strut • Spring from the spring compressor To install: 5. Compress the spring and install it on the strut.

TORQUE

: Nm (kg-cm, lb-ft)

Rear strut components

8-74

HYUNDAI ACCENT • ELANTRA • SONATA • TIBURON • XG 300

Upper Ball Joint The upper ball joints are replaced with the upper control arms as an assembly.

Lower Ball Joint REMOVAL & INSTALLATION

Bolt-On Type

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Front wheel • Ball joint stud from the knuckle • Ball joint from the lower control arm To install:

2. Support the lower control arm assem¬ bly with a floor jack. 3. Remove or disconnect the following: • Front wheel

• Ball joint nut, loosen only • Upper arm ball joint from the steer¬ ing knuckle with Special Tool 09568-34000 • Wheel house panel nuts • Upper arm assembly • Upper arm shaft To install: 4. InstallNm)or connect the following: • Upper control arm shaft • Upper control arm assembly and torque the bolts to 73 ft. lbs. (100 • Wheel house panel nuts and torque the nuts to 48 ft. lbs. (65 Nm)

^Use a new split pin for assembly. 3. Install or connect the following: • Ball joint and torque the mounting bolts to 69-87 ft. lbs. (95-120 Nm) • Stud nut and torque to 43-52 ft. lbs. (60-72 Nm) • Front wheel 4. Check and/or adjust the wheel aliqnment.

• Upper arm ball joint to the steering knuckle and torque the bolts to 33 ft. lbs. (45 Nm) • Front wheel CONTROL ARM BUSHING REPLACEMENT

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Control arm from the vehicle • Control arm bushings by unbolting them To install: 3. Install or connect the following: • New bushings and torque the bolts to 40-48 ft. lbs. (55-65 Nm) • Control arm to the vehicle

80-100 (800-1000, 59-73)

55-65 (550-650, 40-48)

Press-In Type

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

Upper arm

2. Remove or disconnect the following: • Front wheel • Lower control arm • Ball joint dust cover 3. Press the ball joint out of the lower control arm. To install: 4. Press the ball joint into the control arm.

Strut assembly

Drive shaft

1 00-1 20 (1 000-1 200, 74-88)

5. Install or connect the following: • Ball joint dust cover • Lower control arm and torque the Nm) nut to 43-52 ft. lbs. (60-72 stud

Stabilizer link 100-120 (1000-1200, 74-88)

Lower arm

• Front wheel 6. Check and/or adjust the wheel aliqnment.

Upper Control Arm REMOVAL & INSTALLATION Sonata and XG 300

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

Lower arm connector 100-120(1000-1200,

35-45 (350-450, 26-33) 75-90 (750-900,55-66) '

74-88)

120-140 (1200-1400, 88-103) 9347KG18

Exploded view of the upper control arm assembly— Sonata

HYUNDAI

6

ACCENT • ELANTRA • SONATA • TIBURON • XG 300

.

Except Sonata and XG 300 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Front wheel • Stabilizer bar link • Lower ball joint • Rear bushing bracket • Front bolt • Lower control arm To install: 3. Install or connect the following: • Lower control arm and torque the front bolt to 72-87 ft. lbs. (100-120 Nm) • Rear bushing bracket. Tighten the bolts to 58-72 ft. lbs. (80-100 Nm) • Lower ball joint and torque the nut to 43-52 ft. lbs. (60-72 Nm) • Stabilizer bar link and torque the nut to 25-33 ft. lbs. (35-45 Nm) • Front wheel 4. Check and/or adjust the wheel align¬ ment. Sonata and XG 300 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Front wheel • Lower ball joint nut, loosen only • Lower arm ball joint from the lower arm connector with Special Tool 09445-21000 • Ball joint • Fork from the lower arm connector • Stabilizer bar link • Control arm inner bushing bolts • Lower control arm To install: 3. Install or connect the following: • Lower control arm and torque the front bushing bolts to 74-88 ft. lbs. (100-120 Nm) and the rear bush¬ ing bolt to 88-103 ft. lbs. (120-140 Nm) • Stabilizer bar link and torque the nut to 26-33 ft. lbs. (35-45 Nm) • Damper fork lower bolt and torque the Nm) nut to 74-88 ft. lbs. (100-120 • Lower ball joint and torque the nut to 55-66 ft. lbs. (75-90 Nm)

7E I U

• Front wheel

Lower Control Arm

4 . REMOVAL & INSTALLATION

Q tl

ment.

ment. Check an d/or adjust th e wheel align¬

CONTROL BUSHING REPLACEMENT Check ARM and/or adj ust the wh eel align¬ Except Sonata and XG 300

ADJUSTMENT

FRONT BUSHING

Front

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove the lower control arm from the vehicle. 3. Press the front bushing out of the control arm. To install: 4. Lubricate the front bushing with soap and press into the control arm. 5. Install the control arm to the vehicle. 6. Check and/or adjust the wheel align¬ ment. REAR BUSHING 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Front wheel • Rear bushing bracket • Rear bushing nut • Rear bushing To install: 3. Install or connect the following: • Rear bushing and torque the nut to Nm) ft. lbs. (35-45 Nm) 25-33 • Rear bushing bracket and torque the bolts to 58-72 ft. lbs. (80-100 • Front wheel 4. Check and/or adjust the wheel align¬ ment. Sonata and XG 300 FRONT BUSHING

Wheel Bearings

The front wheel bearing is a sealed unit and is not adjustable. Rear WITH REAR DRUM BRAKES 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove the rear wheels. 3. Loosen the spindle nut. 4. Torque the nut to 108-145 ft. lbs. (150-200 Nm). Check for correct bearing end-play by placing a dial indicator on the hub surface and moving the hub outward. Note the movement of the gauge and com¬ pare it to the desired reading of 0.008 in. (0.2mm) or less. If end-play exceeds the desired reading, retighten the rear hub bear¬ ing nut and recheck the end-play. If the read¬ ing is still excessive, replace the hub unit. 5. If end-play is correct, check the start¬ ing torque by attaching a spring balance to the hub lug bolts and pulling at a 90 degree angle while noting the required force to turn the hub. If the force required is above the desired reading of 5 lbs. (2.3 kg) or less, loosen the nut and again tighten to the desired torque. Recheck the starting torque. If the torque is still above the desired read¬ ing, replace the rear bearings. 6. Install the rear wheels. WITH REAR DISC BRAKES The rear wheel bearing is an integral part of the rear hub. No adjustment is possible.

The front control arm bushing is serviced with the control arm as an assembly.

REMOVAL & INSTALLATION

REAR BUSHING AND DAMPER FORK BUSHING

Front

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove the control arm from the vehicle. 3. Press the rear bushing and the damper fork bushing out of the control arm. To install: 4. Press the rear bushing and the damper fork bushing into the control arm. 5. Install the control arm to the vehicle.

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Front wheel • Brake caliper • Lower ball joint • Spindle nut • Knuckle pinch bolts ing. • Steering knuckle

3. Press the hub out of the wheel bear¬

8-76

HYUNDAI ACCENT • ELANTRA * SONATA • TIBURON • XG 300

4. Press the wheel bearings out of the steering knuckle. 5. If necessary, press the inner race off the hub. To install: 6. Press the wheel bearings into the steering knuckle. 7. Install the outer grease seal and press the hub into the wheel bearings. 8. Install or connect the following: • Inner grease seal • Steering knuckle and torque the knuckle pinch bolts to 65-76 ft. lbs. (95-105 Nm) • Lower ball joint and torque the stud nut to 43-52 ft. lbs. (60-72 Nm) • Spindle nut and torque the nut to 144-187 ft. lbs. (195-253 Nm) • Brake caliper and torque the bracket bolts to 50 ft. lbs. (68 Nm) • Front wheel

Knuckle

Snap ring

Wheel bearing

200-260 (2000-2600, 159-192)

Dust cover

9347KG19

Exploded view of the front hub assembly

9. Check and/or adjust the wheel aliqnment. Rear DRUM BRAKES

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Rear wheel • Speed sensor, if equipped • Grease cap • Flange nut • Outer bearing • Brake drum • Inner grease seal • Inner bearing 3. Drive the bearing races out of the drum hub. To install: 4. Install the inner and outer bearing races. 5. Apply grease to the bearings and to the cavity in the hub. 6. Install or connect the following: • Inner bearing • Inner grease seal • Brake drum • Outer bearing • Flange nut and torque the nut to 159-192 ft. lbs. (200-260 Nm) • Grease cap • Wheel speed sensor, if equipped • Rear wheel DISC BRAKES

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Release the parking brake. 3. Remove or disconnect the following: • Rear wheel • Wheel speed sensor, if equipped

Exploded view of the rear hub assembly— with drum brakes

Rear disc

Exploded view of the rear wheel bearing assembly— with disc brakes

• Brake caliper and rotor • Rear axle hub bolts • Tone wheel with Tool 09445-21000 • Carrier assembly • Nut after unstaking it 4. Press out the rear axle hub. 5. Remove the bearing inner race with Tool 09445-21000. 6. Remove the bushings from the car¬ rier with Tools 09453-33000B and 09545-

21100.

To install: 7. Press in the bushings to the carrier with Tools 09453-33000B and 09545-21100.

8. Press in the bearing to the hub with Tool 09221-21000. 9. Tighten the flange nut to meet the concave portion of the spindle. 10. Press in the tone wheel with Tool 09221-21000. Torque the nut to 191 ft. lbs. (260 Nm). 1 1 . Install or connect the following: • Hub and bearing assembly to the backing plate and torque the bolts to 88 ft. lbs. (120 Nm) • Brake caliper and rotor • Wheel speed sensor, if equipped • Rear wheel

HYUNDAI

8-77

ACCENT • ELANTRA • SONATA • TIBURON • XG 300

BRAKES Elantra

Brake Caliper

FRONT

REMOVAL & INSTALLATION

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Front wheels

Accent 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Front wheels • Brake line at the caliper • Brake pads • Pin and sleeve boots • Lower caliper bolt and raise the caliper up and out to remove it To install: 3. Install or connect the following: • Caliper onto its mounting and install the lower mounting bolt. Torque the bolt to 16-24 ft. lbs. (22-32 Nm). • Pin boots, sleeve boots and brake

• Brake line at the caliper • Brake pads • Pin and sleeve boots • Lower caliper bolt and raise the caliper up and out to remove it To install: 3. Install or connect the following: • Caliper onto its mounting • Lower mounting bolt. Torque the Nm). bolt to 16-24 ft. lbs. (22-32 • Pin boots, sleeve boots and brake • Brake line to the caliper with 2 new metal pads gaskets. Torque the brake line Nm). union bolt to 18-22 ft. lbs. (24-30

pads • Brake line to the caliper with 2 new metal gaskets. Torque the brake line union bolt to 18-22 ft. lbs. (25-30 Nm). 4. Bleed the system. • Front wheels

4. Bleed the system. • Front wheels

cau

tio

ns

in the beg inn ing

of thi sec s tio n.

Bleed screw

Carrier

1

• Parking brake cable To install: 3. Install or connect the following: • Parking brake cable • Caliper. Tighten the mounting bolts 16-23 • to Brake hoseft. lbs. (22-32 Nm). • Master cylinder with clean fluid and bleed the hydraulic system • Wheel. Adjust the parking brake. • Center console Sonata and XG 300 FRONT 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. ing: 2. Remove or disconnect the follow¬

• Brake hose from the strut • Brake line from the caliper • Small retaining pin from the lower part of the caliper 3. Swing the caliper up until it clears the rotor and pads. 4. Slide the caliper inboard until the locating pin disengages from its groove in the caliper. Pull the caliper from the locating

rod

Bef

ore

Pad and sensor

•• Caliper Caliper assembly mounting bolts

• Brake tube from the brake hose • Brake hose clip

Cylinder assembly

Guide

• Brake hose

• Front wheels

REAR

pre

2. Remove or disconnect the following: • Center console and loosen the • Wheels parking brake adjustment

ser

vic

ingt

he v

ehi

cle

,ref

er t

To install: 5. Lubricate the locating pin bore with white silicone compound and mount the caliper onto the locating pin. 6. pin.Lower the caliper until the small retaining pin holes are aligned. Install a new retaining pin into the lower part of the caliper. Tighten the pin. 7. Install or connect the following: • Brake line to the caliper and bleed the brakes • Brake hose to the strut • Brake hose clip

o th

e

• Brake tube to the brake hose • Front wheels

assembly

9301 6G 10

Front caliper— Sonata shown

REAR 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

8-78

HYUNDAI ACCENT • ELANTRA • SONATA • TIBURON • XG 300

2. Remove or disconnect the following: • Center console and loosen the parking brake adjustment • Wheels • Brake hose • Caliper assembly mounting bolts • Caliper • Parking brake cable To install: 3. Install or connect the following: • Parking brake cable • Caliper. Tighten the mounting bolts to 16-23 ft. lbs. (22-32 Nm). • Brake hose • Master cylinder with clean fluid and bleed the hydraulic system • Wheel. Adjust the parking brake. • Center console Tiburon

To install: 3. Install or connect the following: • Caliper support and tighten the bolts to 44-63 ft. lbs. (69-85 Nm) • Caliper. Tighten the guide rod bolts to 16-24 ft. lbs. (22-32 Nm). • Brake hose and tighten to 18-22 ft lbs. (25-30 Nm) • Wheels 4. Fill the master cylinder with clean brake fluid and bleed the hydraulic system. REAR

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

2. •Remove Wheelsor disconnect the following: • Brake hose • Caliper

FRONT

• Parking brake cable To install:

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Wheels • Brake hose • Caliper • Caliper support

3. Install or connect the following: • Parking brake cable • Caliper. Tighten the mounting bolts to 16-24 ft. lbs. (22-32 Nm). • Brake hose

Rear caliper — Elantra shown

4. Fill the master cylinder with clean brake •fluid and bleed the hydraulic system. Wheels

Disc Brake Pads REMOVAL & INSTALLATION —

Accent

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Front wheels

• Lower caliper mounting bolt and rotate the caliper upward • Pads from the caliper support • Pad clips, if necessary To install: Pad or cliconnect ps 3. •Install the following:

• Pads onto the pad clips 4. Compress the caliper piston using a C-clamp. Rotate the caliper downward and install •theWheels mounting bolt. Elantra FRONT

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

HYUNDAI ACCENT • ELANTRA • SONATA • TIBURON • XG 300 • Front wheels • Lower caliper mounting bolt and rotate the caliper upward • Pads from the caliper support • Pad clips To install: 3. Install or connect the following: • Pad clips • Pads onto the pad clips 4. Compress the caliper piston using a C-clamp. Rotate the caliper downward and install the mounting bolt. • Wheels

fluid and bleed the hydraulic sys¬ tem • Wheels Sonata, Tiburon and XG 300 FRONT 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. ing:2. Remove or disconnect the follow¬ • 1/2 of the fluid from the brake mas¬ ter cylinder • Front wheels

REAR 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Vz of the fluid from the brake mas¬ ter cylinder • Wheels • Caliper mounting bolts • Caliper • Brake pads and retaining clips To install: 3. Install or connect the following: • New pads and retainers 4. Compress the caliper piston using special tool 09580-3400. • Caliper. Tighten the mounting bolts to 16-24 ft. lbs. (22-32 Nm). • Master cylinder with clean brake

• Small retaining pin from the lower part of the caliper 3. Swing the caliper up until it clears the rotor and pads. • Pads and anti-squeal spring from the caliper support To install: 4. Install or connect the following: • Pads and anti-rattle spring 5. Compress the caliper piston using special tool 09580-3400. • Caliper. Tighten the mounting bolts to 16-24 ft. lbs. (22-32 Nm). • Master cylinder with clean brake fluid and bleed the hydraulic sys¬ tem • Wheels

Q_7Q U

13

REAR 1. Before servicing the vehicle, refer to the tion.precautions in the beginning of this sec¬ 2. Remove or disconnect the following: • 1/2 of the fluid from the brake mas¬ • ter Rearcylinder wheels • Caliper mounting bolts and remove the caliper • Brake pads and retaining clips To install: 3. Install or connect the following: • New pads and retainers 4. Compress the caliper piston using special tool 09580-3400. • Caliper. Tighten the mounting bolts to 16-24 ft. lbs. (22-32 Nm). • Master cylinder with clean brake fluid and bleed the hydraulic sys¬ • tem Wheels

Brake Drums REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following:

Brake shoe adjuster

Backing place Wheel cylinder assembly

Shoe return upper spring

— Trailing line shoe assembly Shoe hold down spnng I

1— Cup washer

Shoe hold down pm

50-60(500-600,37

44)

Leading lined shoe assembly Shoe return lower spring Brake drum Adjuster spring 93016G12

Rear drum brakes — Accent shown

.

8-80

HYUNDAI ACCENT « ELANTRA • SONATA • TIBURON • XG 300

• Wheels

• Dust cap, cotter pin, nut lock, wheel bearing nut and washer from the spindle • Outer wheel bearing • Drum with the inner wheel bearing from the spindle To install:

Brake Shoes REMOVAL & INSTALLATION

1 . Before servicing the vehicle, refer to the tion.precautions in the beginning of this sec¬ 2. •Remove Wheelsor disconnect the following:

• • • •

Lubricated inner wheel bearing New grease seal Drum to the spindle Lubricated outer wheel bearing, washer and nut. Adjust the bearing preload as required. • Nut lock and a new cotter pin • Grease cap Install • Wheels. Adjust the rear brakes as or conrequired. nect the fo llowin g:

• Brake drum

• Self-adjuster spring and the adjuster lever • Spread the shoes and remove the adjuster strut • Shoe-to-shoe spring and the hold¬ down springs • Primary brake shoe • Horseshoe clip and the parking

brake lever from the secondary brake shoe To install: 3. Clean the backing plate with brake cleaning solvent. 4. Install or connect the following: • Light coating of lithium grease to the friction points on the backing

• Primary shoe on the backin • Hold-down spring and pin g plate • Parking brake lever to the sec¬ ondary shoe plate • Secondary shoe to the backing plate • Adjuster strut assembly and the adjuster lever and spring • Lower shoe-to-shoe spring • Brake drum and the wheel 5. Adjust the brake shoes.

HYUNDAI Santa Fe 9-36 BRAKES . 9-25 DRIVE TRAIN . 9-7 . R ENGINE REPAI 9-24 FUEL SYSTEM . 9-7 . PRECAUTIONS SPECIFICATION CHARTS . 9-2 STEERING AND 9-29 SUSPENSION . A

Air Bag . Disarming . Precautions . Alternator . Installation . Removal . B

9-29 9-29 9-29 9-7 9-7 9-7

Ball Joint . Removal & Installation . Brake Caliper . Removal & Installation . Brake Shoes . Removal & Installation .

9-31 9-31 9-36 9-36 9-36 9-36

C

Camshaft . Removal & Installation . Clutch . Adjustments . Removal & Installation .

9-12 9-12 9-25 9-25 9-26

'. Coil Springl . Remova & Installation . CV-Joint . Overhaul . Cylinder Head . Removal & Installation .

9-31 9-31 9-27 9-27 9-9 9-9

Disc Brake Pads . Removal & Installation . Distributor .

9-36 9-36 9-7

D

Power Rack and Pinion

Engine Assembly . Removal & Installation . Exhaust Manifold . Removal & Installa F tion .

9-8 9-8 9-12 9-12

Fuel Filter . Removal & Installation . Fuel Injector . Removal & Installation . Fuel Pump . Removal & Installation . Fuel System Pressure . Relieving . Fuel System Service Precautions . H

9-24 9-24 9-24 9-24 9-24 9-24 9-24 9-24

Halfshaft . Removal & Installation . Hydraulic Clutch System . .. Bleeding .

9-26 9-26 9-26 9-26

Steering Gear . R tion . Removal & Installa

9-29 9-29

Rear Main Seal . Removal & Installation . Rocker Arms/Shafts . S tion . Removal & Installa

9-17 9-17 9-10 9-10

Shock Absorber . Removal & Installation . Starter Motor . Removal & Installation . Strut . T tion . Removal & Installa

9-31 9-31 9-14 9-14 9-30 9-30

Timing Belt . Removal & Installation . Trailing Arm . Removal & Installation . Trailing Arm Bushing

9-17 9-17 9-32 9-32

Ignition Timing . Adjustment . Intake Manifold . Removal & InstallLation .

9-8 9-8 9-10 9-10

Replacement . Transaxle Assembly . Removal & Installation . Transfer Case . Removal & InstallV ation .

9-33 9-25 9-25 9-25 9-25

Lower Control Arm . Removal & Installa 0 tion .

9-32 9-32

Valve Lash . W Adjustment .

9-14 9-14

Oil Pan . Removal & Installation . Oil Pump . Removal & Installa P tion .

9-14 9-14 9-15 9-15 9-23 9-23

9-9 9-9 9-33 9-33 9-33

Piston and Ring . Positioning .

Water Pump . Removal & Installation . Wheel Bearings . Adjustment . Removal & Installation .

9-24

HYUNDAI

9-2

SANTA FE

SPECIFICATION CHARTS

ENGINE AND VEHICLE IDENTIFICATION CHART

Model Year

Engine Code

Code

Liters (cc)

B

2.4(2351)

Cu. In. 120 120

2.7 (2656)

Fuel Sys.

Cyl.

MFI

Engine DOHCType DOHC

MFI

DOHC: Double Overhead Cam

Eng.Mfg.

Year 2001

Code©

2002

Hyundai Hyundai

2003 2004

MFI: Multi-port Fuel Injection © 8th position of VIN

42356-HSFE-C01

GENERAL ENGINE SPECIFICATIONS Engine Displacement 2001

Santa Fe

2002

Santa Fe

2003-04

Santa Fe

Kano

177 @4000

10:01

149 @5500

156 @3000

3.41x3.94

10:01

181 @6000

17704000

3.41x2.95

,156 177 0@3000 4000

3.41x3.94 3.41x2.95

10:01 10:01

149 @5500

156 @3000

D

181 @6000

2.4(2351)

B

MFI

2.7 (2656)

D

2.4 (2351)

B

MFI MFI

D

MFI

B

2.7 (2656)

2.7 (2656)

10:01

3.41x3.94 3.41x2.95

MFI MFI

2.4(2351)

149 @5500 181 @6000

@ rpm

© © © © ©

10:01

©

©11.6 Psi (80 kPa) @ idle. © 7.3 Psi (50 kPa) or more @ idle. 42356-HSFE-C02

ENGINE Gap Engine Displacement 2.4(2351)

Pump NS TUNE-U TimingP SPECIFICATIO

Ignition

Spark Plug Engine B

2-1 2B

~ 0.039-0. 04

£..! (^bob) 0 A /OOCH \ C.A (£001 )

£.( (£boo)

LA (Z351) £./ (£bob)

D B D B D

Valve Clearance

Speed

2-12B

3

7-1 9B

Idle

Fuel

7-1 9B

0.040-0.043 2-1 2B

2-1 2B

7-1 9B

7-1 9B

37 37

625-825

in. ~ 625Ml 825 625-825

NA Ex.

NA 625-825

625-825

NA

NA NA

625-825

0.039-0.043 0.040-0.043 2-1 2B

2-12B

7-1 9B

7-1 9B

0.039-0.043

NA 37 37

625-825

37

625-825

0.040-0.043

625-825

625-825

NA

NA

NA

NA NA

625-825 625-825 NA

37

/ehicle Emission r.nntr M/*vrr. TV

-

v

ouu IIIU9I uc um

E: The fuel pressure readings are given with the vacuum hose connected to the regulator and the engine running B: Before top dead center HYD: Hydraulic NA;: Not Availible 42356-HSFE-C03

HYUNDAI

9-3

SANTA FE

CAPACITIES

Year 2001 2002 2003-04

Engine Oil with Filter

Transmission (PtsJ Man. Auto.

Model

Engine Displacement Liters (cc)

Santa Fe

2.4 (2351)

Engine IDA/IN B

2.7 (2656)

D

4.76

2.2 2.2

2.4 (2351)

B

2.2

Santa Fe Santa Fe

Cooling

2.7 (2656)

D

4.53 4.76

2.4 (2351)

B

4.53

2.7 (2656)

D

4.76

2.2 2.2 2.2

level is obtained. NOTE: All capacities are approximate. Add fluid gradually and check to be sure a proper fluid

Fuel

Case

Front

Rear

Tank

—

—

2.2

14.3

8.2 8.94

— (Pts-) —

— (pts.) —

8.2 8.94 8.2

—

—

2.2 2.2 2.2

—

—

—

—

4.53

(qts.)

Drive Axle

Transfer

8.94

(pts.)

7.35

System 14.3 14.3 (gal.)

8.94 (qts.)

2.2

14.3 14.3

8.94 7.35

2.2

14.3

7.35

8.94

HYUNDAI

9-4

SANTA FE

VALVE SPECIFICATIONS Spring

Year

Engine Displacement Liters (cc)

Engine ID/VIN

2001

2.4 (2351)

B

Free

Face

Seat Angle

Angle

Spring Test Pressure

(deg.) 45

45

(lbs.NA @ in.)

2002

D

Intake

2.4(2351)

B

r |

7. Clean the gasket mating surfaces 8. Install the cylinder head gasket so the surface with the identification mark faces towards the head. 9. Measure the head bolts. The bolt length should be 3.9 inch (99.4mm). If the bolts do not meet specification they must be replaced. 10. Install the cylinder head. 11. If using used parts (bolts, head or block), tighten the cylinder head bolts in sequence as follows: a. Step 1: 14 ft. lbs. (20 Nm). b. Step 2: plus an additional 90 degrees. c. Step 3: plus an additional 90 degrees.

12. If using new parts (even if only one thing is replaced), tighten the cylinder head bolts in sequence as follows: a. Step 1:46 ft. lbs. (64 Nm). b. Step 2: release the bolts. c. Step 3: 14 ft. lbs. (20 Nm). d. Step 4: plus an additional 90 degrees. e. Step 5: plus an additional 90 degrees. 13. Install or connect the following: • Camshafts • Timing belt • Rocker cover • Ignition coil • Exhaust manifold • Intake manifold • Air cleaner

Refer to the camshaft removal and instal¬ lation procedure. Intake Manifold REMOVAL & INSTALLATION

\

sprocket side

2.4L Engine 8

6

1

3

9

fV0

0

0

0

0

0 5.

0 7

10

0 4

0 2

1 . Before servicing the vehicle, refer to the precautibody ons in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Air breather hose from the throttle

9355LG09

Cylinder head bolt tightening sequence — 2.4L engine

Cylinder head bolt tightening sequence — 2.7L engine

• Throttle cable

HYUNDAI body

9-11

SANTA FE

• Engine coolant hose and throttle body • Positive Crankcase Ventilation

(PCV) valve and brake booster vac¬ 3uum hose • Vacuum hose connector • Injector cover • High pressure fuel hose • Fuel injector harness connector • Delivery pipe with the injectors and . the pressure regulator as an assembly • Intake manifold stay • Intake manifold

Tighten the bolts to 11-14 ft. lbs. (15-20 Nm) and the nuts to 22-30 ft. lbs. (30-42 Nm). bly • Delivery pipe and injector assem¬

• Negative body battery cable • Air breather hose from the throttle

• PCV valve and brake booster vac¬ uum hose

• Positive Crankcase Ventilation

• Throttle and cruise control cables • Engine coolant hose and throttle

valve and brake booster vac¬ (PCV)hose uum • Vacuum hose connector • Surge tank stay

• Throttle body and engine coolant hose body cable • Throttle • Air breather hose from the throttle

• • • •

• Negative battery cable 4. Start the engine and check for proper

To install:

3. Install or connect the following: • New intake manifold gasket • Intake manifold and bolts and nuts.

• Intake manifold stay and tighten the bolts to 13-18 ft. lbs. (18-25 Nm) • Fuel injector harness connector • High pressure fuel hose • Injector cover • Vacuum hose connector

operation. 2.7L Engine

High pressure fuel hose Surge tank and gasket Fuel injector harness connector Delivery pipe with the injectors and assembly the pressure regulator as an

• Coolant Temperature Sensor (CTS) electrical connector • Intake manifold

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. ing:2. Remove or disconnect the follow¬

To install:

• New intake manifold gasket

Inst

all

or c

onn

ect

the

foll

owin

g:

Intake manifold

TORQUE

: Nm (kg-cm, Ib-ft) 9355LG12A

Exploded view of the intake manifold — 2.4L engine

Nm). 18-22 ft. lbs. (25-30 Nm) and the M10 bolts to 25-40 ft. lbs. (35-55

T : 8-12 (80-120, 6-9)

? 0 o

• Heat shield

• Negative battery cable 2.7L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Heat shield

• Exhaust manifold retainers • Manifold and gasket To install:

3. Install or connect the following: • New gasket and the manifold. Tighten the manifold bolts to 18-22 ft. lbs. (25-30 Nm). • Heat shie ld

• Negative battery cable Camshaft

REMOVAL & INSTALLATION 2.4L Engine

9355LG12

Exploded view of the intake manifold— 2. 7L engine

Intake manifold and tighten the Nm) to 14-15 ft. lbs. (19-21 bolts CTS electrical connector Delivery pipe with the injectors and the pressure regulator as an assembly Fuel injector harness connector Surge tank and gasket High pressure fuel hose Surge tank stay Vacuum hose connector PCV valve and brake booster vac¬ uum hose

body • Engine coolant hose and throttle body • Throttle and cruise control cables • Air breather hose from the throttle

• Negative battery cable 4. Start the engine and check for proper operation. Exhaust Manifold

REMOVAL & INSTALLATION 2.4L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negat battery cable • Heat ive shield

• Exhaust manifold retainers • Manifold and gasket

To install:

Intake manifold torque sequence — 2.7L engine

3. Install or connect the following: • New gasket and the manifold. Tighten the manifold M8 boits to

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

ing:2. Drain the cooling system. 3. Remove or disconnect the follow¬ • Negative battery cable • Breather hose from the air cleaner and rocker cover • Air cleaner • Timing belt cover • Rocker cover and the Crankshaft Position (CKP) sensor • Camshaft sprocket bolts and the • Timing belt sprockets

• Camshaft bearing cap bolts using several passes • Camshaft bearing caps, camshafts, rocker arms and lash adjusters

To install:

4. Inspect all parts for wear and damage.

5. Install or connect the following:

• Camshafts and apply engine oil to the journa ls. Do not install the rocker arms yet.

'•’The exhaust camshaft has a slit on the rear end for the CKP sensor.

• Bearing caps. The caps are marked

I for intake and E for exhaust, they

also contain the cap number. For

9-13 HYUNDAI SANTA FE

example l2would be intake cap number 2. 6. Make sure the camshafts can turn freely, then remove the caps and the camshafts. 7. Make sure the dowel pins on the ends of camshaft sprockets are facing up. • Rocker arms • Camshafts and bearing caps. Tighten the bearing cap bolts uni¬ formly to 14-15 ft. lbs. (19-21 Nm). 8. Using special tools, camshaft oil seal installer and guide 09221-21000, 09221. Intake side

Exhaust side

21100 install the oil seal. Coat the outside of the seal with oil prior to installation, then slide the seal along the front end of the camshaft and using the driver and a ham¬ mer install the seal until it is full seated. • Camshaft sprockets and bolts. Tighten the bolts to 58-72 ft. lbs. (80-100 Nm). • CKP sensor and rocker cover • Breather hose to the air cleaner and rocker cover • Air cleaner • Negative battery cable 2.7L Engine 1 . Before servicing the vehicle, refer to

The exhaust camshaft has a slit on the rear end for the CKP sensor— 2. 4L engine

Rocker arm cover Camshaft sprockets Camshaft bearing caps Camshafts

To install: 3. Align the camshaft timing chain with the intake timing chain sprocket and exhaust sprocket as shown in the accompa¬ nying 4. illustration. Lubricate the camshaft journals with oil and install them. ^To check the press fit, the camshaft (IN) and timing chain sprocket should be separable by a force greater than 1000kg minimum at room temperature. 5. Install the bearing caps. The caps are marked I for intake and E for exhaust, they

the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: Start • Negative battery cable the e ng•in Engine cover and manifold • eIntake chec for l and engine harness • Breather khose e ks. • Power steering apulley • A/C pulley • Crankshaft pulley • Idler pulley • Tensioner pulley • Timing belt cover • Timing belt from the camshaft sprocket(s) • Spark plug wires

Cap number

• • • •

9355LG20

Remove the camshafts b2.7L j engine

from the head—

Timing mark

Symbol identifying intake or exhaust

■— Camshaft 8 10

exhaust, they also contain the cap num¬ ber. For example l2would be intake cap number 2— 2.4L engine

11

5

o

o

0

z?

9355LG1 6

The caps are marked I for intake and E for

sprocket side 7 12

.os

e

>

9355LG18

Camshaft bearing cap locations— 2. 4L engines

9355LG21

Align the camshaft timing chain with the intake timing chain sprocket and exhaust sprocket — 2.7L engine

10*36'

Make sure the dowel pins on the ends of camshaft sprockets are facing up — 2.4L engine

Installing the camshaft oil seal— 2.4L engine

Install the camshaft oil seal — 2.7L engine

HYUNDAI 9 SANTA FE 1 4 3

also contain the cap . number. For example 12 would be intake cap number 2. 6. Tighten the bearing caps M10 bolts to 10-12 ft. lbs. (14-16 Nm) and the M7 bolts to 7-9 ft. lbs. (10—12 Nm) using several passes. 1 7. Using special tool, camshaft oil seal installer 09221-21000 install the oil seal. Coat the outside of the seal with oil prior to installation, then insert the seal along the front end of the camshaft and using the driver and a hammer install the seal until it is full seated. 0 8. Install or connect the following: • Camshaft sprocket and tighten the bolt to 65-80 ft. lbs. (90-110 Nm) • Rocker cover • Spark plug wires • Timing belt. • Timing belt cover • Power steering pulley • A/C pulley • Crankshaft pulley • Idler pulley • Tensioner pulley • Breather hose and engine harness

To install:

• Intake manifold • Engine cover • Negative battery cable

Tighten motor retainers to 20-25 ft. lbs. (27-34InstNmal). lation is the reverse of remo val.

Valve Lash

Oil Pan ADJUSTMENT REMOVAL & INSTALLATION

The valve lash is controlled by hydraulic adjusters and no adjustment is possible.

2.4L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the engine oil. 3. Disconnect the negative battery cable. 4. Remove the oil pan bolts, note the bolts length and location. 5. Tap the oil pan with a rubber mallet and remove the upper and lower pan com¬

Starter Motor REMOVAL & INSTALLATION

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable and wait at least 3 minutes • Speedometer cable and shift cable from the transaxle • Starter motor wiring • Starter motor bolts and the starter

6. Clean the gasket mating surfaces. ponents. To install: 7. Apply 0.16 inch (4mm) of sealant to the oil pan groove as illustrated. Install the within 15 minutes of sealant installation. 8. Install the upper and lower oil pans and the bolts making sure the proper length Nm). is installed in its original position. Tighten the bolt in sequence to 7-9 ft. lbs. (10-12

27-34 (275-346, 20-25)

9. Connect the negative battery cable. 2.7L Engine

1 . Before servicing the vehicle, refer to ill the precautions in the beginning of this sec¬ thtion. ec ran 2.kc Drain the engine oil. ase wit 3. Remove or disconnec h oi ve battery t the following: • Negati cable l. • Lower oil pan bolts and the pan • Upper oil pan bolts and the pan 4. Clean the gasket mating surfaces

Ref

27-34 (275-346, 20-25)

TORQUE

T:3.0-4.2 kgf.m

: Nm (kg.cm, Ib.ft) 9355LG23

9355LG31

Oil pan torque sequence and sealant

Starter motor mounting

application points— 2. 4L engine

9-15 HYUNDAI SANTA FE 2. Drain the engine oil. 3. Remove or disconnect the following: •• Timing Negative battery cable • Oil pan belt • Oil screen and gasket • Oil pressure switch • Oil filter bracket and gasket 4. Using Tool 09213-33000, remove the plug cap from the oil pump portion of the case. • Plug from the left side of the block and insert an 0.32 inch (8mm) screwdriver into the plug hole. The screwdriver must be inserted at least 2.4 inch (60mm). • Pump driven gear the left counter balance shaft bolt • Front case bolts (noting the bolt length and location), the case and 9355LG32

(19-28 Nm), Upper oil pan torque sequence (tighten bolts indicated with * to 14-20 inch lbs. 22-30 ft. to *** a bolts indicated with a ** to 4-5 ft. lbs. (5-7 Nm) and bolts indicated with lbs. (30-42 Nm)— 2.7L engine

To install: 5. Apply 0.16 inch (4mm) of sealant to the lower oil pan groove. Install the within 15 minutes of sealant installation. 6. Install the upper oil pan and the tighten the bolts in sequence as follows: a. 0.937x 1.4961 inch (10 x 38mm) bolt to 22-30 ft. lbs. (30-42 Nm). b. 0.3150 x 0.866 inch (8 x 22mm) bolt 14-20 inch (19-28 Nm). c. 6.7519 inch (171.5mm) bolt to 4-5 ft. lbs. (5-7 Nm). d. 6.7520 inch (152.5mm) bolt to 4-5 ft. lbs. (5-7 Nm).

7. Install the lower pan and tighten the bolts to 7-9 ft. lbs. (10-12 Nm). 8. Connect the negative battery cable. 9. Refill the crankcase with oil.

Oil Pump

• Two counter balance shafts from the block gasket. • Oil pump cover from the case • Oil pump gears from the case • Screwdriver from the plug hole To install: 5. Install the oil pump gears. 6. Inspect the tip clearance of the gears using a feeler gauge. The specifications are as follows: a. Standard value drive gear: 0.0063-0.0083 inch (0.1 6-0.21 mm).

REMOVAL & INSTALLATION 2.4L Engine

t p tihoe reca n. uti ons

in the beg in

ni

of thi sec s ¬ ng

Using Tool 09213-33000, remove the plug

1

cap from the oil pump portion of the case— 2.4L engine

Bef

ore ser

vic

intg hev

ehi

cle r,ef e

rto

Insert an 0.32 inch (8mm) screwdriver at least 2.4 inch (60mm) into the plug hole— 2.4L engine

9-16

HYUNDAI SANTA FE • Timing belt

4

• Negative battery cable 14. Fill the crankcase to the correct level. 15. Start the engine and check for leaks. 2.7L Engine

9355LG29

Remove the pump driven gear the left counter balance shaft bolt— 2.4L engine

Using crankshaft front oil seal install Tool 09214-32000, install the oil seal into the case — 2.4L engine

S 24mm

(0.9 in.)

Remove the oil pump cover from the case— 2.4L engine 9355LG30

b. Standard value driven gear: 0.0071-0.0083 inch (0.18-0.21mm). c. Limit drive gear: 0.0098 inch (0.25mm). d. Limit driven gear: 0.0098 inch (0.25mm). 7. Inspect the side clearance of the gears using a feeler gauge. The specifica¬ tions are as follows: a. Standard value drive gear: 0.0031-0.0055 inch (0.08-0. 14mm). b. Standard value driven gear: 0.0024-0.0047 inch (0.06-0.12mm). c. Limit drive gear: 0.0098 inch (0.25mm). d. Limit driven gear: 0.0098 inch (0.25mm). 8. Apply engine oil to both gears and align the gear timing marks. 9. Install the oil pump case.

Front case bolt length and location— 2. 4L engine

10. Using crankshaft front oil seal install Tool 09214-32000, install the oil seal into the case. 11. Place special tool 09214-32100 on the front of the crankshaft and apply a coat of oil to the outside of the tool to aid in case installation. 12. Install or connect the following: • New front case gasket and tem¬ porarily tighten the flange bolts • Front case and tighten the bolts to 14-20 ft. lbs. (20-27 Nm), making sure the correct length bolt is installed in the correct location. 13. Insert an 0.32 inch (8mm) screw¬ driver into the plug hole. The screwdriver must be inserted at least 2.4 inch (60mm). Verify the shaft is in place and install the bolt.

• New 0-ring on the groove on the front case

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the engine oil. 3. Remove or disconnect the following: • Negative battery cable Oil pressure switch •• Oil filter and pans • Oil screen and gasket • Oil filter bracket and gasket • Oil relief valve plug from the pump case • Oil pump case To install: 4. Install the oil pump gears. 5. Inspect the side clearance of the gears using a feeler gauge. The specifica¬ tions are as follows: a. Standard body clearance: 0.0039-0.0071 inch (0.1 00-0.1 81 mm). b. Standard side clearance: 0.0016-0.0037 inch (0.040-0.095mm). 6. Install the oil pump case with a new gasket. Tighten the bolt to 9-11 ft. lbs. (12-15 Nm). Nm) and the screw to 6-9 ft. lbs (8-12

7. Install a new oil seal into the pump as tightly as possible. 8. Using crankshaft front oil seal install Tool 09214-33000, install the oil seal into the case. 9. Install the relief plunger and spring and tighten the valve plug to 29-36 ft lbs (40-50 Nm). 10. Install the oil screen and a new gas¬ ket. 11. Oil pans and filter. • Negative battery cable

Side clearance

• Plug case and tighten to 14-20 ft lbs. (20-27 Nm) • Oil Oil scree pan n and gasket

Apply engine oil to both gears and align the gear timing marks— 2.4L engine

• Oil pressure switch using a 24mm deep socket. Apply Threebond 1104 sealant to the threads before installation and tighten to 6-9 ft lbs. (8-12 Nm).

Body clearance

9355LG35

Check the oil pump gears side and body clearance-2. 7L engine

12. Fill the crankcase to the correct level. 13. Start the engine and check for leaks.

marks of the camshaft sprocket and the cylinder head cover should be aligned and the dowel pin of the camshaft sprocket should be at the upper side. 3. Remove or disconnect the following: • Crankshaft pulley, water pump pul¬

Rear Main Seal REMOVAL & INSTALLATION

ley and belt drivecover belt • Timing • Auto tensioner

2.4L Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the follow¬ ing: • Transaxle • Clutch pressure plate and disc, if . equipped • Flywheel • Oil seal case bolts and the case • Oil seal

9355LG36

Apply sealant to the areas shown — 2.7L engine

5. Hold the camshaft with a wrench and loosen the camshaft sprocket bolts. • Sprockets 6. When removing the oil pump socket nut, first remove the plug at the side of the block and insert a 0.3 inch (8mm) diameter screwdriver to keep the left counterbalance shaft in position. Insert the screwdriver at least 2.36 inch (60 mm).

(A/T)

To install:

3. Install or connect the following: • Oil seal. Drive the seal square into the seal case. • Oil seal case so that the oil hole in the separator may be directed downwards. Tighten the bolts to 7-9 ft. lbs. (10-12 Nm). • Flywheel • Clutch pressure plate and disc, if equipped • Transaxle 4. Check the fluid levels. 5. Start the engine and check for leaks. 2.7L Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Transaxle • Clutch pressure plate and disc, if equipped • Flywheel • Drive plate and adapter plate

Oil seal case

Oil separator

Position the oil seal case so that the oil hole in the separator may be directed downwards— 2. 4L engine

4. Mark the timing belt is being reused, mark an arrow on the belt noting the direc¬ tion of rotation or the front of the engine to make sure the belt is reinstalled in its origi¬ • Timing belt nal position.

• Oil pump sprocket nut and the Install the drive plate and adapter plate — 2.7L engine

• Oil seal case bolts and the case • Oil seal To install:

3. Install or connect the following: • Oil seal. Drive the seal square into the seal case. • Oil seal case so that the oil hole in the separator may be directed downwards. Tighten the bolts to 7-9 ft. lbs. (10-12 Nm). • Drive plate and adapter plate. Tighten the bolt to 53—56 ft. lbs. (73-77 Nm). • Flywheel • Clutch pressure plate and disc, if • equipped Transaxle

• sprocket Loosen the right counterbalance shaft sprocket bolt until you can loosen it by hand • Tensioner B and timing belt B. Refer to the accompanying illustra¬ tion for tensioner and belt identifi¬ cation.

Do not attempt to loosen bolts while holding the sprocket with pliers or any tool after removing timing belt B.

• Crankshaft sprocket B from the crankshaft To install:

• Crankshaft sprocket B to the crank¬ shaft

4. Check the fluid levels. U CAUTION Ins 5. Start the engine and check for leaks. tallo rco nn Pay attention to the direction of the ec flange. If it is installed in the wrong the Timing Belt fol on, the belt will break. directi low ing REMOVAL & INSTALLATION : 8. Apply engine oil to the outer surface of the spacer lightly and install the spacer to 2.4L Engine the right counterbalance shaft. Be sure to install spacer correctly. 1 . Before servicing the vehicle, refer to • Counterbalance shaft sprocket onto sec¬ this the right counterbalance shaft and the precautions in the beginning of tion. then tighten the flange bolt by hand until it is tight 2. Align the timing marks to set the No. 9. Align the timing mark on each 1 piston to Top Dead Center (TDC) by rotat¬ ing the crankshaft clockwise. The timing

9-18

HYUNDAI SANTA FE

sprocket with its corresponding timing mark on the front case. • Timing belt B and make sure there is no slack • Tensioner B so that the center of the pulley is located on the left side of the mounting bolt and the

pulley flange faces the front of the engine 10. Align the timing mark on the right counterbalance shaft sprocket with the tim¬ ing mark on the front case. 11. Lift the tensioner B to tighten ten¬ sioner B so that its tension side is pulled Timing belt upper cover

tight. Tighten the bolt on tensioner B. As the bolt is being tightened, make sure the shaft does not turn. If the shaft turns, the belt will be overtightened. 12. Make sure the timing marks are aligned. 13. Check the belt tension by depressing

9-19 HYUNDAI SANTA FE

9355LG77

Remove tensioner B and timing belt B — 2.4L engine

screwdriver Nm) through the plug hole on the left side of the block to keep the left counterbal¬ ance shaft in position. Insert the screwdriver at least 2.36 inch (60 mm). • Oil pump sprocket and tighten the nut to 36-43 ft. lbs. (50-60 • Camshaft sprockets and the bolts 16. Hold the camshaft with a wrench and tighten the camshaft sprocket bolts to 56-72 ft. lbs. (80-100 Nm). 17. Reset the auto tensioner as fol¬ lows: a. Place the tensioner in a soft jawed vice in a level position. If there is a plug at the bottom of the tensioner use a plain washer. b. Compress the rod slowly using the vice until the set hole in the rod is

sprocket 9355LG74

Correct sprocket alignment when the belt is installed — 2.4L engine

the center of the belt span with an index fin¬ ger. The deflection should be 0.20-0.28 inch (5-7mm). • Flange and crankshaft sprocket making sure it is installed prop¬ erly. Installing the flange incor¬

rectly will cause the belt to break. • Crankshaft washer and bolt. Tighten the bolt to 80-94 ft. lbs. (110-130 Nm).

Plug

aligned with the set hole on the cylin¬ der. c. Insert a set pin through the body and rod and leave the pin installed. 18. Install or connect the following: • Tensioner and tighten the bolts to 14-20 ft. lbs. (20-27 Nm). Leave the set pin in place. • Tensioner pulley and tighten the bolt to 31-40 ft. lbs. (43-55 Nm) 19. Rotate the camshaft sprockets so that the dowel pin is at the upper side.

Front

J inc 0.3 erat

Ins r

ete

iam

)d mm

h(8

Counter balance shaft

Hold the camshaft with a wrench and loosen the camshaft sprocket bolts — 2.4L engine

Cylinder block 9355LG76

lance shaft in posi¬ Insert a 0.3 inch (8mm) diameter screwdriver to keep the left counterba tion— 2.4L engine

9-20

HYUNDAI SANTA FE rectly. Set the timing mark of the sprocket cor¬

Place the tensioner in a soft jawed vice in a level position. It there is a plug at the bottom of the tensioner use a plain

^Before installing the belt, the timing mark of the camshaft sprocket doers not coincide with that of the rocker cover, do not rotate the cam sprocket more than 2 teeth of the sprocket in any direction. Rotating the sprocket more that 2 teeth may make the valve and piston contact each other. If it is necessary to rotate the sprocket more that 2 teeth, rotate the crankshaft sprocket counterclockwise first based

on the timing mark. After the camshaft sprocket is properly timed, return the crankshaft to TDC. 20. Align the crankshaft sprocket timing marks. 21. Align the pump sprocket timing marks. 22. Install the timing belt counterclock¬ wise around the tensioner pulley and crank¬ shaft sprocket. Hold the belt onto the tensioner pulley using your hand. 23. Pull the belt around the oil pump sprocket using your other hand.

washer — 2.4L engine

Tension side Timing belt "ET

Pay attention to the direction of the flange, if it is installed in the wrong direc¬ tion, the belt will break — 2.4L engine

Apply thin Right counter coat of oil balance shaft

Oil seal

Flange

Tensioner "B Center of boft

9355LG82

Align the timing mark on the right counterbalance shaft sprocket with the timing mark on the front case— 2.4L engine ’777

7/

l Spacer

kpJ

Chamfer 9355LG80

Apply engine oil to the outer surface of the spacer lightly and install the spacer to the right counterbalance shaft. Be sure to install spacer correctly— 2. 4L engine

Timing mark (on sprocket) Timing mark (on front case)

Timing mark (slot in front case)

Align the timing mark on each sprocket with its corresponding timing mark on the front case — 2.4L engine

9-21 HYUNDAI SANTA FE

(5) 5-7mm (0.2-0.3mm ) Camshatt sprocket alignment— 2. 4L

9355LG84

Make sure the timing belt B marks are aligned and the belt tensioner is correct— 2.4L engine marks— 2. 4L engine

24. Install the belt around the right-hand idler pulley, then the intake camshaft sprocket. 25. Turn the exhaust camshaft sprocket one tooth clockwise to align its timing mark with the cylinder top surface, then pull the belt around the exhaust camshaft sprocket. 26. Raise the tensioner pulley gently so that the belt does not sag and temporarily tighten the pulley center bolt. 27. Recheck that all timing marks are correct. 28. Remove the set pin from the auto tensioner. 29. Rotate the crankshaft two turns clockwise and let it sit for around 15 min¬ utes. After 15 minutes, measure the auto tensioner protrusion A (the distance between the tensioner arm and tensioner) as shown in the accompanying illustration. The

Rotate the camshaft sprockets so that the dowel pin is at the upper side, set the tim¬ ing mark of the sprocket correctly— 2.4L engine

}

Crankshaft

Install the flange and crankshaft sprocket making sure it is installed properly — 2.4L engine

Measure the auto tensioner protrusion A — 2.4L engine

Install the tensioner pulley— 2. 4L engine

9~L0L0 SAHYNTUANDAFEI

— specification should be 0.24-0.35 inch (6-9mm). 30. Install the timing covers. Tighten the bolts to specification. 2.7L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Engine cover 3. Using a 16mm wrench, rotate the tensioner arm clockwise about 14 degrees and remove the drive belt. • Power steering pump pulley, idler

A:8-10 N.m (80-100 kg. cm, 6-7 Ib.tt) B: 10-1 2 N.m (100-120 kg.cm, 7-9 Ib.tt)

pulley,pulley tensioner pulley and crank¬ shaft

9355LG91

Timing cover bolt location and torque specitications A — 2.4L engine

• Upper and lower timing covers • Timing belt tensioner 4. Rotate the crankshaft clockwise and

6-7 (60-70, 4-5)

TORQUE

: Nm (kg.cm, ib.ft)

Exploded view of the timing belt assembly — 2.7L engine

align the timing mark to set the No. 1 cylinder to Top Dead Center (TDC). Make sure the tim¬ ing marks of the camshaft sprocket and cylin¬ der head cover should align with each other. '■••If reusing the belt, mark the direction of rotation on the belt to ensure proper belt installation. 5. Unbolt the tensioner and remove the belt. 6. Hold the flange of the camshaft with a wrench, unfasten the sprocket bolts and remove the sprockets. To install: 7. Install or connect the following: • Idler pulley on the water pump boss • Idler pulley to the roll pin that is pressed in the water pump boss • Tensioner arm and plain washer to the block

9-23 HYUNDAI SANTA FE • Tensioner pulley to the tensioner arm • Camshaft sprockets and align the timing marks. Tighten the bolts to 65-80 ft. lbs. (90-110 Nm). 8. Compress the tensioner and install a set pin to keep the plunger in position. • Tensioner and tighten the bolt to 14-20 ft. lbs. (20-27 Nm) 9. Align the sprocket timing marks and install the belt in the following order: • Crankshaft Idler pulley sprocket

Engine coolant pump pulley

• side Camshaft sprocket on the left hand • Water pump pulley • Camshaft sprocket on the right hand side • Tensioner pulley 10. Remove the tensioner set pin. 1 1 . Adjust the timing belt tension as fol¬ lows: a. Rotate the crankshaft 2 turns clock¬ wise and measure the projected length of the auto tensioner at TDC after being installed for 5 minutes.

Correct timing marks alignment with the timing belt installed— 2. 7L engine

6-8mm.

b. The projected length should be

Make sure the timing marks are in their specified positions or remove and reinstall the belt. 12. Install or connect the following: • Upper and lower timing belt covers • Power steering pump pulley, idler shaft pulley,pulley tensioner pulley and crank¬ • Drive belt • Engine cover

Piston and Ring

The projected length of the auto tensioner Remove

the set pin from the auto ten¬

sioner— 2. 7L engine

at Top Dead Center (TDC) should be 6-8mm— 2.7L engine

Upper side rat!

POSITIONING

Lower side Qjl

90’ Position from the gap of No. 2 ring Gap position of upper spacer

ition of Gaper pos low side rail

Spacer

Gap position of spacer 9355LG38

Ring end gap positioning

9-24

HYUNDAI SANTA FE

FUEL SYSTEM Fuel System Service Precautions Safety is the most important factor when performing not only fuel system mainte¬ nance, but any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle’s fuel system components can be accomplished safely and effectively by adhering to the following rules and guide¬ lines: • To avoid the possibility of fire and per¬ sonal injury, always disconnect the negative battery cable unless the repair or test proce¬ dure requires that battery voltage be applied. • Always relieve the fuel system pres¬ sure prior to disconnecting any fuel system component (injector, fuel rail, pressure reg¬ ulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may pene¬ trate the skin or any part of the body that it contacts. • Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suit¬ able waste container.

• Always keep a dry chemical (Class B) fire extinguisher near the work area. • Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame.

Fuel Filter The fuel filter is part of the fuel pump assembly located in the tank. REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: • Negative battery cable • Fuel pump connector • Fuel feed and return lines from the pump assembly • Pump cover screws • Pump assembly from the tank • Filter from the pump assembly To install: 4. Install or connect the following: • Fuel filter • Pump into the tank • Pump cover screws • Fuel feed and return lines to the pump assembly • Fuel pump connector • Negative battery cable 5. Start the engine and check for leaks.

Fuel Pump

2. Relieve the fuel system pressure. 3. Remove or disconnect the following: • Negative battery cable • Fuel pump connector • Fuel feed and return lines from the pump assembly • Pump cover screws • Pump assembly from the tank To install: 4. Install or connect the following: • Pump into the tank • Pump cover screws • Fuel feed and return lines to the pump assembly • Fuel pump connector • Negative battery cable 5. Start the engine and check for leaks.

Fuel Injector REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. bodythe fuel system pressure. 2. Relieve 3. Remove or disconnect the following: • Negative battery cable body • Air breather hose from the throttle • Throttle cable • Engine coolant hose and throttle • Positive Crankcase Ventilation (PCV)hose valve and brake booster vac¬ uum • Vacuum hose connector • Injector cover

REMOVAL & INSTALLATION

• High pressure fuel hose • Fuel injector harness connector • Delivery pipe with the injectors and

ng

ni

in

¬ sec s thi of

g be the in

ns

io

t au ec pr n. thetio

• Always use a backup wrench when loosening and tightening fuel line connec¬ tion fittings. This will prevent unnecessary stress and torsion to fuel line piping. Always follow the proper torque specifica¬ tions.

3. Remove the fuel pump fuse and crank the engine until it stalls. 4. Disconnect the negative battery cable. 5. Replace the fuse.

Grommet

• Always replace worn fuel fitting Fi¬ rings with new. Do not substitute fuel hose or equivalent, where fuel pipe is installed.

1

e r,ef cle

ehi

hev intg

RELIEVING

vic ser ore

Bef

Fuel System Pressure

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. rto

Delivery pipe 9355LG39

2. Remove the fuel filler cap. Install the injector using a twisting motion

the pressure regulator as an assembly • Injector from the delivery pipe 7 8 Injector O-ring, grommet and dis¬ •. card 1 To install: . 4. Install a new grommet and 0-ring 5. Apply a coating of spindle oil or gasoline to the injector O-ring 6. Install the injector into the delivery 0 pipe while turning the injector left and right

• Vacuum hose connector

making sure the injector turns smoothly. If the injector does not turn smoothly check for a jammed O-ring, remove the injector and reinsert it again.

• PCV valve and brake booster vac¬ uum hose body • Throttle body and engine coolant hose • Throttle cable

• Delivery pipe and injector assembly • Intake manifold stay and tighten the Install bolts to 13-18 ft. lbs. (18-25 Nm) or nn ect theharness connector • Fuelcoinjector fol wi ng: • High pressure fuellohose • Injector cover

DRIVE TRAIN • Transaxle mounting insulator bolt Transaxle Assembly. 65-80 ft. lbs. (90-110 Nm) Clutch release cylinder retainers to • REMOVAL & INSTALLATION 11-16 ft. lbs. (15-22 Nm) 7. Fill the transaxle to the correct level. Manual 8. Start the engine and check for leaks. 9. Check the wheel alignment and adjust 1 . Before servicing the vehicle, refer to as necessary. the precautions in the beginning of this sec¬ tion. Automatic 2. Drain the transaxle. 1 . Before servicing the vehicle, refer to 3. Remove or disconnect the following: • Negative battery cable the precautions in the beginning of this sec¬ tion. • Air cleaner duct 2. Drain the transaxle. • Air cleaner and air flow hose 3. Remove or disconnect the following: • Back-up light connector • Negative battery cable • Clutch line and clip • Air cleaner assembly • Clutch release cylinder • Control cable • Speedometer cable • Gear select or shift cables • Speedometer sensor connector • Transaxle range switch, solenoid, • Starter motor mounting bolts • Transaxle upper bolts and oil temperature sensor connec¬ tors 4. Attach an engine support fixture to • Oil cooler hose the engine. • Transaxle mounting bracket and 4. Attach an engine support fixture to insulator the engine. • Front wheels • Gear box, stabilizer bar, tie rod end, • Tie rod end, lower ball joint and lower ball joint and drive shaft drive shaft • Gear box u-joint bolt and the return tube mounting bolts return the and bolt • Gear box u-joint • Sub-frame mounting bolts and the tube mounting bolts frame • Front muffler • Starter motor • Sub-frame mounting bolts and the • Transaxle mounting bolts frame • Transaxle front and rear mounting 5. Using a suitable jack, remove the brackets transaxle from the vehicle. To install: • Transaxle side mounting bolts 6. Installation is the reverse of removal, 5. Using a suitable jack, remove the transaxle from the vehicle. keeping in mind the following torques: To install: • Transaxle case bolts to 15-20 ft. removal, of 6. Installation is the reverse lbs. (20-27 Nm) torques: following the mind in • Transaxle mounting sub-bracket keeping nut 43-58 ft. lbs. (60-80 Nm) ft. 15-20 • Transaxle case bolts to e mounting bracket bolts Transaxl • lbs. (20-27 Nm) 29-40 ft. lbs. (40-55 Nm) • Transaxle mounting sub-bracket • Transaxle mounting insulator bolt nut 43-58 ft. lbs. (60-80 Nm) • Transaxle mounting bracket bolts 65-80 ft. lbs. (90-110 Nm) 29-40 ft. lbs. (40-55 Nm) 7. Adjust the control cable as follows:

• Air breather hose from the throttle • Negative battery cable

operat i Startont. he

engine

and ch eck foand the r prop a. Move the shift lever er N position the transaxle range switch to and install the cable. b. When attaching the control cable to the bracket, make sure the clip is installs so it contacts the cable. c. Adjust the nut to remove any freethe cable and make sure the lever play movesin freely. 8. Fill the transaxle to the correct level. 9. Start the engine and check for leaks.

adjust as necessary.

Transfer Case

Che

ck

the whe & INSTALLATION REMOVAL el ali gnm ent and the vehicle, refer to 1 . Before servicing

the precautions in the beginning of this sec¬ tion. 2. Attach an engine support fixture to the engine. 3. Drain the transfer case fluid. 4. Remove or disconnect the following: • Negative battery cable • Transfer case and sub-frame • Wheels mounting brackets • Front muffler

from the sub-frame Steering tube • Sub-frame assembly

5. Support the transfer case with a suit¬ able jack. • Driveshafts Transfer y case bolts and the case • assembl

6. Installation is the reverse of removal

Clutch ADJUSTMENTS

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

9-26

HYUNDAI SANTA FE

2. Measure the clutch pedal height from the face of the pedal pad to the floorboard. The proper measurement 218.9mm. 3. Measure the clutch pedal clevis pin play. The measurement should be 0.04-0.11 inch (1-3mm). 4. Adjust the height and clevis pin if necessary as follows: a. Turn and adjust the bolt, then secure it by tightening the lock nut. ^After adjustment, tighten the bolt until it reaches the pedal stopper and tighten the lock nut. b. Turn the push rod until the proper specification is reached and tighten the lock nut. '■••When adjusting the clevis pin play or the pedal height, make sure not to push the push rod towards the master cylinder. c. After the adjustments are made, check that the clutch pedal free play is 0.2-0.5 inch (6-1 3mm). The free play is measured at the face of the pedal pad 5. If the adjustments do not bring the pedal into specifications, check the hydraulic system for air or a faulty compo¬ nent.

11. Torque the pressure plate bolts using a star pattern torque sequence to 11-16 ft. lbs. (15-22 Nm). 12. Install transmission. 13. Connect the negative battery cable.

Hydraulic Clutch System BLEEDING Bleeding air from the hydraulic clutch system is necessary whenever any part of the system has been disconnected or the fluid level (in the reservoir) has been allowed to fall so low that air has been drawn into the master cylinder.

NEVER use fluid that has been bled from a clutch system to fill the mas¬ ter cylinder reservoir, as it may be aerated, contain excessive moisture and/or be contaminated in some other way. 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Fill the clutch master cylinder reser¬ voir with new hydraulic clutch fluid.

3. Attach a hose to the bleeder on the clutch actuator and submerge the other end of the hose in a container of hydraulic clutch fluid. 4. Have an assistant slowly depress and hold the clutch pedal. 5. Loosen the bleeder to purge air. 6. Tighten the bleeder. 7. Repeat the above 3 steps until all air is completely purged from the system. 8. Refill the clutch master cylinder reser¬ voir.

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the transaxle. 3. Remove or disconnect the following: • Negative battery cable • Aluminum wheel cover • Split pin and halfhaft nut • Wheel Speed Sensor (WSS) from the bracket, if equipped

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable. 3. Remove the transmission assembly. 4. If the pressure plate is attached to the flywheel, remove the release bearing using snap-ring pliers as follows: a. Insert the snap-ring pliers under the wave washer and place it in the cen¬ ter of the snap-ring b. Spread the snap-ring by pushing down on the bearing assembly. c. Once the snap-ring is fully expanded, remove the release bearing 5. Install a clutch disc alignment tool. 6. Remove pressure plate retaining bolts using a star pattern in several passes. 7. Remove the pressure plate with clutch disc. To install: 8. Apply multi-purpose grease to clutch splines. 9. Install or connect the following: • Clutch plate to the flywheel • Pressure plate and cover. Do not torque the bolts at this time. 10. Align the bearing to the release fork and install it until it is fully engaged.

TORQUE

: Nm (kg-cm, Ib-ft)

Exploded view of the halfshaft mounting and related components

9355LG40

HYUNDAI

9-27

SANTA FE

• Brake hose from the bracket 5 • Knuckle from the strut by removing . the flange bolts • Halfshaft from the hub by tapping the end with a plastic mallet • Haifshaft from the transaxle using a pry bar. 4. Insert a plug in the transaxle opening.

To install:

(■►Use new circlips, split pins and self¬ locking nuts for assembly. 5. Remove the plug from the transaxle opening. 6. Coat the halfshaft splines and sliding surfaces with gear oil. 7. Make sure the gap of the circlip is facing downwards. 8. Install the inner CV-joint to the transaxle until the circlip locks in the retain¬ ing groove. Pull on the shaft by hand to make sure it is properly engaged. 9. Install or connect the following: • Halfshaft into the hub • Knuckle to the strut

• Flange bolts and tighten to 74-88 ft. lbs. (100-120 Nm) • Halfshaft nut and tighten to • • • •

146-190 ft. lbs. (200-260 Nm) New split pin Brake hose to the bracket WSS to the bracket, if equipped Aluminum wheel cover

• Shaft from the vehicle

To install: • Shaft into the axle hub • Differential carrier to the rear using Install o r connec t the f ollowing • Shaft to the carrier : a jack • Differential carrier mounting nuts and bolts. Tighten the carrier nuts and bolts to 51-58 ft. lbs. (70-80 Nm) and the carrier rear bracket bolt to 58-73 ft. lbs. (80-100 Nm). • Propeller shaft • Spare tire and remove the support from the main muffler hanger • New shaft nut and tighten to

Remove

the boot clamps from the DOJ

146-253 ft. lbs. (200-260 Nm) • New split pin • Rear wheel

CV-Joint OVERHAUL

DOJ-BJ Type The DOJ-BJ type joint is used on both the front and rear of the vehicle and the following overhaul procedure is used.

Remove

the circlip with a suitable tool

D.O.J. outer race

• Negative battery cable 10. Fill the transaxle to the correct level and check for leaks.

Rear 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Rear wheel • Split pin and nut • Spare tire and support the hanger of the main muffler to avoid inter¬ fering with the carrier during right hand shaft removal

3. Matchmark the propeller rubber cou¬ pling and differential flange, then remove the bolts and nuts. 4. Support the differential carrier with a jack and remove the differential carrier mounting nuts and bolts. • Shaft from the carrier by inserting a prybar between the carrier and the shaft • Differential carrier to the rear after lowering the jack • Shaft from the axle hub using a

TORQUE

: Nm (kg-cm, Ib-ft)

plastic mallet

9355LG41

Exploded view of the DOJ-BJ type CV-joint assembly

9-28

HYUNDAI SANTA FE

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. k»Do not disassemble the BJ assembly.

ing:

2. Remove or disconnect the follow¬ • Axle halfshaft from the vehicle and place it in a vise • DOJ boot clamps and push the boot back from the outer race • Circlip with a flat bladed prytool • Driveshaft from the DOJ outer race • Snap-ring and take out the inner bly cage and balls as an assem¬ race,

Install the cage so that it is offset on the race

Install the chamfered side of the cage as shown

3. Clean the outer race, cage and balls without disassembling them. • BJ boot clamps • DOJ and BJ boots To install: *-Use new circlips and boot clamps for assembly.

4. Apply some of the grease supplied with the kit to the halfshaft.. 5. Install the boots. 6. Apply the grease supplied with the kit to the inner race and cage. 7. Install the cage so that it is offset on the race. 8. Apply the grease supplied with the kit to the cage and install the balls 9. Install the chamfered side of the cage as shown in the accompanying illustration, then insert the inner race onto the shaft and

To control the volume of air in the DOJ boot, make sure the distance between the boot bands is as shown

install the snap-ring. 10. Apply the grease supplied with the kit to the BJ outer race (67-73 grams of grease in the joint and 62-68 grams of grease in the boot); and install the outer race onto the shaft. 1 1 . Apply the grease supplied with the kit to the DOJ outer race (62-68 grams in the joint and 37-43 grams in the boot); and install the circlip. 12. Tighten the DOJ boot clamps. 13. Apply the grease supplied with the kit to the BJ.

TORQUE

Remove snap-ring and take out the inner race, cage and balls as an assembly

: Nm (kg-cm, Ib-ft) 9355LG48

Exploded view of the TJ-BJ type CV assembly

9-29 HYUNDAI SANTA FE

9 14. Install the boots. 15. Tighten the BJ boot clamps

(■♦To control the volume ot air in the

1 DOJ boot, make sure the distance

between the boot bands is as shown in . the accompanying illustration.

r i

16. Install the axle halfshaft to the vehicle.

0

TJ-BJ Type

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: . • Axle halfshaft from the vehicle. • TJ boot clamps • TJ boot from the TJ case

9355LG50

in If installing the dynamic damper, keep the BJ shaft in a straight line and attach the damper the direction shown

. • Snap-ring and spider assembly • BJ boot clamps, then pull out the TJ boot and the BJ boot erly

3. Clean all the components prop¬

To install: p»Use new circlips and boot clamps for assembly. 4. Apply the grease supplied with the kit to the shaft and install the boots. 5. If installing the dynamic damper, keep the BJ shaft in a straight line and attach the damper in the direction shown in the accompanying illustration, then install the boot clamp. 6. Apply the grease supplied with the

To control the volume of air in the TJ boot, make sure the distance between the boot bands is as shown

kit to the TJ boot (97-103 grams in the joint and 42-48 grams in the boot), then install the boot. 7. Tighten the TJ boot clamps. 8. Add the grease supplied with the kit to the BJ as much as was wiped out during cleaning and inspection.

Ins

tal

Jb

oot

** CAUTION Some vehicles are equipped with an air bag system. The system must be disarmed before performing service on, or around, system components, the steering column, instrument panel components, wiring and sen¬ sors. Failure to follow the safety pre¬ cautions and the disarming procedure could result in accidental air bag deployment, possible injury and unnecessary system repairs. PRECAUTIONS

Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible per¬ sonal injury. • Never carry the inflator module by the

wires or connector on the underside of the module.

nec

t

• When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed away. • Place the inflator module on a bench fte or other surface with the bag and trim Acover rwo facing up. r

sure to refer to the precautions in the begin¬ ning of this section as well. DISARMING

1 . Turn the wheel to the straight ahead position. 2. Disconnect the negative battery cable and wait at least 30 seconds for the air bag energy to deplete.

the bat ter y

.

cab

le.

Power Rack and Pinion Steering Gear REMOVAL & INSTALLATION

kh • With the inflator module on the bench, as b

never place anything on or close to the module which may be thrown in the event of an accidental deployment. Before servicing the vehicle, also make

cla

mps

STEERING AND SUSPENSION Air Bag _

lth e

boo the volume of air in the TJ «-To control ts. make sure the distance between boot, Tig the boot bands is as shown in the hte nth eB accompanying illustration

ee

n c 1 . Before servicing the vehicle, refer to om pl et ed ns in the beginning of this sec¬ the precautio tion. ,co n¬

2. Center the steering wheel and lock it

in position. 3. Drain the power steering system. 4. Remove or disconnect the following: • Negative battery cable • Pressure and return hoses • Joint assembly connecting bolt •• Tie end from the knuckle Feedrodtube • Gear box mounting bolts

• Gear box assembly with the rubber mounts

9-30

HYUNDAI SANTA FE Nm). the fittings to 9-13 ft. lbs. (12-18

To install:

• Gear box assembly with the rubber mounts • Gear box mounting bolts and tighten Nm) to 66-81 ft. lbs. (90-110 5. In stall or conn ect the foll • Feed tube and tightenowin tog:7-11 ft. lbs. (10-16 Nm) • Tie rod end from the knuckle and

.

• Negative battery cable 6. Fill the power steering system. 7. Check the wheel alignment and adjust as necessary.

Nm) to 18-25 ft. lbs. (24-34 tighten • Joint assembly connecting bolt and tighten Nm) to 11-14 ft. lbs. (15-20 • Pressure and return hoses. Tighten

the pre in the begi of this sec¬ nnin tion. caution g s Dust cover

40 - 50 (400 - 500, 30 - 37)

1 B efor e

Self-locking nut

2. Remove or disconnect the following: • Front wheel • Brake hose clip from the strut mounting bracket • Wheel Speed Sensor (WSS) from the knuckle • Stabilizer bar link • Strut-to-knuckle bolts • Strut • 3 upper mounting nuts To install: 3. Install or connect the following: • Strut. Tighten the upper mount nuts to 30-37 ft. lbs. (40-50 Nm). • Strut-to-knuckle bolts and tighten to 74-88 ft. lbs. (100-120 Nm)

60 - 70 (600 - 700, 44 - 52)

se

rvic strut mounting nut Upper ing the v insulator assembly Strut ehi cle,

refer

to

Upper spring seat Upper spring pad Bumper rubber

Dust cover

Coil spring

100-120 (1000-1200, 74- 88) Strut mounting bolt

TORQUE

: Nm (kg cm, Ib-ft) 9355LG52

Exploded view ot the front strut assembly and mounting

9-31 HYUNDAI SANTA FE • Stabilizer bar link and tighten to 30-37 ft. lbs. (30-50 Nm) • WSS from the knuckle

• Brake hose clip to the strut mount¬ ing bracket • Front wheel

nut to 15-22 ft. lbs. (20-30 Nm) and the lower nut to 104-1 1 8 ft. lbs. (140-1 • Rear wheel 60 Nm).

6. Install the upper strut mounting com¬ ponents and tighten the nut to 44-52 ft. lbs. (60-70 Nm). 7. Install the strut to the vehicle. 8. Check the wheel alignment and adjust as necessary. Rear

as necessary.

1 . Before servicing the vehicle, refer to

Shock Absorber REMOVAL & INSTALLATION Rear

. the vehicle, refer to Che1c.k Before the wheservicing el alignm ent and of this sec¬ the precautions in the beginning adjust tion. 2. Support the vehicle under the lower control arm. 3. Remove or disconnect the following: • Rear wheel • Upper shock absorber upper nut • Lower shock absorber nut • Shock absorber To install: 4. Install or connect the following: • Shock absorber. Tighten the upper

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove the strut from the vehicle and install in a strut spring compressor. Com¬ press the spring until the end of the spring comes away from the spring seat. 3. Remove the upper strut mount, spring seat and related components. 4. Remove the coil spring from the strut

spring compressor. To install:

the precautions in the beginning of this sec¬ tion. 2. Support the vehicle under the lower ing: arm. control

3. Remove or disconnect the follow¬ • Rear wheel • assembly Flange nut and brake caliper • Parking brake assembly • Wheel Speed Sensor (WSS) and brake cable • the Rearparking shock assembly 4. Lower the jack assembly and remove the spring.

i-»Use a new self-locking nut.

5. Compress the spring and position the strut so that the end of the spring aligns with the notch in the spring seat.

To install: 5. Install or connect the following:

Spring and raise the jack into posi¬ • tion • Rear shock assembly • Parking brake cable and WSS • Parking brake assembly • assembly Flange nut and brake caliper • Rear wheel

Ball Joint REMOVAL & INSTALLATION

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove the control arm.

09551-g.3100 and 092163. Using the bushin removetools 21100,

TORQUE

: Nm (kg-cm, Ib-ft) 9355LG53

Exploded view of the rear suspension assembly

Removing the bushing from the control arm using the appropriate removal and installation tools

9-32

HYUNDAI

SANTA FE 4 . 11. Using tool 09545-11000, install the dust cover until it is completely seated on the snap ring. 12. Install the control arm. Ball joint flange

Lower Control Arm 9355LG56

REMOVAL & INSTALLATION

Installing the ball joint dust cover

4. Using a suitable prytool and remove the dust cover from the ball joint. 5. Remove the snap-ring. 6. Remove the ball joint from the arm using a plastic hammer. To install: 7. Install the ball joint. 8. Install the bushings into the arm using the appropriate tools. Make sure that the ball joint flange is supported while pressing down on the bushing until the flange touches the arm surface. 9. Install the ball joint snap-ring. Be careful to keep the snap-ring expansion as small as possible during installation. dust cove lip and insi of the cove r. de r

Front 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Front wheel • Ball joint-to-knuckle bolt • Sub frame bolts and the frame • Lower arm bolts and the arm 3. Installation is the reverse of removal. Tighten the fasteners as follows: a. Tighten the arm bolt A to 74-88 ft. lbs. (100-120 Nm) and bolt B to 66-81 ft. lbs. (90-110 Nm). b. Tighten the sub frame bolts to 118-148 ft. lbs. (160-200 Nm). c. Tighten the ball joint-to-knuckle bolt to 74-88 ft. lbs. (100-120 Nm)

as necessary. Check the whee l alignment an d adjust

Trailing Arm

REMOVAL & INSTALLATION Rear 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Support the vehicle under the lower control arm. 3. Remove or disconnect the following: • Rear wheel • assembly Flange nut and brake caliper • • • •

Parking brake assembly Wheel Speed Sensor (WSS) and Spriparking ng the brake cable Rear shock assembly

• Rear driveshaft from the rear axle • Upper and lower arm using tool 09517-43001. • Trailing arm bolt and the arm

to t

he

TORQUE

: Nm (kg-cm, Ib-ft) 9355LG54

Lower control arm assembly

9-33 HYUNDAI SANTA FE

Wheel Bearings ADJUSTMENT The wheel bearings are sealed units and are not adjustable.

• • • •

Strut from the knuckle Tie rod end from the knuckle Lower ball joint bolt Axle shaft from the knuckle using a plastic hammer

REMOVAL & INSTALLATION Front

Using tools 09216-21300 and 0955238100, press fit the trailing arm bushing

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Front wheel ► Wheel Speed Sensor (WSS) from the knuckle • Brake caliper and suspend it aside using wire • Split pin and nut from the axle

Remove the wheel bearing outer race from the knuckle

9355LG59

Position the groove in the arm bushing so that it is aligned as shown, before press¬ ing the bushing into position

To install:

4. Install or connect the following: • Trailing arm and tighten the trailing arm Nm) bolt to 118-133 (160-180

Install the bearing onto the knuckle

• Upper and lower arm. Tighten the ball joint nut to 104-11 ft. lbs. (140-118 Nm). • Spring and raise the jack into posi¬ tion • Rear shock assembly • Parking brake cable and WSS • Parking brake assembly • Flange nut and brake caliper assembly • Rear wheel TRAILING ARM BUSHING REPLACEMENT 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the trailing arm. 3. Press the bushing from the trailing arm. (■►Position the groove in the arm bush¬ ing so that it is aligned as shown in the accompanying illustration, then press fit the bushing.

4. Using tools 09216-21300 and 09552-38100, press fit the bushing.

Remove the wheel bearing inner race from the hub

Check the wheel bearing starting torque

9-34

HYUNDAI SANTA FE

• Brake disc • Knuckle assembly

4. Apply a thin coat of multi-purpose grease bearing.to the surface on the knuckle and

• Snap-ring from the hub • Hub from the knuckle by installing tools 09517-3A00 and 09517-2900, then tighten the nut of the tool to separate the tool from the knuckle • Wheel bearing inner race from the hub using tools 09455-2100 and 09545-34100 • Wheel bearing outer race from the knuckle using tools 09532-3200 and 09216-22100

. dam

age

] : N*m

(kg-m, in-lb)

: N-m

(kg-m, ft-lb)

n

®

Intake manifold collector

@ (D

EGR valve EGR temperature sensor

(4) Throttle body (D

IACV-AAC

d)

Injector

valve

@

Fuel tube assembly

(|) Intake manifold 9307HG07

Exploded view of the intake manifold assembly, related components and the throttle body torque sequence— 4. 1L engines

and the attaching bracket, if

Exhaust Manifold

• equipped Exhaust Gas Recirculation (EGR) sensor electrical connection and the sensor • Exhaust manifold cover • Exhaust manifold nuts, starting at the outside and working towards the middle • Exhaust manifold and discard the

REMOVAL & INSTALLATION 2.0L Engine

To prevent possible tube breakage, be sure to tighten the fuel tube mounting

To install:

gasket .

ld

t

ifo

ket

gas

man

l

aus exh

new a

tal

ins

bolts according to the sequence shown

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Negative battery cable • Undercover and dust covers, if equipped • Exhaust pipe at the manifold flange • Air Injection Valve (AIV), AIV tube,

INFINITI G20 • G35 • 130 • 135 • Q45

10-47

i-*Tf necessary, soak the exhaust pipe nuts with penetrating oil to retaining only loosen them. • Engine cover, G35 only • Air cleaner assembly and duct, G35 • Front exhaust pipe from the exhaust manifolds • Heated Oxygen Sensors (HO2S) from the manifold, as necessary Protective covers from the mani¬ • folds

9307HG23

2. OL engines Be sure to tighten the exhaust manitold nuts in the proper sequence—

4. Install or connect the following: • Exhaust manifold. Torque the nuts in sequence, in 2 steps, to 27-35 ft. lbs. (37-48 Nm). • Exhaust manifold cover and EGR sensor Exhaust gas sensor electrical con¬ • nection . AIV, AIV tube, and the attaching bracket, it equipped • Exhaust pipe to the manifold

flange. Torque the nuts to 30-35 ft. lbs. (41-48 Nm). • Negative battery cable 5. Start the engine, check for leaks and repair if necessary. 3.0L and 3.5L Engines

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Negative battery cable

Right bank

• Exhaust manifold-to-engine mount¬ ing nuts • Manifold from the engine and dis¬ card the gaskets To install: 3. Clean all gasket mounting surfaces. 4. Install or connect the following: • Exhaust manifold with new gaskets. Torque the bolts, in sequence, in 2 steps to 21-23 ft. lbs. (28-32 Nm). • Protective shields. Torque the bolts Nm). in 2 steps to 46-57 inch lbs. (5-6 • HO2S to the manifold, as necessary • Exhaust manifolds to the exhaust pipes. Torque the bolts/nuts to 32-37 ft. lbs. (43-50 Nm) for all models except G35. For the G35, nuts to 45-48 ft. lbs. torque the (60-66 Nm). • Air cleaner assembly and engine cover, G35 only • Negative battery cable 5. Start the engine, check for exhaust leaks and repair if necessary. 4.1L Engines

Left bank

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Negative battery cable • Engine undercovers • Exhaust pipe at the manifold flange fromd the exhaust mani¬ Heat shield • fold, if equippe • Exhaust Gas Recirculation (EGR) sensor electrical connection and if remove the sensor necessary,manifold • Exhaust nuts, starting at the ends and working towards the center • Exhaust manifold and discard the To install: the gasket mating surfaces. 3. Clean gasket or connect the following: 4. Install • Exhaust manifold with new gaskets.

the sequence for removal— G35 Exhaust manifold tightening sequence. Use the reverse of shown

ft. lbs. Torque Nm).nuts to 16-21 (22-28 the

10-48

INFINITI G20*G35»

130* 135* 045

1.

Heated oxygen sensor 2 (rear) (bankl )

2.

Three way catalyst (RH bank)

4.

Heated oxygen sensor 1 (front) (bankl)

5.

Exhaust manifold cover (RH bank)

Exhaust manifold (LH bank)

8.

Exhaust manifold cover (LH bank)

7. 10.

Heated oxygen sensor 1 (front) (bank2)

11.

Gasket 3.

Exhaust manifold (RH bank) Three way catalyst (LH bank)

6. Heated oxygen sensor 2 (rear) (bank2) 9. 9357MG13

Exploded view of the exhaust manifold and related components — G35 shown

• Heat shield on the exhaust mani¬ fold, if equipped • EGR sensor. Torque the fastener to 30-37 ft. lbs. (40-50 Nm), if removed. • EGR sensor electrical connection • Exhaust pipe to the manifold

Right bank exhaust manifold

flange. Torque the nuts to 33-44 ft. lbs. (45-60 Nm). • Negative battery cable 5. Start the engine, check for leaks and repair if necessary.

Camshaft and Valve Lifters REMOVAL & INSTALLATION 2.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Relieve the fuel system pressure.

Vr3

4

5

6 G20 • G35

7 INFINITI

130 • 135 • Q45

10-49

9. The procedure for tightening bearing cap bolts must be followed exactly to pre¬ vent camshaft damage. Torque bolts as fol¬ lows: a. Torque the right camshaft bolts 9 and 10 (in that order) to 17 inch lbs. (2 Nm), then bolts 1 through 8 (in that order) to the same specification. b. Torque the left camshaft bolts 11 and 12 (in that order) to 17 inch lbs. (2 Nm), then bolts 1 through 10 (in that order) to the same specification. c. Torque all bolts in sequence to 52 inch lbs. (6 Nm). Be sure to align the marks on the sprockets with the marks on the chain— 2. 0L engine

d. Torque all bolts again in sequence to 78-1 02 inch lbs. (9-12 Nm), then bolts 8 and 9 on the left camshaft to 13-19 ft. lbs. (18-25 Nm). 10. Line up the mating marks on the timing chain and camshaft sprockets and install the sprockets. Torque sprocket bolts to 101-116 ft. lbs. (137-157 Nm). 11. Install or connect the following:

• Timing chain guide and chain ten¬ sioner • Distributor making certain that the tion rotor head is at the 5 o’clock posi¬ Loosen

in numerical

order. 9307HG24

Camshaft bearing cap bolt loosening sequence— 2. 0L engine

12. Clean the rocker cover and mating surfaces and apply a continuous bead of liquid gasket to the mating surface. 13. Install the rocker cover and oil sepa¬ rator. Tighten the rocker cover bolts as fol¬ lows:

3. Remove or disconnect the following: sur • Negative battery cable cap and coa the mat bea tI • Rocker arm cover theingcam face gas wit ringliq nst a. Torque the nuts 1, 10, 11 and 8, in s uid k a h • Oil separator cap eoti.l tub ll and baf hafptlat bea that order to 36 inch lbs. (4 Nm). f s e s e l rin ,. 4. Rotate the crankshaft until the No. 1 s , e o key is at 12 ’c Ens g the left cam b. Torque the nuts 1 through 13 as loc piston is at Top Dead Center (TDC) on the sh ure r o 1 a i k a k c t and he ig s t 0 'cl compression stroke and the mating marks ht amsh ft ey ock a . f on the camshaft sprockets line upC with the t lea mating marks on the timing chain. nt hel Engine • Timing chain tensioner eft -ha • Distributor front ncda RH camshaft msh • Timing chain guide aft en • Camshaft sprockets. Use a wrench d to hold the camshaft while loosen¬ ing the sprocket bolt. 5. Loosen the camshaft bearing cap bolts in sequence. • Camshaft from the cylinder head 6. When removing the rocker arm, be careful not to drop the valve shims into the cylinder head. After removing the adjuster, set them upright or lay them down in a pan of clean engine oil. Do not lay them down on the bench or the oil will drain out and the adjuster will become air bound. Keep all of these parts in order so they can be Baffle plate installed in the same locations. LH To install:

7. Install the adjusters, shims and rock¬ ers into their original locations.

camshaft

7923HG41

Camshaft bearing cap bolt torque sequence— 2. OL engine

10-50

INFINITI G20 • G35 • 130 • 135 • Q45

indicated in the figure to 72-84 inch lbs. (8-10 Nm). 3.0L and 3.5L Engines EXCEPT

G35 MODELS

1 . Before servicing the vehicle, refer to 14the . precautions in the beginning of this sec¬ Co tion. nnect the negative batter y cable. 2. Relieve the fuel system pressure. 3. Drain the engine oil. 4. Drain the cooling system. 5. Remove or disconnect the following: • Negative battery cable • Left side rocker cover ornament ►►Before disconnecting any hoses or connectors, note the locations for reassembly.

• Air duct to intake manifold hose, collector hose, blow-by hose, and vacuum hoses • Fuel hoses and disconnect the har¬ ness connection • Evaporative emissions (EVAP) can¬ ister purge hoses • Water hoses from the cylinder head and intake manifold

• Ignition coils • Sparkplugs • Exhaust Gas Recirculation (EGR) tube • Intake manifold collector supports and the collector • Fuel tube • Intake manifold • Rocker arm covers • • • • • •

Engine undercovers Right front wheel Engine side covers Drive belts and idler pulley Power steering oil pump and belt Camshaft Position (CMP) sensor (PHASE) and Crankshaft Position (CKP) sensors (REF)/(POS) 6. Set the No. 1 piston to Top Dead center (TDC) of compression stroke by rotating the crankshaft. • Ring gear cover access plate 7. Loosen the crankshaft pulley bolt while securing the ring gear so the crank¬ shaft cannot rotate. ►►Use care not to damage the ring gear teeth.

• Crankshaft pulley, using a suitable puller RH exhaust camshaft

• A/C compressor and bracket • Front exhaust pipe and install engine slingers 8. Support the transaxle with jack. • Right side engine mounting bracket • Center crossmember assembly • Oil pan bolts and oil pans • Timing chain • O-rings from the front of the engine block 9. Loosen the camshaft bearing caps in several steps. The bearing caps MUST be loosened in sequence. ’•-Keep all bearing caps and camshafts in proper order for reinstallation.

• Left-hand and right-hand camshaft tensioners from the cylinder head • Camshafts from the cylinder heads (-►The valve adjusters have a replace¬ able shim on the top of the adjuster. Note the proper locations of each shim to adjuster and remove the shims from the adjusters.

• Valve adjusting shim from the adjuster, using a magnet • Adjuster assembly from the bore. Be sure to note the locations from where each adjuster came. 10. Check the diameter of the valve adjuster and the valve adjuster guide bore. 11. The diameter of the adjuster should be 1.3764-1.3770 in. (34.960-34.975mm) and the diameter of the bore should be 1.3780-1.3788 in. (35.000-35.021 mm). • All traces of liquid gasket from the timing chain case and from the water pump covers • All traces of liquid gasket from the engine block 12. Inspect the camshafts for excessive wear or damage and replace as necessary. To install:

13. Lubricate the valve adjusters with clean engine oil and install the adjusters into the bore from which they were removed. 14. Lubricate the valve adjuster shims with clean engine oil and install the shims into the adjuster from which they were removed. 15. Turn the crankshaft clockwise until the No. 1 piston is set 240° before TDC on compression stroke. 16. Install or connect the following: • Camshaft tensioners on both sides of the cylinder heads. Torque the To avoid camshaft damage, loosen the bearing cap bolts in the sequence shown — 3.0L and 3.5L engines, except G35

tensioner mounting bolts to 75-96 inch lbs. (8-11 Nm).

INFINITI

3p

G20 • G35 • 130 • 135 • Q45

10-51

RH exhaust camshaft

o 0>o (

Positioning of the camshaft keys during installation— 3.0L and 3.5L engines, except G35

Engine front

(■•The camshafts can be identified by the paint marks on the camshaft. The left cylinder head camshafts have a YELLOW paint mark and the right cylin¬ der head camshafts have a WHITE

RH intake camshaft

Tighten in numerical order.

paint mark. When installing the camshafts, position the camshaft keys at the 12 o’clock position in respect to the cylinder head angle.

position the crankshaft to TDC of compres¬ sion stroke and align the dowels of the camshaft sprockets to the 12 o’clock posi¬ tion in respect to the cylinder head • Lower chain guide on the dowel pin with the front mark on the guide facing upward a workbench, align the marks on On 21. exhaust camshaft sprockets and intake the with the marks of the chain.

7923HG46

and 3.5L Be sure to tighten the camshaft bearing cap bolts in the correct sequence— 3. 0L engines (except G35), right cylinder head

• Exhaust and intake camshafts and install the bearing caps. Before installing the No. 1 bearing cap, apply liquid gasket to the corners of the cap. 17. Torque the camshaft bearing caps as follows: a. Nos. 7 through 10 then, Nos. 1 through 6 to 17 inch lbs. (2 Nm). b. All bolts in order to 52 inch lbs. (6 Nm). c. Nos. 1 though 6 to 80-104 inch

' lbs.d.(9-11 though 10 to 74-91 inch Nos. 7Nm). lbs. (9-11 Nm). • New 0-rings to the front of the engine block 18. Apply sealant to the hatched portion of the of the rear timing chain case. 19. Align the rear timing chain case with the dowel pins and install onto the cylinder heads and engine block. Torque the rear timing chain case mounting bolts in sequence to 105-121 inch lbs. (11.8-13.7 Nm). • Crankshaft sprocket with the mating mark facing out 20. Rotate the crankshaft clockwise and

Camshaft bracket

Camshaft bracket LH intake camshaft

o mo

m

front

1®C

— g-ti

LH exhaust camshaft Tighten in numerical order.

7923HG47

3.5L engines (except Tighten the camshaft bearing cap bolts in the correct sequence— 3. 0L and head G35), left cylinder

• Exhaust camshaft sprockets onto the dowel pin. Torque the bolts to 88-95 ft. lbs. (120-129 Nm). Be sure to secure the camshafts while tightening the bolts. • Align and install the timing chains and sprockets to the camshafts • Timing cover evenly and gently. Be sure to align the dowel pin holes ^Leave the bolts unattended for 30 minutes or more after tightening.

22. Apply a 0.091-0.130 in. (2.3-3.3mm) continuous bead of liquid gasket to the water pump cover and install the cover. Tighten the bolts to 84-108 inch Nm).covers lbs. (10-13 • Rocker 23. Apply sealant to the front and rear seal of the oil pan and install the oil pan. • Center crossmember assembly • Right side engine mounting bracket and mount assembly • Engine slinger assembly

10-52

INFINITI G20 • G35 • 130 • 135 • Q45

• Front exhaust pipe and its support • Air conditioning compressor and bracket • Crankshaft pulley to the crankshaft and install the mounting bolt 24. Torque the mounting bolt to 14-22 ft. lbs. (20-29 Nm). Torque the crankshaft bolt an additional 60-66° clockwise. This is approximately the angle from 1 hexagon bolt head corner to another. • Ring gear cover plate • CMP sensor (PHASE) and CKP sensors (REF)/(POS) • Power steering pump assembly, drive belts and the idler pulley • Engine side cover • Right front wheel • Engine undercovers • Intake manifold, using new gaskets • Fuel tube assembly using new insulators. Torque the bolts in sev¬ eral steps to 15-20 ft. lbs. (21-26 Nm). • Intake manifold collector gasket with the arrow facing forward • Intake manifold collector assembly and support bracket • EGR tube using new insulators. Torque the bolts in two steps to 15-20 ft. lbs. (21-26 Nm). • Spark plugs and ignition coils. Torque the bolts to 27-33 inch lbs. (2.9— 3.8 Nm). • Water hoses to the cylinder head and intake manifold • Fuel hoses and wiring harness connections to the fuel rail • Air duct to intake manifold hose, collector hose, blow-by hose, and vacuum hoses • Negative battery cable 25. Fill the engine with clean oil. 26. Fill and bleed the cooling system. 27. Start the engine and run at 3000 RPM under no load to purge the air from the high pressure chamber. The engine may produce a rattling noise. This indicates that air still remains in the chamber and is not a matter of concern.

Inteke valve timing Engine front control solenoid valve

Inteke valve timing control solenoid valve

9357MG14

Location of the intake valve timing control solenoid valves — G35 models

RH bank

G35 MODELS

LH bank 9357MG15

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. tem.

2. Drain the engine oil and cooling sys¬ 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: • Negative battery cable • Front timing chain case • Camshaft sprocket • Timing chain

Intake and exhaust camshaft bracket bolts tightening sequence. Use the reverse sequence for removal— G35 models

• Rear timing chain case • Camshaft Position (CMP) sensors (PHASE) from the back side of the cylinder heads • Intake valve timing control solenoid valves from the No. 1 camshaft bracket

(-►Before removal, matchmark the posi¬ tion of the camshafts, brackets and bolts, so they are reinstalled in their original locations.

• Intake and exhaust camshaft brack¬ ets. Loosen the bolts in several

INFINITI G20 • G35 • 130 • 135 • Q45

stages, in reverse of the sequence shown. • Camshafts • Valve lifters if necessary, noting their installed positions

RH camshaft brackets Exhaust side

To install:

5. Install or connect the following: • Valve lifters, in their original posi¬ tions • Camshafts with the dowel pin attached to its front end face on the exhaust side • Camshaft brackets, as shown in the illustration 6. Torque the camshaft bracket bolts, in sequence, as follows: a. Step 1: Nos. 7-10, then Nos. 1-6 to 17 inch lbs. (2 Nm). b. Step 2: Nos. 1-10 to 52 inch lbs. (5.9 Nm). c. Step 3: Nos. 1-6 to 80-104 inch lbs. (9-12 Nm). d. Step 4: Nos. 7-10 to 74-91 inch lbs. 7. Measure the difference in levels between the front end faces of the No. 1 camshaft bracket and the cylinder head. If the measurement falls out of the range of 0.0055-0.0055 in. (-0.1 4-0.1 4mm), you must reinstall the camshaft and brackets. 8. Check and adjust the valve clear¬ ance. • Intake valve timing control solenoid valves • CMP sensors (PHASE) • Rear timing chain case, timing chain, camshaft sprocket and front timing chain case • Negative battery cable 9. Fill the engine with oil. 10. Fill and bleed the cooling system. 1 1 . Start the vehicle, check for leaks and repair if necessary.

Intake side

Camshaft

4.1L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: • Negative battery cable • Ornament cover • Undercover • Radiator and cooling fan • Inlet and outlet hoses • Alternator belt and idler bracket • Air duct and intake manifold collec¬ tor • Intake valve timing control solenoid • Rocker arm covers

Camshaft bracket installation— G35 models

10-53

,NF,• NmG35 *a G20 iI nU -04

• 130 • 135 • Q45 Left bank

*_

Right

/

10

n f—

-

ra7:

12

B

Tighten the bolts in sequence to prevent warping the sealing surface of the oil pan— 4.3L vehi¬ cles

ISUZU HOMBRE

11-25

joint (front) and the crankshaft rear seal retainer-to-block joint (rear). Continue the bead of sealant about 1 in. (25mm) in both directions from each of the 4 corners. 9. Install or connect the following: • Oil pan, using a new gasket. Tighten the retainers, in sequence, to 18 ft. lbs. (25 Nm). • Starter motor • Differential by rolling it back into position • Front driveshaft • Front differential through-bolts • Idler arm and secure using the retaining bolts • Pitman arm and secure using the bolts • Transfer case shield • Flywheel cover • Front skid plate • Front axle shield • Drive belt splash shield • Dipstick • Negative battery cable 10. Refill the engine crankcase. 1 1 . Start the engine and check for leaks.

Oil Pump REMOVAL & INSTALLATION

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Oil pan • Oil pump and the pickup tube/shaft, if equipped • Extension shaft and retainer from the pump, if necessary for the 2.2L engine careful not to crack the retainer. To install:

3. For the 2.2L engine, if the extension shaft was removed, heat the extension shaft retainer in hot water, then install the shaft and retainer to the oil pump. Be sure the retainer does not crack during installation. 4. Ensure that the pump pickup tube is tight in the pump body. If the tube should come loose, oil pressure will be lost and oil starvation will occur. If the pickup tube is loose it should be replaced. 5. If the pump has been disassembled and is being replaced or for any reason oil has been removed, it must be primed. It can either be filled with oil before installing the cover plate and oil kept within the pump during handling or the entire pump cavity can be filled with petroleum jelly.

7924JG18

Exploded view of the oil pump mounting— 2. 2L engine

Rear Main Seal If the pump is not primed, the engine could be damaged upon start up.

6. Install or connect the following: • Oil pump. Tighten oil pump/pickup tube retainer(s) to 32 ft. lbs. (44 Nm) for the 2.2L engine or to 65 ft. lbs. (90 Nm), for the 4.3L engine. fHf the oil pump does not build up oil pressure almost immediately, remove the pan and check for a loose oil pumpto-pickup tube attachment. If necessary dismantle the pump and pack the pump cavity with petroleum jelly.

REMOVAL & INSTALLATION 2.2L Engines

Please note that the transmission assem¬ bly and transfer case, if equipped, must be removed to perform this procedure. 1. Before servicing the vehicle, refer to

• Oil pan

7. Refill the crankcase. 8. Disable the ignition system; crank engine for approximately 10 seconds to aid in priming the oil pump and reducing the risk of engine damage.

|: WARNING Running the engine without measur¬ will . cause exten¬ ge maure oil press sive able da Carefully pry the rear main oil seal out of its bore— 2.2L engine

ISUZU I I

b

C Q

HOMBRE

• Alternator and brackets from the

the precautions in the beginning of this sec¬ y tion. 2. Remove or disconnect the following: • Negative battery cable • Transmission *assembly and trans¬ fer case, if equipped • Flexplate, if equipped • Clutch assembly and flywheel, if equipped 1 • Crankshaft seal by prying it from out ’•'Be careful not to damage the crank¬ shaft seal surface with the prying tool. To install:

3. Install the new rear seal by lubricating it with engine oil and using a seal tool J34686. 4. Slide the seal over the mandrel until the dust lip bottoms squarely against the tool collar. 5. Align the dowel pin of the tool with the dowel pinhole in the crankshaft and attach the tool to crankshaft. 6. Tighten the T-handle of the tool to push the seal into the bore. Continue until the tool collar is flush against the block. 7. Loosen the T-handle completely. Remove the attaching screws and tool. Check to be sure the seal is seated squarely in the bore. 8. Install or connect the following: • Flywheel/clutch assembly or flexplate • Transmission assembly and trans¬ fer case, if equipped • Negative battery cable 9. Start the engine and check for leaks. 4.3L Engines

Please note that the transmission assem¬ bly and transfer case, if equipped, must be removed to perform this procedure. 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

engine, then position them aside • Oil pan bolts, loosen but do not remove • Crankcase (timing) front cover bolts and the cover. Make sure all bolts are removed and be careful not to force and damage the cover. • Old crankshaft seal from the cover using a suitable prytool. Be very careful not to distort the front cover Carefully pry the rear main seal out of the 2 retainer — 4.3L engine

Timing Chain, Sprockets, Front Cover and Seal REMOVAL & INSTALLATION Front Cover and Seal

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Drive belt • • • • • Rear main oil seal installation using tool

To install:

3. Carefully remove all traces of gasket or sealant from the mating surfaces. • Negative battery cable 4. Lubricate the lips of a new seal with • Transfer case, if equipped * clean engine oil, then use a seal centering • Transmission tool (such as J-35468) to install the seal to • Clutch assembly/flywheel or flexthe front cover. Leave the tool in position in the seal until the cover is installed. 3. Remove the crankshaft rear oil seal by * 5. inserting aplate suitable prying tool into the A ( 5mm pplytahick bead of RTV seale to the oil notches provided in the seal retainer and r pan )at the % frion. cra cov sea su prying the seal out. Take care not to damage e n t face The app (10 a Vkaca in. (6m r by liVnsg in. r¬ the crankshaft sealing surface. s m l n . m) y m e (3m thic bea o)f wRidTeV to the cra To install: d m fron ) cov k at the blo sea 5/ sur nkcas 4. Inspect the crankshaft for grit, rust or fac e er ck l e t e. g 6. Install or connect theinifollowing: burrs and correct as necessary. • Crankcase front cover to the engine 5. Clean the running surface of the using the seal tool to assure it is crankshaft with a non-abrasive cleaner. 6. Install or connect the following: properly centered and prevent dam¬ age to the hub. Tighten the cover • New rear seal lubricated with retaining bolts to 97 inch lbs. (11 engine oil and a seal installer • Flywheel and clutch or flexplate Nm), then remove the seal center¬ • Transmission • Starter Oil ing pan tool. bolts • Transfer case, if equipped • Negative battery cable • Alternator with brackets 7. Start the engine and verify no oil • pulley assembly • Belt Belt tensioner/idler assembly leaks.

2.21 ENGINES

J-34686 — 2.2L engine

or to score the end of the crank¬ shaft.

Cooling fan assembly and pulley Crankshaft pulley and hub Belt tensioner/idler pulley assembly Front oil pan-to-front cover nuts or studs Starter

• Crankshaft pulley and hub • Cooling fan assembly and pulley • Negative battery cable 4.3L ENGINES 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Negative battery cable • Drain the engine cooling system. • Crankshaft pulley and damper

WARNING The outer ring (weight) of the tor¬ sional damper is bonded to the hub with rubber. The damper must be removed with a puller that acts on the inner hub only. Pulling on the outer portion of the damper will break the rubber bond or destroy the tuning of the unit.

ISUZU

11-27

HOMBRE

• Water pump assembly • Crankshaft Position (CKP) sensor

7. Properly refill the engine cooling sys¬ tem. 8. Run the engine until normal operating temperature has been reached, then check for leaks.

(■►Depending upon the year of your truck, you may just need to loosen the oil pan bolts, or you may need to remove it completely.

• Oil pan or loosen bolts, as applica¬ ble ■ Crankshaft Position (CKP) sensor, if equipped • Front cover bolts and the reinforce¬ ments, if equipped • Front cover from the engine 3. Pry the seal out of the front cover using a small prytool. Be very careful not to distort the front cover or to score the end of the crankshaft. To install: (••Anytime the front cover is removed, the cover must be replaced upon reassembly. If you reuse the old cover, oil leaks may develop.

Timing Chain and Sprockets

2.2L ENGINES 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. ng: Remove or disconnect the followi¬ 2. J 35468

• Negative battery cable • Crankcase (timing) front cover from the engine 3. Turn the crankshaft until the timing marks on the sprockets are in alignment. The marks should also be in alignment with the tabs on the tensioner. • Tensioner retaining bolts • Camshaft sprocket retaining bolts

88453GAU

Installing the crankshatt tront oil seal— 4.3L engines

• Oil pan, if removed • Tighten the oil pan bolts Water pump • Crankshaft damper and pulley • Negative battery cable

4. Clean the gasket mating surfaces of the engine and cover of all remaining gasket or sealer material. Be careful not to score or damage the surfaces. •The manufacturer suggests you wait until the front cover is mounted to the engine before you install the replace¬ ment crankshaft oil seal. This assures the cover is properly supported.

5. Install or connect the following: • New front cover gasket to the engine or cover using gasket cement to hold it in position. Lubri¬ cate the front of the oil pan seal with enqine oil to aid in reassem¬ bly. • Front cover to the engine. Take care while engaging the front of the oil pan seal with the bottom ot the cover. Apply sealer 12346141 to the oil pan rail where it contacts the timing cover-to-block joint (front) and the crankshaft rear seal retainer-to-block joint (rear). Con¬ tinue the bead of sealant about 1 in. (25mm) in both directions from each of the four corners. • Front cover retaining bolts and tighten to 106 inch. lbs. (12 Nm) 6. Lightly coat the lips of the replace¬ ment crankshaft seal with clean engine oil, then position the seal with the open end facing inward the engine. Use a suitable seal installation driver to position the seal in the front cover. • CKP sensor O-ring and the sensor, if equipped

1

BOLT

2 3

SPROCKET, BOLT

4

TENSIONER

5 r

A

BOLTS

CPnrkTT

CAMSHAFT

CRANKSHAFT

ALIGN TABS ON TENSIONER WITH MARKS ON CAMSHAFT Sc CRANKSHAFT SPROCKETS. 85383289

Timing chain, sprocket and camshaft mounting— 2. 2L engine

ISUZU

11-28

HOMBRE

9

0 A insert pin after tension has been . B

TABS, USED ALIGNMENT

FOR

CAMSHAFT

applied

AND CRANKSHAFT

85383290

Locking the timing chain tensioner into position for chain . installation— 2. 2L engine

• Camshaft sprocket and timing chain at the same time • Tensioner assembly • Crankshaft Position (CKP) sensor, if equipped • Crankshaft sprocket using J22888-20, if equipped

To install:

4. Install or connect the following: • Crankshaft sprocket using a suit¬ able installer such as J-5590, if removed. Make sure the sprocket is fully seated against the crank¬ shaft. 5. Compress the tensioner spring and insert a cotter pin or nail in the hole pro¬ vided to hold the tensioner in position. • Tensioner retaining bolts • Camshaft sprocket in the timing chain, position the chain under the crankshaft sprocket and the camshaft sprocket to the camshaft 6. Verify that the timing marks are all properly aligned, then loosely install the camshaft sprocket bolt. • CKP sensor, if equipped • Tighten the tensioner bolts to 18 ft. lbs. (24 Nm), then tighten the camshaft sprocket bolt to 96 ft. lbs. (130 Nm) 7. Remove the cotter pin or nail holding the tensioner in position off the chain. • Timing cover to the engine 4.3L ENGINES '■►The following procedure requires the use of the Crankshaft Sprocket Removal tool No. J-5825-A and the Crankshaft Sprocket Installation tool No. J-5590.

A. Align Marks as Shown 85383292

Timing mark alignment— 4. 3L engine

1 . Before servicing the vehicle, refer to

ing sprockets for wear or damage, replace the damaged parts as necessary. the precautions in the beginning of this sec¬ tion. 2. Remove the timing cover from the mou sur Usi sol cle the ven fac an ng nti t e oil andng gre frso. the gas m,ou engine. k a m n et se tin sur 3. If equipped, remove the crankshaft fac g es. reluctor ring. 4. Rotate the crankshaft until the No. 4 U • Crankshaft sprocket key, if removed si cylinder is on the Top Dead Center (TDC) of ng a put ty k its compression stroke and the camshaft nife , cl sprocket mark aligns with the mark on the ean the crankshaft sprocket (facing each other at a Insta gas ll o ket r point closest together in their travel) and in con nec line with the shaft centers. tth e fo 5. Remove or disconnect the following: llo win • Crankshaft Position (CKP) sensor g: reluctor ring, if equipped • Camshaft sprocket-to-camshaft nut and/or bolts • Camshaft sprocket (along with the timing chain). If the sprocket is dif¬ ficult to remove, use a plastic mal¬ let to bump the sprocket from the camshaft. '■►The camshaft sprocket (located by a dowel) is lightly pressed onto the camshaft and should come off easily. The chain comes off with the camshaft sprocket.

6. If necessary use J-5825-A crankshaft sprocket removal tool to free the timing sprocket from the crankshaft. 7. If necessary, remove the crankshaft sprocket key. To install:

8. Inspect the timing chain and the tim¬

85383293

Removal (top) and installation of the crankshaft timing gear

ISUZU

11-29

HOMBRE

• Crankshaft sprocket onto the crank¬ shaft using J-5590 crankshaft sprocket installation tool and a hammer without disturbing the position of the engine

ARROW FRONT

• Camshaft sprocket-to-camshaft retainers to 18 ft. lbs. (25 Nm) 11. With the timing chain installed, turn the crankshaft two complete revolutions, then check to make certain that the timing marks are in correct alignment between the shaft centers. • CKP sensor reluctor ring, if equipped • Timing cover

Top Compression Ring andSpacer Oil Control

7924 AG 12

Piston/connecting rod-to-engine position¬ ing— GM/lsuzu 2.2L engines

Piston ring end-gap spacing— GM/lsuzu 2.2L engine

front -notch "F" to TOWARDS

0

engine. ■ of FRONT

OF ENGINE

arc)

4. Oil ring spacer gap

1. OH nog rait gap* 2. 2nd Compression 3. Notch in piston

rtnfl

(tang in hoi* or slot wt th 5. Top compression

ring

BEARIN END HEAVY GSIDE OF ROD TO REAR

gap flap

HEAVY SIDE BEARING END

7924AG07

Piston and Ring POSITIONING

ENGINE

Control Upper Rail Oil

(■►During installation, coat the thrust surfaces lightly with Molykote* or an equivalent pre-lube.

• Timing chain over the camshaft sprocket. Arrange the camshaft sprocket in such a way that the tim¬ ing marks will align between the shaft centers and the camshaft locating dowel will enter the dowel hole in the cam sprocket. • Timing chain under the crankshaft sprocket, then place the cam sprocket, with the chain still mounted over it, in position on the front of the camshaft

TOWARDS OF

OF

Piston ring end-gap spacing— GIVI 4.3L engines

ROD

TO FRONT

Piston and connecting rod assembly posi¬ tioning— GM 4.3L engine

FUEL SYSTEM Fuel System Service Precautions Safety is the most important factor when performing not only fuel system maintenance but also any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle’s fuel system components can be accomplished safely and effectively by adher¬ ing to the following rules and guidelines. • To avoid the possibility of fire and per¬ sonal injury, always disconnect the negative battery cable unless the repair or test proce¬ dure requires that battery voltage be applied. • Always relieve the fuel system pres¬ sure prior to disconnecting any fuel system component (injector, fuel rail, pressure reg¬ ulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may pene-

trate the skin or any part of the body that it contacts. • Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surtaces. Ensure that all fuel soaked cloths or towels are deposited into a suit¬ able waste container. • Always keep a dry chemical (Class B) fire extinguisher near the work area. • Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame.

• Always use a back-up wrench when loosening and tightening fuel line connec¬ tion fittings. This will prevent unnecessary stress and torsion to fuel line piping. Always follow the proper torque specifica¬ tions.

• Always replace worn fuel fitting 0rings with new. Do not substitute fuel hose or equivalent where fuel pipe is installed.

Fuel System Pressure RELIEVING Multi-Port Fuel Injection and Central Port Injection Systems

The fuel systems operate under high fuel pressures. It is very important that the pres¬ sure be properly relieved prior to servicing the system or any of its components. A Schrader valve is provided on these fuel systems to conveniently test or release the system pressure. A fuel pressure gauge and adapter will be necessary to connect the

Most of the MFI sys¬ to the a fitting. gauge utilize service valve on one end of tems the fuel rail assembly. 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable to assure the prevention of fuel spillage if

-m on isuzu ■ OU HOMBRE the ignition switch is accidentally turned ON while a fitting is still detached.

*

3. Loosen the fuel filler cap to release the fuel tank pressure. 4. Be sure the release valve on the fuel 9 gauge is closed, then connect the fuel gauge to the pressure fitting located on the inlet fuel pipe fitting.

.

N IO UT CA

When connecting the gauge to the fit¬ ting, be sure to wrap a rag around the fitting to avoid spillage. After repairs, place the rag in an approved container.

. 5. Install the bleed hose portion of the fuel gauge assembly into an approved con¬ tainer, then open the gauge release valve and bleed the fuel pressure from the sys¬ tem.

9358KG03

Hold the fuel sender down, and remove

• Fuel filler cap

• Negative battery cable

Fuel Pump REMOVAL & INSTALLATION

6. When the gauge is removed, be sure to open the bleed valve and drain all fuel 1. Before servicing the vehicle, refer to from the gauge assembly. Star the precautions in the beginning of this sec¬ 7. When fuel service is finished, tighten t thtion. e en gine the fuel filler cap and connect the negative 2. Properly relieve the fuel system and chec battery cable. k f pressure. leak negative battery 3. Disconnect orthe s. cable. Fuel Filter 4. Lower the spare tire. 5. Remove or disconnect the following: REMOVAL & INSTALLATION • Rear tail lamp assemblies • Frame-to-pickup box bolts 1. Before servicing the vehicle, refer to • Wiring harness ground wire from the precautions in the beginning of this sec¬ the frame tion. • License plate lamp 2. Properly relieve the fuel system pres¬ • Fuel filler neck-to-pickup box sure. wire and screws • ground Pickup box 3. Remove or disconnect the following: • Negative battery cable • Fuel sender electrical connectors • Fuel filler cap • Fuel sender and Evaporative Emis¬ • Quick connect fittings from the fil¬ sion (EVAP) pipes ter

• Filter feed nut and the clamp bolt • Filter and the clamp from the vehicle To install:

4. Install or connect the following: • Filter and clamp with the direc¬ tional arrow facing away from the fuel tank, towards the throttle body '■►The filter has an arrow (fuel flow direction) on the side of the case, be sure to install it correctly in the sys¬ tem, the with arrow facing away from the fuel tank.

• Tighten the fuel feed nut • Tighten the filter clamp assembly bolt

• Fuel quick disconnect fittings to the filter

the snapring from the designated slots (1) found on the retainer

The fuel sender assembly may spring up from the fuel tank. When remov¬ ing the sender from the fuel tank, keep in mind that the reservoir bucket is full of fuel, so you must tip the sender slightly during removal to avoid damaging the float. Discard the fuel sender O-ring and replace with a new on during installation.

6. While holding the module fuel sender down, remove the snapring from the designated slots (1) found on the retainer. To install:

7. Install a new O-ring on the fuel sender to the tank. 8. Align the tab on the front of the

sender with the slot on the front of the retainer snapring.

th sp se un it al flues rwiitnhg-lthe reta ndeorn thetiltank igns . h oade iner d

^Make

sure that the snapring is prop¬

Slow and fully seated in the tab slots. erly ly a pply 10. Install preors connect the following: sure into to ththe proper slots •• Snapring Fuel and EVAP epipes top o • Electrical connectors f • Negative battery cable 1 1 . Check for fuel leaks as follows: a. Turn the ignition ON for 2 sec¬ onds.

b. Turn the ignition OFF for 10 sec¬ onds. c. Turn the ignition ON. d. Check for leaks. 12. Install or connect the following: • Pickup box to the truck • Filler neck-to-pickup box screws

ground • and Licens e platewire lamp • frame Wiring harness ground wire to the

• Frame-to-pickup box bolts and tighten to 52 ft. lbs. (70 Nm) • Rear tail lamp assemblies

Fuel Injector REMOVAL & INSTALLATION 2.2L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: • Negative battery cable • Intake manifold, if necessary • Fuel injector electrical connections by pushing in the wire connector

ISUZU HOMBRE

11-31

\ 9358KG05

Exploded view of a typical fuel injector— 2.2L engine

9358KG04

Exploded view of the fuel meter assembly, including the injectors

• Return pipe to the fuel pressure regulator. Tighten the fuel pipe nut to 22 ft. lbs. (30 Nm). • Fuel feed inlet pipe to rail

clip and gently pulling on the con¬ nector • Fuel teed inlet pipe from the rail ^►Use a back-up wrench on the fuel rail return fitting to prevent it from turning.

^Rotate the fuel injectors as neces¬ ing the wire har¬ sary ness. to avoid stretch

• Fuel return pipe from the fuel pres¬ sure regulator • Fuel pressure regulator • Fuel rail attaching bolts and lift the fuel rail assembly from the cylinder head • Fuel rail by moving the rail towards the front of the engine • Fuel injector retaining clip • Fuel injector

^When installing the injector care should be taken not to tear or misalign O-rings.

cle

an

eng

ine

a. Turn the switch to the ON position for 2 seconds. b. Turn the ignition switch OFF for 10 seconds. c. Turn the ignition switch to the ON position and check for leaks. 4.3L Engines

ws: llo

: l a t s n i I To

s fo ksa lea ftor pec Ins

^Because each injector is calibrated for a specific flow rate, make sure you only replace fuel injectors using an IDENTICAL part number to the old injectors.

• Injector electrical connections • Intake manifold, if removed • Negative battery cable

oil and inst the inje cto m all r.

in¬ cyl the l rai clip to in l it fuge n ing ri e 0- th tain nsert to re i er low tor toarnd c c d je je il d an in in ra hea g l l el rin Fue Fue Fu der • • • • Fuel rail retaining bolts and tighten to 18 ft. lbs. (25 Nm) • Fuel pressure regulator

K*Use a back-up wrench on the fuel rail return fitting to prevent it from turning.

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Relieve the fuel system pressure. Refer to the fuel system relief procedure in this section. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: • Negative battery cable • Fuel meter body electrical connec¬ tion and the fuel feed and return hoses from the engine fuel pipes • Upper manifold assembly • Poppet nozzle out of the casting socket • Fuel meter body by releasing the locktabs F*Each injector is calibrated. When replacing the fuel injectors, be sure to replace it with the correct injector.

• Lower hold-down plate and nuts 5. While pulling the poppet nozzle tube downward, push with a small prytool down between the injector terminals and remove the injectors. To install:

6. Lubricate the new injector 0-ring seats with engine oil. 7. Install or connect the following: • 0-rings on the injector • Fuel injector into the fuel meter socket. body injector Nm). • Lower hold-down plate and nuts. Torque the nuts to 27 inch lbs. (3 • Fuel meter body assembly into the intake manifold. Torque the fuel meter bracket retainer bolts to 88 inch. lbs. (10 Nm).

:c CAUTION To reduce the risk of fire or injury ensure that the poppet nozzles are casting sockets _ properly seated and locked in their

• Fuel meter body into the bracket and lock all the tabs in place • Poppet nozzles into the casting sockets • Electrical connections • New o-ring seals on the fuel return and feed hoses. • Fuel feed and return hoses and tighten the fuel pipe nuts to 22 ft. lbs. (30 Nm). • Negative battery cable

8. Turn the ignition ON for 2 seconds and then turn it OFF for 10 seconds. Again turn the ignition ON and check for leaks. 9. Install the manifold plenum.

_

ISUZU 11I ~OQO L HOMBRE DRIVE TRAIN Manual Transmission Assembly REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Shift the transmission into 3rd or 4th gear position. 3. Remove or disconnect the following: • Negative battery cable • Shift lever and the if necessary, the shift housing • Parking brake cable for clearance • Propeller shaft • Sid plate, if eguipped • Transfer case and shift lever, on 4WD models • All wiring harness that would inter¬ fere with transmission removal • Fuel line retainers from the rear crossmember • Muffler from the catalytic converter • Exhaust pipes from the exhaust manifold sary • Catalytic converter hanger, if neces¬ • Exhaust section • Bolts and nuts attaching any trans¬ mission braces to the engine and transmission • Hydraulic clutch quick-connect from the concentric slave cylinder following 1 of the 2 steps: a. Use 2 small prytools at 180 degrees from each other to depress the white plastic sleeve on the quick connect to separate the clutch line from the con¬ centric slave cylinder quick connect. b. Use special tool J— 36221 to depress the white plastic sleeve on the quick connect to separate the clutch line end from the concentric slave cylinder quick connect. 4. Remove or disconnect the following: • Bolts securing the clutch housing cover to the transmission, if equipped • Clutch plate and clutch cover, if necessary 5. Support the transmission with a suit¬ able jack. • Rear crossmember from the frame rail • Wiring harness from the front crossmember, if equipped. Move the wiring harness away from the transmission oil pan. Lower the transmission enough to gain

access to the top of the transmis¬ sion. • Fuel line retainers or wiring har¬ ness’s from the top of the transmis¬ sion • Bolt, washer, and nut securing the wiring harness ground wires to the engine block • Bolts retaining the transmission to the engine. Pull the transmission straight back on the clutch hub splines. 6. Lower the transmission using the transmission jack. To install:

Installation is the reverse of removal, but please note the following important steps. 7. Place a THIN coat of high-tempera¬ ture grease on the main drive gear (input shaft) splines. 8. Secure the transmission to the floor jack and raise the transmission into posi¬ tion. ^On some models, it may be neces¬ sary to rotate the transmission clock¬ wise while inserting it into the clutch hub.

9. Slowly insert the input shaft through the clutch. Rotate the output shaft slowly to engage the splines of the input shaft into the clutch while pushing the transmission forward into place. Do not force the trans¬ mission into position, the transmission should easily fall into place once everything is properly aligned. 10. Tighten the transmission mounting bolts to 35 ft. lbs. (47 Nm). 11. Do not remove the transmission jack until the crossmembers have been installed. 12. Check the transmission fluid level and replenish as necessary.

Automatic Transmission Assembly

• Shift cable from the transmission control lever and bracket • Nut and washer securing the trans¬ mission mount to the crossmember • Bolts and washers securing the mount to the transmission manifold(s) • Exhaust pipe from the exhaust • Bolts securing the converter pan cover to the transmission, if equipped • 3 bolts securing the torque con¬ verter to the flywheel • Bolt, clip, and strap securing the three fuel lines and transmission vent hose to the transmission case • Bolts and nut securing the trans¬ mission to the engine • Oil filler tube and seal from the transmission • Transmission cooler lines from the transmission. Plug the lines and the ports in the transmission. • Wiring harness connectors from the transmission. 5. Inspect for any other wiring, brackets etc. which may interfere with the removal of the transmission. 6. Since the transmission acts as a rear engine mount, properly support the rear of the engine with an underbody sup¬ port or other suitable support before attempting to remove the transmission. Otherwise the rear of the engine may pitch downward and components on the rear of the engine and on the firewall may be damaged. 7. Remove the transmission from the engine by pulling the transmission rearward to disengage it from the locator dowel pins on the back of the block. Carefully lower the transmission from the vehicle. Use care that the torque converter does not fall out of the front of the transmission. ^Use converter holding strap tool No.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable 3. Drain the transmission fluid. • Driveshaft from the transmission (2WD) and transfer case, if equipped (4WD) 4. Support the transmission with a suit¬ able transmission jack.

J-21366, to secure the torque converter to the transmission during removal and installation procedures. To install:

Installation is the reverse of removal, but please note the following important steps. 8. Make sure the torque converter is fully seated in the pump drive. If not, the transmission will not fit tightly to the rear of the engine block. 9. Raise the transmission into position and remove the torque converter holding

ISUZU HOMBRE

11-33

88457G33

Transmission mounting on 2.2L engines

strap and carefully. Slide the transmission forward until the dowel pins are engaged. 10. The torque converter should be flush with the flywheel and turn freely by hand. 11. Install the transmission— to— engine bolts. Tighten the bolts to 34 ft. lbs. (47 Nm).

12. Tighten the torque converter-to-flywheel bolts to 46 ft. lbs. (63 Nm). 13. If equipped, tighten the converter pan cover to the transmission bolts to 37 ft. lbs. (50 Nm)

14. Tighten the bolts and washers secur¬ Nm). ing the transmission mount to 35 ft. lbs. (47 15. Tighten the nut and washer securing the transmission mount to the crossmember to 38 ft. lbs. (52 Nm). 16. Refill the transmission with the proper amount and type of fluid. 17. Connect the negative battery cable. Start the vehicle and allow to warm while checking for leaks. Road test the vehicle to check for shift quality.

Clutch REMOVAL & INSTALLATION

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Transmission

3. Install a clutch alignment tool or a used transmission input shaft to support the clutch. 4. If the clutch assembly is going to be reused, mark the flywheel, clutch cover and pressure plate lug for alignment when ainstalling. 5. Remove or disconnect the following: • Clutch cover bolts and washers • Clutch cover assembly and the clutch plate • Clutch alignment tool

6. Clean all parts and inspect for dam¬ To install:

age.7. Install or connect the following: • Clutch alignment tool, to support the clutch • Clutch cover by aligning the matchmarks or, if new, align the lightest part of the cover, identified by a yellow dot, with the heaviest part identified by an X. • Clutch plate/clutch cover assembly to the flywheel. Tighten the bolts to 33 ft. lbs. (45 Nm) for 2.2L engines or to 29 ft. lbs. (40 Nm) for 4.3L Transmission mounting on 4.3L engines

engines.

ISUZU 11I_QOHA HOMBRE 3. Have an assistant fully depress and hold the clutch pedal, then open the bleeder screw. 4. Close the bleeder screw and have your assistant release the clutch pedal. 5. Repeat the procedure until all of the air is evacuated from the system. Check ahd refill master cylinder reservoir as required to prevent air from being drawn through the master cylinder. '■►Never release a depressed clutch pedal with the bleeder screw open or air will be drawn into the system.

7924JG53

Exploded view of the clutch disc and related components

6. If the previous steps do not result in satisfactory pedal feel, remove the reservoir cap and pump the clutch pedal very fast for 30 seconds. Stop to let the air escape, then repeat the procedure as necessary to purge all remaining air. 7. Test the clutch for proper operation.

Transfer Case Assembly

J 33169

REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to

7924JG22

Use the clutch alignment tool to center and support the clutch disc during installation

^Tighten each screw 1 turn at a time to avoid warping the clutch cover.

8. Remove the clutch alignment tool. 9. Install or connect the following: • Transmission • Negative battery cable

Hydraulic Clutch System

the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable. 3. Shift the transfer case into the4Hlrange. 4. Drain the transfer case fluid. 5. Support the transfer case. 6.• Remove or disconnect the following: Skid plate

CAUTION Always use new fluid from a sealed container. Never, under any circum¬ stances, use fluid that has been bled from a system to fill the reservoir as it may be aerated, have too much moisture content and possibly be contaminated.

• Front and rear driveshafts from the transfer case. Matchmark the shafts prior to removal. • Vacuum lines and/or the electrical connectors, as equipped • Transfer case shift rod/cable from the case, if applicable • Support brace-to-transfer case bolts, if applicable

Bleeding air from the hydraulic clutch system is necessary whenever any part of the system has been disconnected or the fluid level (in the reservoir) has been allowed to fall so low, that air has been drawn into the master cylinder. BLEEDING 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Fill master cylinder reservoir with new brake fluid conforming to DOT 3 speci¬ fications.

7924JG27

Transfer case-to-manual transmission mounting — Typical

ISUZU 1-1 HOMBRE

■ ■

marks made during removal. Install the three bolts and three nuts and tighten to 41 ft. lbs. (55 Nm). 14. Install the outer CV-joint into the steering knuckle. 15. Support the lower control arm with the hydraulic jack. 16. Attach the steering knuckle and lower ball joint to the lower control arm. Tighten the strut bolts and nuts to 65 ft. lbs. (90 Nm). Tighten the ball joint nut to 63 ft. lbs. (85 Nm) and install a new cotter

• Transfer case 7. Remove all traces of old gasket material from the mating surfaces. To install:

8. Install or connect the following: • New gasket using sealer to hold it in position • Transfer case. Torque the bolts to 33-35 ft. lbs. (45-47 Nm). • Support brace bolts. Torque the bolts to 35-37 ft. lbs. (47-50 Nm), if equipped • Shift rod to the case, if equipped • Vacuum lines and/or electrical con¬ nections, as necessary • Front and rear driveshafts by align¬ ing the matchmarks 9. Refill the transfer case. • Skid plate, if equipped • Negative battery cable

Halfshaft REMOVAL & INSTALLATION

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Unlock the steering column so the steering linkage is free to move. 3. Remove or disconnect the following: • Negative battery cable • Front wheels • Skid plate • 6 bolts and the flange • Snapring • Spindle washer

CAUTION The coil spring is under extreme pressure. Make sure the control arm

is firmly supported with a hydraulic jack before removing the lower ball joint nut. After the lower ball joint nut has been removed, lower the hydraulic jack slowly to relieve coil spring pressure. If this precaution is not observed, serious bodily injury

17. Remove the hydraulic jack from the lower control arm. 18. Install the spindle washer and snapring to the end of the halfshaft. pin. Apply sealer, GM part no. 1052366, 19. or equivalent, to the flange. Install the flange. Torque the flange bolts to 35 ft. lbs. (48 Nm). 20. If equipped, install the locking hub. 21. Install the front wheel. 22. Install the skid plate, if equipped. 23. Lower the vehicle.

CV-Joints

may result.

4. Support the lower control arm with a hydraulic jack. 5. Remove the cotter pin and nut attaching the ball joint to the lower control arm.

6. Remove the nuts and bolts connect¬ ing the strut to the steering knuckle. Sepa¬ rate the steering knuckle from the strut and lower control arm. 7. Slowly lower the hydraulic jack until coil spring pressure is relieved. 8. Remove the outer CV-joint from the steering knuckle. 9. If removing the right side halfshaft, place tool J 37780 or equivalent, between the front axle housing and the inner CVjoint. Gently tap the inner CV-joint away and out of the front axle housing. 10. If removing the left side halfshaft, scribe a reference mark on the left inner axle shaft flange and the inner CV-joint flange to ensure correct installation. Remove the three bolts and three nuts and separate the inner CV-joint from the left inner axle shaft. 11. Remove the halfshaft from the vehicle. To install:

12. If installing the right halfshaft, install the inner CV-joint into the axle housing, the snapring seats in the differ¬ suregear. makingside ential 13. If installing the left halfshaft, install the left inner axle shaft flange to the inner CV-joint flange, aligning the reference

OVERHAUL Outer CV-Joint

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. or disconnect the following: 2.• Remove Front wheel • Halfshaft and position it in a vise

• Large CV-joint boot clamp and dis¬ card it • Small CV-joint boot clamp and dis¬ card it • CV-joint boot and slide it back on the shaft • Outer race from the halfshaft, by race-to-halfshaft retaining ring, using Snapring the outer spreading Pliers J-8059 • Retaining ring from the halfshaft and discard it • CV-joint boot from the halfshaft and discard it, if damaged 3. Disassemble the chrome alloy balls from the CV-joint cage as follows: a. Position a brass drift against the CV-joint cage and tap it with a hammer to tilt the cage. b. Remove the 1st chrome alloy ball from the cage.

cage in the opposite direc¬ tion.c. Tilt the

OU i H.■Qf

ISUZU HOMBRE b. Align the cage windows with inner race lands. c. Insert the inner race into the cage by rotating the inner race downward. d. Insert the cage/inner race into the outer race. 8. Assemble the chrome alloy balls into the CV-joint cage, as follows: a. Position a brass drift against the CV-joint cage and tap it with a hammer to tilt the cage. b. Insert the 1st chrome alloy ball into the cage.

d. Remove the opposite chrome alloy ball. e. Repeat the procedure until all 6 balls are removed. 4. Disassemble the CV-joint cage and inner race as follows: a. Pivot the cage and race 90 degrees to the center line of the outer race. b. Align the cage windows with outer race lands. c. Remove the cage from the outer race. d. Rotate the inner race upward and remove it from the cage. 5. Thoroughly clean and inspect all parts.

0

tion.c. Tilt the cage in the opposite direc¬ d. Insert the opposite chrome alloy ball. e. Repeat the procedure until all 6 balls are inserted.

To install:

6. Lubricate the parts with a light coat . of grease. 7. Assemble the CV-joint cage and inner race, as follows:

9. lnstallV2kit grease into the CV-joint. • Small ring clamp on the CV boot • New retaining ring on the halfshaft

the cage cent erli ne.

• Large ring clamp on the CV boot • Outer race assembly onto the half¬ shaft until the ring engages the halfshaft groove 1 1 . Slide the small end of the CV-joint boot/clamp into place, with the seal lip in the halfshaft groove '•■Make sure the boot lies flat against the halfshaft.

12. Using the Crimp tool J-35910, a torque wrench and a breaker bar, crimp the small CV-joint boot clamp to 100 ft. lbs. (136 Nm). 13. Check the clamp gap dimension; if it is not 0.085 in. (2.15mm), continue tighten¬ ing the clamp until it is. 14. InstallVfckit grease into the CV-joint boot. 15. Measure approximately 0.687 in. (17.5mm) up from the bottom edge of the outer CV-joint assembly. 16. Slide the large end of the CV boot/clamp into place, with the seal lip in place over the outer race. f»Make sure the boot lies flat against the outer race.

Inst

all

or c

onn

ect

17. Using the Crimp tool J-35910, a torque wrench and a breaker bar, crimp the

the

fol

low

large CV-joint boot clamp to 130 ft. lbs. (176 Nm). 18. Check the clamp gap dimension; if it is not 0.102 in. (2.60mm), continue tighten¬ ing the clamp until it is. 19. Install the halfshaft and the front wheel.

ing

:

er r

Inner (Tri-Pot) Joint

ace

1. Before servicing the vehicle, refer to 90

deg

the precautions in the beginning of this sec¬ tion. 2.• Remove or disconnect the following: Front wheel

ree

s to

• Halfshaft and place it in a vise • Snapring from the stub shaft and discard it • Small CV-joint boot clamp, cut and discard it

(1) Differential Shaft Ring

(11) Halfshaft Swage

(2) Tripot Housing (3) Spacer Ring

(12) CV Joint Boot (13) Swage Ring

(4) Tripot Joint Spider Assembly (5) Spacer Ring

(14) Clamp Protector (15) Race Retaining Rinq

Assembly

• Large CV-joint boot clamp, cut and discard it • CV-joint boot by sliding it away from the tri-pot joint 3. Install a Stub Shaft Removal tool J38868-A to the stub shaft snapring

Ring

(6) Tripot Bushing (7) Boot Retaining Clamp (8) Tripot Joint Boot (9) Halfshaft Swage (10) Halfshaft Bar

Ring

(16) Ball (17) CV Joint Inner Race (18) CV Joint Cage (19) CV Joint Outer Race 9308JG09

Exploded view of the CV-Joint Assembly

4. Using a slide hammer groove. the stub shaft from the tri-pot 5. Remove or disconnect • Tri-pot housing from spider

puller, press housing. the following: the tri-pot

ISUZU HOMBRE

• Inboard spacer ring slide it rear¬ ward on the shaft using Snapring Pliers tool J-8059 • Outboard retaining ring using Snapringit Pliers tool J-8059 and discard • • • •

Tri-pot joint spider assembly Inboard spacer ring and discard it CV-jointboot Trilobal tri-pot bushing from the housing 6. Thoroughly clean and inspect all parts.

Axle Shaft, Bearing and Seal REMOVAL & INSTALLATION For the Axle Shaft, Bearing and Seal, Removal and Installation, please refer to Wheel Bearing procedure located in the sec¬ tion.

Pinion Seal REMOVAL & INSTALLATION

To install:

ing:

7. Install or connect the follow¬

• New snapring onto the stub shaft • Small boot clamp • CV-jointboot 8. Using the Crimp tool J-35910, a torque wrench and a breaker bar, crimp the small CV-joint boot clamp to 100 ft. lbs. (136 Nm). 9. Install or connect the following:

• Inboard spacer ring slide it rear¬ ward on the shaft using Snapring Pliers tool J-8059, past the 2nd groove • Tri-pot joint spider assembly onto the shaft until it passes the 2nd groove • Outboard retaining ring into the axle shaft groove using Snapring Pliers tool J-8059 • Tri-pot joint spider assembly, slide ■ it against the outboard retaining ring

• Inboard spacer ring, seat it in the groove • Vfckit grease into the boot ing grease into the tri-pot hous¬ • Vfekit

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. ^The following procedure requires the use of the Pinion Holding tool J-861410, the Pinion Flange Removal tool J8614-1, J-8614-2, J-8614-3 and the Pinion Seal Installation tool J-23911.

2. Remove or disconnect the following: • Driveshaft from the pinion flange. Matchmark the driveshaft prior to removal. • Driveshaft from the rear axle pinion flange and support the shaft up in body tunnel by wiring it to the exhaust pipe. i~lf the U-joint bearings are not retained by a retainer strap, use a piece of tape to hold bearings on their journals.

3. Mark the position of the pinion stem, flange and nut for reference. 4. Use an inch lbs. torque wrench to

11-37

measure the amount of torque necessary to turn the pinion, then note this measurement as it is the combined pinion bearing, seal, carrier bearing, axle bearing and seal pre¬ load. ing: 5. Remove or disconnect the follow¬ • Pinion flange nut and washer, using a Pinion Holding tool J-8614-10 and a Pinion Flange Removal tool J-8614-1, J-8614-2, J-8614-3, as • Pinion flange applicable • Pinion oil seal by driving it out of the differential with a blunt chisel; DO NOT damage the carrier To install:

6. Examine the seal surface of pinion flange for tool marks, nicks or damage, such as a groove worn by the seal. If dam¬ aged, replace flange. 7. Examine the carrier bore and remove any burrs that might cause leaks around the O.D. of the seal. 8. Apply GM seal lubricant 1050169 to the outside diameter of the pinion flange and sealing lip of new seal. 9. Install or connect the following: • New pinion oil seal using a seal installer tool • Pinion flange and tighten nut to the same position as marked earlier. Tighten the nut a little at a time and turn the pinion flange several times after each tightening in order to set the rollers. 10. Measure the torque necessary to turn the pinion and compare this to the reading taken during removal. Tighten the nut addi-

. Trilobal tip-pot bushing flush with the tri-pot housing face • New large seal clamp onto the CVjoint boot • Tri-pot housing, slide it over the tri-pot joint spider assembly • CV-joint boot/clamp, slide it into place, over the trilobal tri-pot bushing with the seal lip in the groove tM-Make sure the boot lies flat against the trilobal bushing.

10. Position the CV-joint boot so it mea¬ sures 4.9 in. (125mm). 11. Using the Crimp tool J-35566, latch the large CV-joint boot clamp. 12. Install the halfshaft and the front wheel.

88457G82

fixture tool Removing the pinion nut using a pinion holding

11I "OQQ O

ISUZU HOMBRE

tionally, as necessary to achieve the same preload as measured earlier.

PINION FLANGE

~\\ fluid was lost from the differential housing during this procedure, be sure to check and add additional fluid, as necessary.

11. Remove the support then align and secure the driveshaft assembly to the pinion flange. (■►The original matchmarks MUST be aligned to assure proper shaft balance and prevent vibration.

A puller and adapter should be used to withdraw the pinion from the housing

Use the appropriately sized installation tool to drive the new seal into position.

STEERING AND SUSPENSION Air Bag _

** CAUTION Some vehicles are equipped with an air bag system, also known as the Supplemental Inflatable Restraint (SIR) system. The system must be disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible per¬ sonal injury and unnecessary system repairs.

PRECAUTIONS Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible per¬ sonal injury. • Never carry the inflator module by the wires or connector on the underside of the module. • When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed away. • Place the inflator module on a bench or other surface with the bag and trim cover facing up. • With the inflator module on the bench, never place anything on or close to the module, that may be thrown in the event of an accidental deployment. DISARMING 1. Turn the steering wheel so that the vehicle’s ahead. wheels are pointing straight 2. Turn the ignition switch to LOCK,

remove the key, then disconnect the nega¬ tive battery cable. 3. Remove the AIR BAG fuse from the fuse block. 4. Remove the steering column filler panel or knee bolster. 5. Unplug the Connector Position Assurance (CPA) and yellow two way con¬ nector at the base of the steering column. 6. Remove the Connector Position Assurance (CPA) from the passenger yellow two way connector located behind the glove box. 7. Unplug the yellow two way connector located behind the glove box. 8. Connect the negative battery cable. '■►With the AIR BAG fuse removed, the battery cable connected and the igni¬ tion in the ON position, the AIR BAG warning lamp will be ON. This is nor¬ mal and does not indicate a system malfunction.

ARMING 1 . Disconnect the negative battery cable. 2. Attach the yellow two way connector located behind the glove box. 3. Install the Connector Position Assur¬ ance (CPA) to the passenger yellow two way connector located behind the glove box. 4. Turn the ignition switch to LOCK, then remove the key. 5. Attach the two way connector at the base of the steering column and the Con¬ nector Position Assurance (CPA). 6. Install the steering column filler panel or knee bolster. 7. Install the AIR BAG fuse to the fuse block. 8. Connect the negative battery cable. 9. From the passenger seat, turn the ignition switch to RUN and make sure that the AIR BAG warning lamp flashes seven times and then shuts off. If the warning

lamp does not shut off, make sure that the wiring is properly connected. If the light remains on, take the vehicle to a reputable repair facility for service.

Power Steering Gear REMOVAL & INSTALLATION Two Wheel Drive

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Position a fluid catch pan under the power steering gear.

:* WARNING Do NOT rotate the steering shaft after the steering column has been removed.

3. Lock the steering column through the access hole in the steering column lower trim cover using steering column anti-rota¬ tion pin J 42640. 4. Remove or disconnect the following: • Air cleaner assembly • Intermediate shaft from the steering

gear

Use J 42640 to lock the steering column

ISUZU HOMBRE

the precautions in the beginning of this sec¬ tion.

2

.

power steering gear.

WARNING

Position

a flu

id c tch after pan undshaft Do NOT rotate the asteering er the been has column steering the removed. _

• Feed and return fluid hoses from the steering gear. Immediately cap or plug all openings to prevent sys¬ tem contamination or excessive fluid loss. • Intermediate shaft lower coupling shield, if equipped • Lower intermediate shaft coupling bolt • Matchmark the lower intermediate shaft coupling and the steering shaft • Lower intermediate shaft coupling from the steering shaft • Pitman arm from the gear pitman shaft

• Power steering gear-to-frame bolts and washers, then carefully remove the steering gear from the vehicle

To install:

5. Install or connect the following: • Steering gear to the vehicle and tighten Nm) the bolts to 55 ft. lbs. (75 • Pitman arm • Intermediate shaft to the power steering, making sure the matchmarks line up. Tighten the bolt to 26 ft. lbs. (35 Nm). • Pressure and return hoses to the power steering gear. Tighten the pressure hose to 18 ft. lbs. (25 Nm) for 2.2L engines and 22 ft. lbs. (30 Nm) for 4.3L engines. Tighten the return hose to 18 ft. lbs. (25 Nm). • Shield over the intermediate shaft lower coupling, if equipped • Air cleaner assembly 6. Remove the steering column lock pin 7. Bleed the power steering system Four Wheel Drive

This procedure requires the use of the following special tools: J 2431 9-B Steering Linkage and Tie Rod Puller, J 42640 Steer¬ ing Column Anti-Rotation Pin, J 29193 Steering Linkage Installer (12mm), J 29194 Steering Linkage Installer (14mm).

3. Lock the steering column through the access hole in the steering column lower trim cover using steering column anti-rotation pin J 42640. 4. Remove or disconnect the following: • Air cleaner assembly • Intermediate shaft lower coupling shield, if equipped • Wiring harness clip from the power steering return hose at the power steering gear • Feed and return fluid hoses from the steering gear. Immediately cap prevent sys¬ all openingsortoexcessive or plug tem contamination fluid loss. • Lower intermediate shaft coupling bolt • Matchmark the lower intermediate shaft coupling and the steering shaft • Lower intermediate shaft coupling from the steering shaft 5. Raise the vehicle. • Steering linkage shield • Differential carrier shield mounting bolts • Differential carrier shield • Pitman arm ball stud cotter pin and nut at the relay rod • Pitman arm from relay rod using a suitable puller • Steering gear mounting bolts and the washers from the frame • Steering gear • Pitman arm To install:

6. Install or connect the following: • Pitman arm • Steering gear Nm) • Power steering gear to the frame washers and mounting bolts. Tighten the bolts to 55 ft. lbs. (75

• Relay rod to the pitman arm ball stud. Ensure the seal is on the stud 7. Seat the taper using a J 29193 J Nm). 29194 and tighten the tool to 48 ft. lbs. (62 8. Remove the special tool from the pit¬ man arm ball stud.

11-39

9. Install or connect the following: • New nut and cotter pin to the pit¬ man arm ball stud at the relay rod and tighten the pitman arm ball stud nut at the relay rod to 61 ft. lbs. (83 Nm) • Differential carrier shield • Differential carrier shield mounting bolts • Steering linkage shield 10. Lower the vehicle. • Intermediate shaft to the power sure the matchsteering,linemaking marks up. Tighten the bolt to 26 ft. lbs. (35 Nm). • Pressure and return hoses to the power steering gear. Tighten the pressure hose to 22 ft. lbs. (30 Nm) and the return hose to 18 ft. lbs. (25 Nm). • Wiring harness clip to the power steering return hose at the power steering gear • Shield over the intermediate shaft lower coupling, if equipped • Air cleaner assembly 11. Remove the steering column lock pin 12. Bleed the power steering system

Shock Absorbers REMOVAL & INSTALLATION Front

2WD MODELS

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. • Wheel 2. Remove or disconnect the following: • Mounting nut (••Hold the shock absorber stem with a wrench while backing the nut off.

• Retaining nut and grommet • Shock absorber-to-lower control arm bolts • Shock absorber

• Replace the parts, as necessary. To install:

3. Fully extend the shock absorber stem, then push it up through the lower control arm and spring so that the upper stem passes through the mounting hole in the bracket. upper control arm frame the following: 4. Install or connect • Retaining nut and grommet on the stem. Tighten the nut to 106 inch lbs. (12 Nm). • Shock absorber-to-lower control

,suzu dfl HOMBRE 1 1I -Hu &

• Shock absorber upper nut and bolt • Shock absorber

3

To install:

.

• Shock absorber to the bracket. Tighten the nuts/bolts to 54 ft. lbs. Inst•allWheel (73 Nm). or conn ect th e follo wing:

7. Install a safety chain around the spring and through the lower control arm. 8. Remove or disconnect the following: • Lower control arm pivot bolts, the rear first • Lower control arm and allow it to hang free • Spring assembly To install:

Rear

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. bly.2. Properly support the rear axle assem¬ 7924JG33

Front shock absorber mounting— 2WD

arm bolts and tighten to 22 ft. lbs. (30 Nm) • Wheel 4WD MODELS 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Wheel • Lower nut/bolt and collapse the shock absorber

3. Remove or disconnect the following: • Automatic level control air lines from the shock absorber, if equipped • Shock absorber-to-frame retainers at the top of the shock • Shock-to-axle retainers at the bot¬ tom of the shock • Shock absorber To install:

4. Install the shock in the vehicle and loosely install the upper mounting fasteners to retain it 5. Align the lower-end of the shock absorber with the axle mounting, then loosely install the retainers. 6. Tighten the upper shock retainers to 18 ft. lbs. (25 Nm). Tighten the lower shock retainers to 62 ft. lbs. (84 Nm) on pick-up and two door utility models and 74 ft. lbs. (100 Nm) on four door utility models. 7. If equipped, attach the automatic level control air lines to the shock absorber.

Coil Springs REMOVAL & INSTALLATION 7924JG34

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. •Remove Wheel or disconnect the following:

Front shock absorber mounting — 4WD vehicles

• Shock absorber lower bolts 3. Push the shock absorber through the control arm and into the spring. 4. With the vehicle supported so the control arms hang free, install tool J-23028, onto a support and into the lower control arm bushings. 5. Remove or disconnect the following: • Stabilizer bar from the control arm • Stabilizer from the lower control 7924JG35

Rear shock absorber mounting

arm 6. Raise and remove the tension on the lower control arm bolts.

'»When positioning the spring in the lower control arm, be sure the spring insulator is in the proper position before lifting the control arm in place.

9. Install or connect the following: • Spring assembly • Lower control arm • Lower control arm pivot bolts • Stabilizer to the lower control arm

Leaf Springs REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. '•The following procedure requires the use of two sets of jackstands.

2. Support the rear axle with jackstands, support the axle and the body separately in order to relieve the load on the rear spring. • Wheel 3. Remove or disconnect the following: • Shock absorber

• U-bolt nuts, washers, anchor plate and bolts • Spare tire, if equipped • Rear exhaust hangers and lower the rear exhaust, if necessary • Shackle-to-frame bolt, washers and nutsary Spring •• Fuel tank, if necessary • Front bracket nut, washers and bolt

• Shackle from the spring, if neces¬ To install:

4. Install or connect the following: • Shackle to the rearward spring eye using the bolt, washers and nut, but do not fully tighten at this time. • Spring assembly • Spring to the front bracket using the bolt, washers and nut, but do not fully tighten at this time. • Fuel tank, if removed • Shackle-to-frame bolt, washers and nut, but do not fully tighten at this

ISUZU HOMBRE

2 To install: time. If used, remove the spring . 3. Install or connect the following: support. • Torsion bar and support • U-bolts, anchor plate, washers and U-bolt nuts. Torque the nuts using • Upper link mount. Torque the nut to 48 ft. lbs. (68 Nm). sequence: 2 passes of a diagonal 4. Place a jack under the torsion bar to a. Step 1: Torque to 18 ft. lbs. (25 tension. release Nm). 3 5. Install or connect the following: b. Step 2: Torque to 73 ft. lbs. (100 • Lower link mount bushing and nut. Nm) in the sequence. Nm). the nut to 37 ft. lbs. (50 Torque 5. Position the axle to achieve an approximate gap of 6.46-6.94 in. • Torsion bar unloader tool. Tighten between the axle housing . (164-1 76mm) the tool against the adjusting arm tube and the metal surface of the rubber the same number turns recorded the from Measure frame bumper bracket. earlier and remove the tool. This housing between the U-bolts to the metal loads the torsion bars. part of the rubber bump stop on the • Transmission shield, if removed frame. 6. While supporting the axle in this Ball Joints position, tighten the front and rear spring mounting fasteners to 89 ft. lbs. (122 Nm). 7. Install or connect the following: REMOVAL & INSTALLATION • Rear exhaust in position and tighten the hangers 2WD Vehicles • Spare tire • Shock absorber UPPER

Torsion Bar Instead of the coil spring used on the front suspension of 2WD vehicles, the 4WD vehicles are equipped with a torsion bar.

pre

cau

tio

ns

REMOVAL & INSTALLATION

in the beg inn ing

of this sect ion .

11-41

(■••The following procedure requires the use of a ball joint separator tool such as J-23742 and J-9519-E ball joint remover and installer set.

vehicle safely by placing stands securely underRaitshe alnodwersu control arms. Because the pport vehicle’ weight is usedthetofrroenltieovfe tspring s h tension on the upper control arm, tehe stands between the spring must be positi seats and the loonweedr control arm ball joints for maximu leverage . m

:c CAUTION With components unbolted, the stand is holding the lower control arm in place against the coil spring. Make sure the stand is firmly positioned and cannot move, or personal injury could result.

• Tire and wheel assembly • Brake caliper and support it from the vehicle using a coat hanger or wire. Make sure the brake line is Rem not stretched or damaged and that ove or d isc onn ect the foll owin g:

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 1 Bef the ^The following procedure requires ore stool e r vic Juse of the Torsion Bar Unloader ing 36202. the veh icl : e,re following the t disconnec or 2. Remove fer to t • Transmission shield, if equipped he • Torsion bar unloader tool to relax the tension on the torsion bar adjusting arm screw; record the number of turns necessary to prop¬ erly install the tool. Remove the adjusting screw and the unloader tool. • Lower link mount nut from one side • Torsion bars by disengaging them w-Note the direction of the forward end and side of the torsion bar being removed

• Lower link nut from the opposite side • Lower link mount, upper link mount nut • Upper link mount • Torsion bar from the frame

85388020

U

ISUZ _A0 HOMBRE 7 11 I . the caliper's weight is not sup¬ ported by the line. • Cotter pin and retaining nut from the upper ball joint • Anti-lock brake sensor wire bracket, if equipped • Upper ball joint from the steering knuckle using tool J-23742 and pull the steering knuckle free of the ball joint ’‘-After separating the steering knuckle from the upper ball joint, be sure to support the steering knuckle/hub assembly to prevent damaging the brake hose.

from the uppe contr arm as follo r ws: ol (6mm) deep into each rivet.

b. Then use aV^in. (13mm) drill bit, to drill off the rivet heads. c. Using a pin punch and the ham¬ mer, drive out the rivets in order to free the upper ball joint from the upper con¬ trol arm assembly, then remove the upper ball joint. 5. Clean and inspect the steering knuckle hole. Replace the steering knuckle if the hole is out of round. To install:

6. Install or connect the following: • Ball joint in the upper control arm • Ball joint retaining nuts and bolts. Position the bolts threaded upward from under the control arm. Tighten the ball joint retainers to 17 ft. lbs. (23 Nm). • Anti-lock brake sensor wire bracket, if removed • Ball joint to the knuckle. Make sure the joint is seated, then install the stud nut and tighten to 61 ft. lbs. (83 Nm). Insert a new cotter pin. ^When

installing the cotter pin, never

loosen the castle nut to expose the cot¬ ter pin hole.

85388021

Drill a small guide hole into each ball joint rivet

the r ivete d up per bail joint n. ( 3mm) hole, abou tVii n.

• Thread the grease fitting into the ball joint. Use a grease gun to lubricate the upper ball joint until grease appears at the seal. • Brake caliper

• Tire and wheel assembly

ment, as necessary. Check and adjust the front end al LOWER ign¬ 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. f^The following procedure requires the use of a ball joint remover/installer set (the particular set may vary upon appli¬ cation but must include a clampingtype tool with the appropriately sized adapters) and a ball joint separator tool, such as J-23742.

• Tire and wheel assembly 2. Position a jack under the spring seat of the lower control arm, then raise the jack to support the arm.

The jack MUST remain under the lower control arm, during the removal and installation procedures, to retain the arm and spring posi¬ tions. Make sure the jack is securely positioned and will not slip or release during the procedure or per¬ sonal injury may result.

3. Remove or disconnect the following: • Brake caliper and support it aside using a hanger or wire. Make sure the brake line is not stressed or damaged. • Lower ball joint cotter pin and dis¬ card • Ball joint stud nut • Lower ball joint from the steering knuckle using tool J-23742 4. Carefully guide the lower control arm out of the opening in the splash shield using a putty knife. Position a block of wood between the frame and upper control arm to• keep the fitting knuckle out of the way. Grease

85388022

Then drill off the rivet heads

• Ball joint from the control arm using the ball joint remover set along with the appropriate adapters

To install:

5. Clean the tapered hole in the steering knuckle of any dirt or foreign matter, then check the hole to see if it is out of round, deformed or otherwise damaged. If a prob¬ lem is found, then knuckle must be

85388023

Punch the rivets out and remove the ball joint

85388024

Service ball joints are bolted to the control arm

replaced. 6. Install or connect the following: • Press the new ball joint (with grease fitting pointing inward) until it bottoms in the control arm using a suitable installation set. Make

ISUZU HOMBRE

11-43

4WD Vehicles

1 . Before servicing the vehicle, refer to tion. the precautions in the beginning of this sec¬ On 4WD vehicles both the upper and lower ball joints are removed in the same manner. Once the joint is separated from the steering knuckle the rivets are drilled and punched to free the joint from the control arm. Service joints are bolted into position with the retaining bolts threaded upward from beneath the control arm. In this man-, in an almost identi¬ the jointto isthereplaced ner, fashion upper joints on 2WD cal vehicles. ing: 2. Remove or disconnect the follow¬ • Tire and wheel assembly

• Wheel speed sensor wiring connec¬ tor from the upper control arm, if removing the upper ball joint • Cotter pin from the ball joint, then loosen the retaining nut 3. Position a suitable ball joint separator tool such as J-36607, then carefully loosen the joint in the steering knuckle. Remove the tool and the retaining nut, then separate the joint from the knuckle.

85388025

from the knuckle Use a ball joint separator to drive the lower joint

sure the grease seal is tacing inboard. . Ball joint stud into the steering knuckle • Ball joint retaining nut and tighten to 79 ft. lbs. (108 Nm)

7. Use a grease gun to lubricate the joint at the seal. until grease • Brakeappears caliper • Tire and wheel assembly

8. Check and adjust the front end align¬ ment, as necessary.

(■►When installing the cotter pin, never loosen the castle nut to expose the cot¬ ter pin hole.

^ After separating the steering knuckle from the upper ball joint, be sure to support the steering knuckle/hub assembly to prevent damaging the brake hose.

4. Remove the riveted ball joint from the control arm: a. Drill aVsin. (3mm) hole, aboutViin. rivet. each (13mm) intoaVsin. deep use (6mm) drill bit, b. Then heads. rivet the to drill off

c. Using a pin punch and the ham¬ mer, drive out the rivets in order to free the ball joint from the control arm assembly, then remove the ball joint.

• Grease fitting into the ball joint, if not already installed

To install:

5. Install or connect the following: • Ball joint in the control arm • Ball joint retaining nuts and bolts. Position the bolts threaded upward from under the control arm. Tighten the ball joint retainers to 17 ft. lbs. (23 Nm). • Ball joint to the knuckle. Make sure the joint is seated, tighten the lower nut to 79 ft. lbs. (108 Nm) and the upper nut to 61 ft. lbs. (83 Nm). Install a new cotter pin. *-When installing the cotter pin, never

Driving the lower joint from the control

Installing a new ball joint

loosen the castle nut to expose the cot¬ ter pin hole, but DO NOT tighten more than an additionaM/feturn.

ISUZU -A A HOMBRE 1 1I To install:

3 .

• Upper control arm

Install otighten (—Always r con nut on the thinner shim pack first.nect the followi ng: • Mounting nuts/bolts and shims. Torque the nuts to 81-85 ft. lbs. (110-115 Nm). • Steering knuckle to upper control arm ball joint • New cotter pin (-►Tighten the nut to align the hole never loosen. • Wheel speed sensor harness bracket retaining bolt and nut, if • equipped Wheel 4 Wheel Drive 1. Before servicing the vehicle, refer to

7924JG40

The replacement ball joint comes with nuts and bolts for installation

6. Use a grease gun to lubricate the upper ball joint. • Wheel speed sensor wiring connec¬ tor to the upper control arm, if the upper ball joint was removed • Tire and wheel assembly 7. Check and adjust the front end align¬ ment, as necessary.

Upper Control Arm REMOVAL & INSTALLATION 2 Wheel Drive 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Wheel • Wheel speed sensor harness bracket retaining bolt and nut, if equipped • Steering knuckle from upper con¬ trol arm ball joint • Mounting nuts/bolts and shims ’■"-Make sure to note the location of the control arm shims prior to removal so that they may be installed in their orig¬ inal positions. • Upper control arm

the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Tire and wheel assembly • Cotter pin from the ball joint, then loosen the retaining nut • Steering knuckle from the upper ball joint. Be sure to support the steering knuckle/hub assembly to prevent damaging the brake hose. (-►The 4WD vehicles do not use shims to adjust the front wheel alignment. Instead, the upper control arm bolts are equipped with cams, which are rotated to achieve caster and camber adjustments. In order to preserve adjustment and ease installation, matchmark the cams to the control arm before removal. If the control arm is being replaced, transfer the alignment marks to the new component before installation. • Front and rear nuts retaining the control arm retaining bolts to the frame • Outer cams from the bolts • Bolts and inner cams • Control arm from the vehicle • Retaining nut and the bumper from the control arm, if necessary 3. If the bushings are being replaced, use a suitable bushing service set to remove the bushings from the arm. To install: 4. Install or connect the following: • Bushing service set to drive the new bushings into the control arm, if removed

• Bumper and retaining nut to the control arm, if removed. Tighten the bumper retaining nut to 20 ft. lbs. (27 Nm). • Control arm, retaining bolts (from the inside of the frame brackets fac¬ ing outward) and the inner cams. The inner cams must be positioned on the bolts before they are inserted through the control arm and frame brackets. • Outer cams over the retaining bolts, then the nuts to the ends of the bolts at the front and rear of the control arm 5. Align the cams to the reference marks made earlier, then tighten the end nuts to 85 ft. lbs. (115 Nm). • Ball joint to the knuckle • Tire and wheel assembly 6. Check and adjust the front end align¬ ment, as necessary. CONTROL ARM BUSHING REPLACEMENT 2 Wheel Drive 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • vice Upper control arm and place it in a • Upper control arm shaft nuts and retainers • Upper control arm bushings using tool J 22269-1 , a slotted washer and a short piece if pipe that is slightly larger than the bushing • Upper control arm shaft To install: • Upper control arm shaft • Upper control arm bushings using tool J 22269-1, a slotted washer and a short piece if pipe that is slightly larger than the bushing 3. Tighten J 22269-1 until the bushing is positioned on the shaft and the control arm as shown in the accompanying illustra¬ tion. The measurement should be 0.48-0.52 inch (12.8-1 3.8mm) at both sides when the properly installed. • Nm). Upper control arm shaft nuts and retainers. Tighten to 85 ft. lbs. (115 • Upper control arm 4 Wheel Drive If the bushings require replacement, refer to the control arm removal and installation procedure for bushing replacement.

ISUZU

HOMBRE

Lower Control Arm REMOVAL & INSTALLATION 2 Wheel Drive

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Coil spring • Lower ball joint from the steering knuckle • Lower control arm from the vehicle To install:

3. Install or connect the following: • Lower control arm • Lower ball joint stud into the steer¬ ing knuckle • Ball joint-to-steering knuckle nut and tighten to specification • New cotter pin to the lower ball joint stud • Coil spring 4. Align the vehicle. 4 Wheel Drive

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec-

J— 36202, lower control arm bushing service kit J— 36618 (if the control arm bushing are being replaced) and ball joint C-clamp J— 9519— 23. Whether or not the control arm or bushing are being replaced, NEW control arm retaining nut should be used once the old ones have been loosened and removed.

2. Remove or disconnect the following: • Front wheels • 2 bolts from the front splash shield and pivot it in order to gain access to the tie rod • Stabilizer bar from the control arm (keeping all of the link hardware sorted for proper installation). If necessary, completely remove the bar from the vehicle for access. • Shock absorber • Inner tie rod from the relay rod using a tie rod separator • Outer halfshaft nut and washer • Bolts from the hub and bearing kit 3. Unload the torsion bar using the unloading tool J— 36202. First, mark the adjuster for installation. • Adjustment arm. Slide the bar for¬ ward and the adapter out of the rear to remove the adjusting arm. Lower ball joint cotter pin, nut and ball joint from the control arm using a ball joint separator

11-45

• Nuts and bolts and lower control arm with the torsion bar assembly. Note the direction which the control arm retaining bolts are facing for installation purposes. To install:

4. Install or connect the following: • Torsion bar to the lower control arm and place the assembly into the vehicle. Position the front leg of the lower control arm into the crossmember before installing the rear leg into the frame bracket. • Control arm bolts (facing in the direction as noted during removal or shown in the accompanying illustration) with NEW nuts. (■•The control arm retainers MUST be tightened with the vehicle suspension at normal ride height. This can either be accomplished by starting the nuts now, then installing the remaining components along with the wheels and lowering the vehicle, or by moving jackstands under the ends of the lower control arms and resting the vehicle on them. If the latter solution is tried, make sure front suspension is at actual ride height compression. If you are unsure, it is best to start the nuts now and tighten them to specification once the vehicle is lowered.

• Ball joint stud in the knuckle 5. With the suspension at the correct height, tighten the control arm retaining nuts to 98 ft. lbs. (133 Nm). (-►The lower ball joint retaining nut MUST be tightened with the vehicle suspension at normal ride height. This can either be accomplished by starting the nut now, then installing the remain¬ ing components along with the wheels and lowering the vehicle, or by moving jackstands under the ends of the lower control arms and resting the vehicle on them. If the latter solution is tried, make sure the FULL WEIGHT of the vehicle front end is on the suspension.

14. BUSHING 18. 44 62. 63. 64 66 67. 68

BALL JOINT, LOWER ARM KIT. LOWER NUT WASHER BOLT NUT BUMPER BRACE 88268GB1

i

Exploded view of the lower control arm assembly mounting

6. Install or connect the following: • Joint-to-control arm nut, then tighten the nut to 92 ft. lbs. (125 Nm) with the suspension at normal ride height and compression. • New cotter pin to the castellated nut. Tighten the nut (but no more than an additional Ve turn) in order to align the cotter pin. DO NOT loosen the nut from the specified torque. • Adjuster arm by sliding the adapter

lsuzu dfi HOMBRE 1I 1I -HrU

• • • • • • •

forward, over the torsion bar to install the sides of the nut. Load the torsion bar and install the adjuster bolt aligning the installation mark. Drive axle through the hub and bearing assembly Tighten the hub and bearing assembly retaining bolts Drive axle shaft nut and washer Inner tie rod end to the relay rod Shock absorber Stabilizer bar, if removed Stabilizer link(s) to the control arm(s)

• Splash shield • Front wheels 7. Recheck all fasteners for proper torque and installation before road testing. 8. Refill the differential if any fluid was lost. 9. Check and adjust the front end align¬ ment, as necessary. CONTROL ARM BUSHING REPLACEMENT 2 Wheel Drive

th pr tioen ecauti . o

ns

in the beg in

nin

g

of this sec¬

J 22269 -01 J 21474-4

9308JG12

Installing the lower control arm rear bush¬ ing — all 2 wheel drive

Installing the lower control arm front

2. Remove lower control arm and place it in vise.

bushing — 4 wheel drive

3. Install tools J 22269-01, 21474-8, 12 and 13 on the rear bushing and tighten until the bushing is removed. 4. Using a blunt chisel, drive the front bushing flare flush with the rubber part of the bushing. 5. Place a wedge or a spacer between the bushing housing to keep the housing from bending while removing or installing the bushing. 6. Install tools J 21474-3, 4, 5 and 6 on the front bushing and tighten until the bushing is removed. To install:

7. Install the front bushing into the control arm. 8. Install tools J 21474-4, 5 and 13. Tighten until the bushing is fully seated. 9. Install the rear bushing into the con¬ trol arm 10. Install tools J 22269-01, J 21474-2 and 13. Tighten until the bushing is fully seated. 11. Install the lower control arm.

J 21474 -4

J 21474-3

9308JG13

Installing the lower control arm rear bush¬ ing— 4 wheel drive

2. Remove lower control arm and place it in vise. 3. Using bushing service set J 21474, remove the front and rear bushings. To install:

4. Using bushing service set J 21474, install the front and rear bushings. 5. Install the lower control arm.

4 Wheel Drive

Wheel Bearings Removing the lower control arm rear

ion

t sec s thi of

ADJUSTMENT

.

i nn

gi be the in ng

ns tio cau pre

bushing— all 2 wheel drive

J 21474-5

2WD Models

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

refe

r to

1

2. If equipped, remove the wheel/hub cover for access, then remove the dust cap from the hub. 3. Remove the cotter pin and loosen the

e r,ef cle ehi

ev ntgh

ici

v ser ore Bef Installing the lower control arm front

he

t rto

bushing — all 2 wheel drive

Removing the lower control arm front bushing— 4 wheel drive

spindle nut. the wheel forward by hand and 4. Spin torque the nut to 12 ft. lbs. (16 Nm) in order to fully seat the bearings and remove any burrs from the threads.

isuzu -|-|-47 HOMBRE

5. Back off the nut until it is just loose, then finger-tighten the nut. 6. Loosen the nutV^Vaturn until either hole in the spindle lines up with a slot in the nut, then install a new cotter pin. This may appear to be too loose, but it is the proper adjustment. 7. Proper adjustment creates 0.001-0.005 in. (0.025-0.1 27mm) endplay. 4WD Models

The front wheel bearings on the 4-wheel drive vehicles are not adjustable. If the bearings become loose or make noise, they 0 must be replaced. REMOVAL & INSTALLATION Front 2WD

MODELS

servicing the vehicle, refer to 1 . Before. ns in the beginning of this sec¬ the tion.precautio 2. Remove or disconnect the following: • Wheel

• Brake caliper with the pads without disconnecting the brake line • Grease cap • Cotter pin, spindle nut and washer • Hub

WARNING Be careful not to drop the outer wheel bearing. As the hub is pulled forward, the outer wheel bearings will often fall forward and they may easily be removed at this time. _

• Outer roller bearing assembly • Inner seal by prying it out of the hub and discard it • Inner bearing assembly To install:

3. Clean all parts in solvent and allow to air dry, then check for excessive wear or damage. Inspect all of the parts for scoring, pitting or cracking and replace if necessary. (■►DO NOT remove the bearing races from the hub, unless they show signs of damage.

4. If it is necessary to remove the wheel bearing races, use the GM front bearing race removal tool J-29117 to drive the races from the hub/disc assembly. A hammer and brass drift may also be used to drive the races from the hub, but the race removal tool is quicker.

7924J642

Wheel bearings, races and related components— 2WD vehicles

5. If the bearing races were removed, position the replacement races in the freezer for a few minutes and then install them to the hub: a. Lightly lubricate the inside of the hub/disc assembly using wheel bearing

grease. b. Using the GM seal installation tools J-8092 and J-8850, drive the inner bearing race into the hub/disc assembly until it seats. Be sure the race is properly seated against the hub shoulder and is not cocked. (■►When installing the bearing races, be sure to support the hub/disc assem¬ bly with GM tool J-9746-02.

the seal flange faces the bear¬ making ing cup. sure ►^Although a seal installation tool is preferable, a section of pipe with a smooth edge or a suitably sized socket may be used to drive the seal into posi¬ tion. Be sure the seal is flush with the outer surface of the hub assembly.

8. Install or connect the following: • Wheel hub over the spindle • Outer bearing into the hub by hand •• Spindle washer and nut Brake caliper • Wheel

9. Properly adjust the wheel bearings •• New Dust cotter cap pin

c. Using the GM seal installation tools J-8092 and J-8457, drive the outer • Wheel cover race into the hub/disc assembly until it seats. Ins 4WD MODELS 6. Using a high melting point wheel tallor c 1 . Before servicing the vehicle, refer to bearing grease, lubricate the bearings, races onne c of gob a place to t sure and spindle; be hethe fol precautions in the beginning of this sec¬ tion. grease (inside the hub/disc assembly) low ing Install Torsion Bar Unloading tool J 2. sup¬ ample an provide between the races to : 36202 on the torsion bar adjusting bolt and t. ply of lubrican remove the bolt. To aid during installation, i~To lubricate each bearing, place a count the number of turns required to gob of grease in the palm of the hand, remove the bolt. then scoop the bearing through the 3. Remove the wheel. grease until it is well lubricated. 4. Install an axle shaft boot seal protec¬ 7. Place the inner bearing in the hub, tor to the Tri-pot axle joint. 5. Remove or disconnect the following: then apply a thin coating of grease to the • Cotter pin and retainer sealing lip and install a new inner seal,

U a |SUZ -i iI -ii H-O HOMBRE The axle shaft and seal may be removed and replaced without disturbing the bearing or seal but it is highly recommended to replace the seals when removing the axle shaft. 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. ing: 2. Remove or disconnect the follow¬

6

• Rear wheels • Brake drums 3. Using a wire brush, clean the dirt/rust from around the rear axle cover. 4. Drain the fluid. ing: 5. Remove or disconnect the follow¬

.

• Rear pinion shaft lockbolt and the pinion shaft • C-lock from the button end of the axle inwardshaft by pushing the axle shaft • Axle shaft from the axle housing ^Be careful not to damage the oil seal.

Use Torsion Bar Unloading tool J 36202 to remove the adjusting bolt and unload the torsion bar

• Castle nut and the thrust washer • Brake caliper and support it aside using wire or a coat hanger

6. Clean and inspect the parts for nicks, scores and/or damage, then replace them as necessary. To install:

da or

hed etc str

.

d ge ma

• Brake disc from the wheel hub • Halfshaft from the hub/bearing assembly, using a Spindle Remover tool J-28733-A to prevent damage to the shaft or hub/bearing assembly • Hub/bearing assembly from the knuckle

the backing plate, immediately adja¬ cent to the shaft.

ing

:

. ary

ess

,

ght

nec as

• Oil seal by prying the it from the 7. Install or connect the following: end of the rear axle housing • Hub and bearing assembly by WARNING aligning the threaded holes. TorqueRem o ve the bolts to 77 ft. lbs. (105 Nm). or DO NOT damage the housing oil seal dis • Tie rod end to the steering knuckle con surface. using the retaining nut nec • New cotter pin t he fol • Wheel • Brake assembly low bearing using the GM Slide ¬ tool J-2619, the GM Hammer • Halfshaft nut. Tighten the nut to Adapter tool J-2619-4 and the GM 180 ft. lbs. (245 Nm). Axle Bearing Puller tool J-22813• Retainer and a new cotter pin but DO NOT back off specification in To install: order to insert the cotter pin. 01 and inspect the components for 7. Clean 8. Remove the torsion bar unloader tool excessive wear or damage and replace and the drive axle boot protector. them, if necessary. 9. Install the wheel. 8. Install or connect the following: • New or reused bearing, coated with gear lubricant, using the Axle Shaft Bearing Installer tool Rear J-34974 to drive the bearing in until it bottoms against the A new pinion shaft lockbolt should be installed whenever either of the axle shafts seat is removed. hei

Hub and bearing assembly — 4WD vehicles

If equipped with an Anti-Lock Brake System (ABS), be careful not to dam¬ age the reflector ring on the axle shaft or the speed sensor bolted to

ISUZU 11-49 HOMBRE

■ ■

WARNING

AXLE SHAFT

m

Be sure the bearing installer does not contact and damage the speed sen¬ sor onABSequippedvehicles. _

• New seal lubricated with gear oil

BEARING

using the GM Axle Shaft Seal Installer tool J-33782 to seat it in the housing until it is flush with the axle tube ^Be sure the seal installer does not contact and damage the speed sensor on ABS equipped vehicles.

• Axle shaft into the housing by engaging the splines • C-lock retainer on the axle shaft button end

WARNING BE CAREFUL not to damage the wheel bearing seal. _

AXLE HOUSING BRAKE BACKING PLATE 7924JG55

Cross-sectional view of the rear axle, bearing and seal assembly

• Axle shaft by pulling it outward to seat the C-lock retainer in the counterbore of the side gears • Pinion shaft through the case and • • ••

the bolt pinions. to 27 ft. Tighten lbs. (36 the Nm).new lockNew rear axle cover gasket Housing cover Brake Wheelsdrums

9. Refill the housing.

“C“ lock Lock bolt 7924JG56

Pinion shaft lockbolt and axle C-lock locations, inside the differential

11-50

ISUZU

6

BRAKES

.

Brake Caliper REMOVAL & INSTALLATION

• Wheel

• Caliper from the rotor • Disc brake pads from the caliper . Disc brake pad retaining clips from inside the caliper To install:

Front

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove % of the brake fluid from the master cylinder reservoir. 3. Remove or disconnect the following: • Wheel . Caliper fluid line and plug to avoid contamination • Bolts retaining the caliper to the rotor

4. Clean and lubricate the sleeves and bushings with silicon grease. 5. Install or connect the following: • Pads in the caliper • Caliper in position over the rotor and tighten the mounting bolts to 38 ft. lbs. (51 Nm) for single piston calipers; 85 ft. lbs. (115 Nm) for dual piston calipers . Fluid lines to the caliper and tighten to 33 ft. lbs. (45 Nm)

rect level. Bleed the brake system if the fluid lines Rewfeirlle tdheismcaosntneerct from the caliper. ecdylinder to the co r¬ Rear

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. ing: 2. Remove or disconnect the follow¬ • Rear wheels • Brake hose and cap line Caliper from caliper • Retainers • Brake pads, if necessary

CALIPER BORE VALVE. REAR BRAKE CALIPER BLEEDER CAP. REAR BRAKE CALIPER BLEEDER VALVE BOLT/SCREW. REAR BRAKE CALIPER GUIDE PIN UPPER HOUSING. REAR BRAKE CALIPER PIN. REAR BRAKE CALIPER GUIDE BOOT. REAR BRAKE CALIPER GUIDE PIN 18 BRACKET. REAR BRAKE CALIPER ANCHOR 19 SEAL. REAR BRAKE CALIPER PISTON PISTON, REAR BRAKE CALIPER N 20 BOOT. REAR BRAKE CALIPER PISTO 29 PAD. REAR DISC BRAKE INNER BRAKE OUTER 30 52 PAD. REAR DISC BOLT/SCREW. REAR BRAKE CALIPER GUIDE PIN LOWER

INSULATOR, REAR DISC BRAKE OUTER PAD 93026G44

Rear brake caliper

UZU 11

■ ■

HOMBRE ing: disconnect the follow¬ or 2. •Remove Wheel

To install:

3. Install or connect the following: • Brake pads, if removed • Caliper and retainers, and tighten to 23 ft. lbs. or (31 Nm) • Brake hose, and tighten to 20 ft. lbs. (27 Nm) 4. Bleed brake system and install the wheels. 5. Refill the master cylinder and pump

• Brake drum. If the drum will not pull of the axle, use a rubber mallet and tap it around the edge. To install:

3. Install or connect the following: Drum on the axle • Wheel 4. Refill the master cylinder and pump

pedal to attain full brake pedal before Roadtesting the vehicle.

Disc Brake Pads

pedal to attain full brake pedal before roadtesting the vehicle. Exploded view of the disc brake assembly

mounting bolts. Bend the tabs, on the outboard brake pad, over the • caliper. Wheels

REMOVAL & INSTALLATION . Front

1 . Before servicing the vehicle, refer to ful bra peda befo Road to at pe the precautions in the beginning of this sec¬ re l tesdtal the tavienhi l ke tion. c i l n e g . 2. Remove % of the brake fluid from the Rear master cylinder. 3. Place a C-clamp around the outer pad 1 . Before servicing the vehicle, refer to and caliper; tighten the C-clamp until the the precautions in the beginning of this sec¬ tion. piston is fully compressed in the caliper.Re 4. Remove or disconnect the following:fill th 2. Remove % of the brake fluid from the e • Top caliper retainer, and rotate , mastmaster cylinder. er c yli Remove or disconnect the following: caliper away from rotor 3. n•de Wheel r an • Inboard pad and retaining spring dp up from the caliper 4. Place a mC-clamp around the outer pad • Outboard pad from the caliper and caliper; tighten the C-clamp until the • Sleeves and bushings piston is fully compressed in the caliper. To install: • Top caliper retainer, and rotate 5. Clean and lubricate the sleeves and caliper away from rotor • Inboard pad and retaining spring bushing with silicone lubricant and install them in the caliper. from the caliper 6. Install or connect the following: • Outboard pad from the caliper To install: • Retaining spring onto the inboard pad and the pad in the caliper 5. Clean and lubricate the sleeves and • Outboard pad into the caliper bushing with silicone lubricant and install them in the caliper. • Caliper in position and tighten the 6. Install or connect the following: • Retaining spring onto the inboard pad and the pad in the caliper • Outboard pad into the caliper • Caliper in position and tighten the mounting bolts • Wheels 7. Refill the master cylinder and pump pedal to attain full brake pedal before Roadtesting the vehicle.

Brake Drums

REMOVAL & INSTALLATION

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. ing: or disconnect the follow¬ 2. •Remove Wheel • Brake drum. If the drum will not pull of the axle, use a rubber mallet and tap it around the edge. • Return springs from the brake shoes • Shoe guide • • • •

Hold-down springs and pins Actuator lever and pivot Lever return spring Actuator link

• Parking brake strut and spring • Parking brake lever • assembly Brake shoes and the adjuster To install:

3. Lubricate the contact points on the backing plate and the adjuster with lithium 4. Install or connect the following: grease.• Parking brake lever, adjusting screw and spring assembly • Shoe assembly onto the backing

Parking brake lever, strut and strut • spring • Actuator lever and lever pivot plate link • Actuator

• • • •

spring, the hold-down pins Leversprings and Shoe guide Return springs Brake drum

5. Adjust the brakes as follows: a. Remove the knockout area in the backingy.plate, behind the adjuster assembl

REMOVAL & INSTALLATION 93026G47

n.

tio sec s thi of

i inn beg the in

aut

c pre

Compressing the caliper piston with a Cclamp

Brake Shoes

ISUZU f HOMBRE .

11-52

b. Ensure the parking brake system is adjusted properly with no tension on the cables or parking brake lever. The tops of the shoes should be firmly seated against the upper spring retaining anchor, if not as specified, loosen the parking brake cables. c. Install the drum and turn the brake

8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

adjuster until the wheels can just be turned by hand. d. Then, back the adjuster off 24 notches. No brake drag should be felt after 12 notches. e. Install an adjusting hole plug in the to prevent dirt and mois¬ backing ture from plate entering.

ACTUATOR UNK RETURN SPRING RETURN SPRING HOLD DOWN SPRING LEVER PIVOT LEVER RETURN SPRING STRUT SPRING ADJUSTING SCREW ASSEMBLY ADJUSTING SCREW SPRING PRIMARY SHOE

Exploded view of the drum brake components

necessary. Readjust the parkin 6. Install the wheels. g brake cable as 7. Refill the master cylinder and pump pedal to attain full brake pedal before Road-testing the vehicle.

ISUZU AND HONDA Amigo • Axiom • Rodeo • Rodeo Sport • Trooper • Vehicross • Passport BRAKES . DRIVE TRAIN . ENGINE REPAIR . FUEL SYSTEM . PRECAUTIONS . SPECIFICATION CHARTS . STEERING AND

12-70 12-56 12-13 12-55 12-13 12-2

SUSPENSION . A

12-65

Air Bag . Disarming . Precautions . Alternator . Installation . Removal . B

12-65 12-65 12-65 12-13 12-14 12-13

Brake Caliper . Removal & Installation . Brake Drums . . Removal & Install C ation

12-70 12-70 12-73 12-73

Camshaft and Valve Lifters . Removal & Installation . Clutch . Adjustments . Removal & Installation .

12-42 12-42 12-61 12-61 12-61 12-66 12-66 12-64 12-64 12-36 12-36

Coil Spring . Removal & Installation . CV-Joints . Overhaul . Cylinder Head . Removal & Installation .

D

Disc Brake Pads . Removal & Installation . Distributor . Removal . E

12-72 12-72 12-13 12-13

Engine Assembly . Removal & Installation . Exhaust Manifold . Removal & Installation .

12-14 12-14 12-40 12-40

Front Crankshaft Seal . Removal & Installation .

12-41 12-41

F

Fuel Filter . Removal & Installation . Fuel Injector . Removal & Installation . Fuel Pump . Removal & Installation . Fuel System Pressure . Relieving . Fuel System Service

12-55 12-55 12-56 12-56 12-55 12-55 12-55 12-55

Precautions . H

12-55

Halfshaft . Removal & Installation . Heater Core . Removal & Installation . Hydraulic Clutch System . Bleeding .

12-62 12-62 12-17 12-17

Ignition Timing . Adjustment . Intake Manifold . Removal & Install Lation .

12-14 12-14 12-39 12-39

Lower Ball Joint . Removal & Installation . Lower Control Arm . Control Arm Bushing

12-67 12-67 12-69

Replacement . Removal & Install 0 ation .

12-69 12-69

Oil Pan . Removal & Installation . Oil Pump . P ation . Removal & Install

12-48 12-48 12-50 12-50

Pinion Seal . Removal & Installation . Piston and Ring . R Positioning .

12-64 12-64 12-54 12-54

12-61 12-61

Rack and Pinion Steering

Gear . Removal & Installation .

12-65 12-65

Rear Axle Shaft, Bearing

and Seal . Removal & Installation . Rear Brake Shoes . Removal & Installation . Rear Main Seal . Installation . Removal & Ball Recirculating

12-64 12-64 12-73 12-73 12-51 12-51

Steering Gear . Removal & Installation . Rocker Arms/Shafts . S tion . Removal & Installa

12-65 12-65 12-39 12-39

Shock Absorber . Removal & Installation . Starter Motor . T tion . Removal & Installa

12-65 12-65 12-48 12-48

Timing Belt and Cover . Removal & Installation . Torsion Bar . Removal & Installation . Transfer Case Assembly . Removal & Installation . Transmission Assembly . U ation . Removal & Install

12-51 12-51 12-66 12-66 12-61 12-61 12-56 12-56

Upper Ball Joint . Removal & Installation .

12-67 12-67

. ol Arm ContrArm Upper Control Bushing

12-68

.. Replacement . V . ation Install & l Remova

12-68 12-68

Valve Lash . W Adjustment .

12-47

Water Pump . Removal & Installation . Wheel Bearings . Adjustment . Removal & Installation .

12-16 12-16 12-70 12-70 12-70

12-47

ISUZU

a o o lt“L

AND

HONDA

AMIGO • AXIOM • RODEO

• RODEO

SPORT * TROOPER

SPECIFICATION ENGINE

AND

VEHICLE

* VEHICROSS

CHARTS IDENTIFICATION Model Year

Engine Code D W X

Liters (cc) 2.2(2198) 3.2(3165) 3.5 (3494)

Cu. In. 134 193 213

Cyl. 4 6 6

* PASSPORT

Fuel Sys. Engine Type MFI DOHC MFI DOHC MFI DOHC

NA: Not available MFI: Multi-port Fuel Injection DOHC: Double Overhead Camshaft

Eng. Mfg. Isuzu Isuzu Isuzu

Year 2000

Code © Y 1 2 3 4

2001 2002 2003 2004

©10th position of VI N 42356-ISUZ-C01

GENERAL

ENGINE

SPECIFICATIONS

Net Net Engine Engine Displacement Series Fuel Horsepower Torque @ rpm Year Model Liters (cc) VIN) System @ rpm (ft. lbs.) MFI D Amigo 2000 2.2 (2198) 144@4000 130@5200 W 3.2 (3165) 214@3000 205@5400 MFI D Rodeo 2.2 (2198) 144@4000 130@5200 MFI MFI W 3.2 (3165) 214@3000 205@5400 MFI W 3.2 (3165) Passport 214@3000 205@5400 X 3.5 (3494) Trooper 215@5400 230@3000 MFI X VehiCROSS 3.5 (3494) 230@3000 215@5400 MFI MFI D Rodeo 2001 2.2 (2198) 144@4000 130@5200 MFI W 3.2 (3165) 205@5400 214@3000 D 2.2 (2198) 144@4000 Rodeo Sport 130@5200 MFI W 3.2 (3165) 214@3000 205@5400 MFI W 3.2 (3165) 214@3000 Passport 205@5400 MFI MFI X 3.5 (3494) Trooper 230@3000 215@5400 MFI X VehiCROSS 3.5 (3494) 230@3000 215@5400 MFI D Rodeo 2002 2.2 (2198) 144@4000 130@5200 W 3.2 (3165) 214@3000 205@5400 MFI MFI D 2.2 (2198) 144@4000 Rodeo Sport 130@5200 W 214@3000 3.2 (3165) 205@5400 MFI W Passport 3.2 (3165) 214@3000 MFI 205@5400 X Axiom 3.5 (3494) 230@3000 230@5400 MFI MFI X 3.5 (3494) Trooper 215@5400 230@3000

Oil ComBore x Stroke pression Pressure (in.) Ratio @ rpm 3.39x3.72 22@800 9.6:1 60-80@3000 3.68x3.03 9.1:1 3.39x3.72 9.6:1 22@800 60-80@3000 3.68x3.03 9.1:1 9.1:1 57-80@3000 3.68x3.03 60-80@3000 3.68x3.35 9.1:1 60-80@3000 3.68x3.35 9.1:1 10.0:1 22@800 3.39x3.72 60-80@3000 9.1:1 3.68x3.03 3.39x3.72 3.68x3.03 3.68x3.03 3.68x3.35 3.68x3.35 3.39x3.72 3.68x3.03 3.39x3.72 3.68x3.03 3.68x3.03 3.68x3.35 3.68x3.35

10.0:1 9.1:1 9.1:1 9.1:1 9.1:1 10.0:1 9.1:1 10.0:1 9.1:1 9.1:1 9.1:1 9.1:1

22@800 60-80@3000 57-80@3000 60-80@3000 60-80@3000 22@800 60-80@3000 22@800 60-80@3000 57-80@3000 60-80@3000 60-80@3000

MFI: Multiport fuel injection 42356-ISUZ-C02

ISUZU AND HONDA AMIGO * AXIOM * RODEO

_

• RODEO

ENGINE TUNE-UP

SPORT * TROOPER

* VEHICROSS

• PASSPORT

-I 0.0 u

1

SPECIFICATIONS _

Ignition Idle Valve d Spee Fuel Timing Spark Plug Engine Clearance (rpm) _ Pump _ (deg.) Gap Displacement Engine AT MT (psi) AT MT (in.) VIN Liters (cc) Year HYD 800 800 D 41-55 © © 2000 0.040 2.2 (2198) HYD 750 750 W © © 0.040 48-55 3.2 (3165) 0.013 0.014 750 750 48-55 X © © 0.040 3.5 (3494) 0.0090.0100.014 0.013 HYD 800 D © © 0.040 2001 41-55 2.2 (2198) 0.009HYD 800 0.010750 750 W 0.040 © © 3.2 (3165) 48-55 0.013 750 0.014 750 X 0.040 © © 48-55 3.5 (3494) 0.0090.0100.013 0.014 HYD 800 0.040 41-55 D © © 2002 2.2 (2198) HYD 800 900 0. 750 750 W 48-55 0.010© © 0.040 3.2 (3165) 750 0.013 0.014 48-55 X © © 0.040 3.5 (3494) 750 0.0100.0090.013 0.014 chart. this in those from differ 9they if used be 00 must 0. NOTE: The Vehicle Emission Control Information label figures 0.010B Before top dead center HYD: Hydraulic © Controlled by the PCM 42356-ISUZ-C03

Front of the Vehicle

79243G50

3.2L DOHC and 3.5L engines 1-2-3-4-5-6 Firing order: less ignition system (one coil on each cylinder) Distributor

12-4

ISUZU AND HONDA AMIGO • AXIOM • RODEO

• RODEO

SPORT • TROOPER

• VEHICROSS

• PASSPORT

79244G39

Accessory serpentine belt routing — 3.2L engines

rJ

\Jlr— *n

J 9359NG99

Accessory serpentine belt routing— 3. 5L engines

AMIGO • AXIOM • RODEO

SPORT • TROOPER

• RODEO

ISUZU AND HONDA

• PASSPORT

• VEHICROSS

CAPACITIES Oil with

Engine Displacement Tear 2000

IVIUUCI Amigo Rodeo Passport Trooper VehiCROSS

2001

Rodeo Sport Rodeo Passport Trooper VehiCROSS

2002

Rodeo Sport Rodeo Passport Axiom Trooper

NOTE:

2.2 3.2 2.2 3.2 3.2

(2198) (3165) (2198) (3165) (3165)

3.5 (3494) 3.5 (3494) 2.2 (2198) 3.2 (3165) 2.2 (2198) 3.2 (3165) 3.2 (3165) 3.5 (3494) 3.5 (3494) 2.2 (2198) 3.2(3165) 2.2 (2198) 3.2 (3165) 3.2 (3165) 3.5 (3494) 3.5 (3494)

Engine D W D W W X X D W D W W X X D W D W W X X

(pts.) _

4.8 5.0 4.8

4.5

5.0 5.0 5.0 4.8 5.0

6.2 6.2

5.0 4.8 5.0 5.0 5.0 5.0 4.8 5.0 4.8 5.0 5.0 5.0 5.0

—

— 6.2 4.5

5.8 — 6.2 6.2 4.5 6.2 6.2 5.8 — 6.2 6.2 6.2 6.2 6.2 —

5.8

l L.

Cooling

Engine Transmission

Filter _

-|9 E

18.2 18.2 18.2 18.2 18.2 — 18.2 — 18.2 18.2

Transfer Case 3.0 3.0 3.0 3.0 3.0 3.0© 3.0© 3.0 3.0 3.0 3.0 3.0

18.2 18.2 —

3.0© 4.0 3.0

18.2 —

3.0 3.0

18.2 18.2

3.0 3.0 2.8

18.2 18.2

Drive Axle

3.0©

All capacities are approximate. Add fluid gradually and check to ensure a proper level has been reached.

Front 3.0 3.0 2.2 2.6 2.6 3.0 3.0 2.2 2.6 2.2 2.6 2.6 3.0 3.0 2.2 2.6 2.2 2.6 2.6 2.66

Fuel Rear

3.7 3.7 3.7 3.7 3.74 6.4 6.4 3.7 3.7 3.7 3.7 4.6 3.74 6.4 3.7 3.7 3.7 3.7 3.74 3.64

Tank 17.7 17.7 21.1 21.1 21.1 22.5 22.5 17.7 17.7 20.0 19.5 22.5 22.5 17.7 17.7 19.5 19.5 19.5 19.5 22.5

3.0

System 7.3 7.3 11.2 11.6 11.6 © © 7.3 11.2 7.3 11.6 11.6 © 7.3 7.4 11.2 7.3 11.6 11.6 11.7 ©

6.4

©4.0 pts. if equipped with Torque On Demand ©A/T:

7.4 qts.

M/T: 7.0 qts. 42356-ISUZ-C04

ISUZU AND HONDA

12-6

AMIGO • AXIOM • RODEO

CRANKSHAFT

Year 2000

2001

Engine Displacement Engine Liters (cc) V1N D 2.2 (2198) 3.2 (3165)

W

3.5 (3494)

X

2.2 (2198)

D

3.2 (3165)

2002

W

3.5 (3494)

X

2.2 (2198)

D W

3.2 (3165)

X

3.5 (3494)

• RODEO

AND CONNECTING

Year 2000

2.2 (2198)

Engine VI N D

Seat Angle (deg.) NA

3.2 (3165)

W

45

3.5 (3494) 2001

2.2 (2198) 3.2 (3165)

2002

X D W

3.5 (3494)

X

2.2 (2198)

D

3.2 (3165)

W

3.5 (3494)

X

45 NA 45 45

NA 45 45

Face Angle (deg.) NA 45 45

NA 45 45

NA 45 45

* PASSPORT

ROD SPECIFICATIONS

All measurements are given in inches. _ Crankshaft _ Shaft Main Brg. Thrust Main Brg. Oil End-play on No. Journal Dia. Clearance 2 2.25900.0008 2.2610 0.0016 0.00070.00043 2.51650.0094 2.5170 0.00070.00240.0017 3 2.51650.0094 0.00072.5170 0.0017 0.00242 2.25900.0008 2.2610 0.00070.00040.0016 3 2.51650.0094 2.5170 0.00070.0017 0.00243 2.51652.5170 0.0094 0.0017 0.002400070. 2 2.25900.0008 2.2610 0.00070.0016 0.00043 2.51650.00072.5170 0.0017 0.0094 0.00243 2.51652.5170 0.0017 0.0094 0.00070.0024-

VALVE Engine Displacement Liters (cc)

• VEHICROSS

SPORT • TROOPER

Journal Diameter

Connecting Rod Oil Side Clearance Clearance

1.9100 1 .9090-

0.0012 0.0002-

2.1235 2.1229-

0.0023 0.0010-

2.1235 2.1229-

0.0023 0.0010-

1.9100 1 .9090-

0.0012 0.0002-

2.1235 2.1229-

0.0023 0.0010-

2.1235 2.1229-

0.0023 0.0010-

1.9100 1 .9090-

0.0012 0.0002-

2.1235 2.1229-

0.0023 0.00100.0023 0.0010-

2.1235 2.1229-

SPECIFICATIONS Spring

Spring Test Pressure (lbs. @ in.) NA 41-44@

Installed Height (in.) NA 1.38

411.38 -44@ 1.38 1.38 NA 41-44@ 411.38 -44@

1.38 NA 41-44@

NA 1.38 1.38 NA 1.38

411.38 -44@

1.38 1.38

Stem-to-Guide Clearance

0.0150 0.00500.0150 0.00500.0150 0.00500.0150 0.00500.0150 0.00500.0150 0.00500.0150 0.00500.0150 0.00500.0150 0.005042356-ISUZ-C05

Stem Diameter (in.)

(in.) Intake NA

Exhaust NA

0.0025 0.0012-

0.2353 0.2346-

0.0009 0.0002-

0.0025 0.0012-

0.2353 0.2346NA

0.2350 0.23430.2350 0.2343NA

0.0022 0.0012-

0.0026 0.0016-

0.0009 0.0002-

0.0025 0.0012-

0.2353

0.2350

0.23460.2353 0.2346NA

0.23430.2350

Intake

Exhaust

0.0022 0.0012-

0.0026 0.0016-

0.0009 0.0002-

0.0009 0.0002-

0.0025 0.0012-

0.0022 0.0012-

0.0026 0.0016-

0.0009 0.0002-

0.0025 0.0012-

0.0009 0.0002-

0.0025 0.0012-

0.2343NA

0.2353 0.23460.2353 0.2346-

0.2350 0.23430.2350 0.2343-

NA- Not Available 42356-ISUZ-C06

ISUZU AND HONDA AMIGO * AXIOM • RODEO

• RODEO

SPORT * TROOPER

RT * VEHICROSS Top* PASSPO

1 9_7 1

1

PISTON AND RING SPECIFICATIONS All measurements are given in inches. Ring Side Clearance Ring Gap_ Engine Oil Bottom Oil Piston Top Bottom Displacement Engine Control Control Clearance Compression Compression Liters (cc) VIN Compression! Oompressior NA D 2.2 (2198) NA 0.01180.0195 0.055 0.0546 0.0195 0.0546 01180. 0.00080.0008NA 601 NA 0. W 0.0060 3.2 (3165) 0.0015 0.0236 0.01180.0157 0.002 0.01770.018 0.00060.0006X 3.5 (3494) NA 0.0015 0.018 0118NA 0. 0.0236 0.0157 0.0015 01770. 0.00060.006NA 0.0006NA D 2.2 (2198) 0.0195 0.01180.0195 0.055 0.0546 0.0546 01180. NA 0.00080.0008NA 0.0060 W 0.0163.2 (3165) 0.01180.0157 0.002 0.0236 0.0015 0.018 01770. 0.0006NA 0.0006NA X 3.5 (3494) 0.0015 0.01180.0236 0.0015 0.018 0.0157 01770. 0.00060.00066NA D 00 0. 2.2 (2198) 0.055 0.01180.0195 0.0195 NA 0.0546 0.0546 0.01180.0008NA 0.0008601 0. W 0.0060 3.2 (3165) NA 0.0157 0.018 0.002 01180.0015 0. 0.0236 01770. 0.00060.0006NA X 3.5 (3494) 0.0015 NA 0.0236 0.0015 01180.01770. 0.0157 0.018 0.00060.0060.0006-

Year 2000

2001

2002

NA: Not Available

Lug

SPECIFICATIONS

TORQUE Engine Displacement Engine Liters (cc) VIN D 2.2 (2198) W 3.2 (3165) X 3.5 (3494) D 2.2 (2198) W 3.2 (3165) X 3.5 (3494) D 2.2 (2198) W 3.2 (3165) X 3.5 (3494)

Year 2000

2001

2002

Cylinder Head Bolts

Main Bearing

©

© 29

© © © © © © ©

© © 29

Bolts

All readings in ft. lbs. Crankshaft Rod Bearing Damper Flywheel Bolts Bolts Bolts 40 © © © 40 123 40 123 40

© © 29 ©

© 40 40

© 123 123

© 40 40

© 40 40

© 123 123

© 40 40

Manifold Intake Exhaust 18 16 © 42 38 18 16 © 42 18 18 16 © 38 42 18 18

Plugs 18 Spark 13 13 13 18 13 18 13 13

38 ©Stepl:

18 ft. lbs.

© Crankshaft sprocket:

Step 2: Plus 90 degrees

Step 1: 94 ft. lbs.

Step 3: Plus 90 degrees

Step 2: Plus 45 degrees

Step 4: Plus 90 degrees ©Step

1: 37ft. lbs.

Step 2: Plus 45 degrees Step 3: Plus 15 degrees ©Step

1: 25ft. lbs.

Step 2: Plus 45 degrees Step 3: Plus 1 5 degrees

Crankshaft balancer: Step 1: 14 ft. lbs.

©Step

Nuts

87 87 87 87 87 87 87 87 87

1: 21 ft. lbs.

Step 2: 47 ft. lbs. © Step 1 : 22 ft. lbs. Step 2: Plus 55-65 degrees

Step 3: Crankcase

side bolts to 29 ft. lbs.

Step 2: Plus 45 degrees © Step 1 : 48 ft. lbs. Step 2: Plus 30 degrees Step 3: Plus 15 degrees

© Step 1:112 inch lbs. Step 2: 14 ft. lbs.

Step 3: 14 ft. lbs. 42356-ISUZ-C08

12-8

ISUZU AND HONDA AMIGO • AXIOM • RODEO

• RODEO

SPORT • TROOPER

WHEEL

• VEHICROSS

ALIGNMENT

Caster Range

• PASSPORT Steering

Camber Preferred Setting

Range

Inclination

+2.50 2000

Amigo Rodeo Passport

0.75

F R F R F R

—

1.00 —

Rodeo Sport Rodeo Passport

—

0.75 0.75 1.00 —

F R F R F

Trooper VehiCROSS 2002

Rodeo Sport Rodeo Passport Axiom Trooper

F R F R F R

— +2.50

1.00

Trooper VehiCROSS 2001

— +2.50

R 1

+2.10 —

+2.10 +2.50 — +2.50

1.00 —

— +2.50

1.00 —

— +2.10

0.75 0.75

+2.10 +2.50

1.00 — 0.75 — 1.00 —

1.00 0.75

0.30 1.00 0.50 1.00 0.50 1.00

— +2.50 — +2.50

0.50 0.50 0.50 1.00 0.50 1.00 0.50 1.00 0.50 0.50 0.50 1.00 0.50

— +2.50

1.00 0.50 1.00

+2.10

0.50 0.50

Axis

Setting Preferred

0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

Toe-in 0+/-0.08 0+/-0.20 0+/-0.08 0+/-0.20 0+/-0.08

— — —

—

—

0+/-0.20 0+/-0.08 0+/-0.08 0+/-0.08 0+/-0.20 0+/-0.08 0+/-0.20 0+/-0.08 0+/-0.20 0+/-0.08 0+/-0.08 0+/-0.08 0+/-0.20 0.04+/-0.04 0+/-0.20 0+/-0.08 0+/-0.20 0+/-0.08 0+/-0.08

—

— — — — — — — — — — — — — —

— — —

— 42356-ISUZ-C09

ISUZU AND HONDA AMIGO * AXIOM * RODEO

Year 2000

SPORT • TROOPER

• VEHICROSS

* PASSPORT

^

■

AND BALL JOINT SPECIFICATIONS

TIRE, WHEEL Model Amigo

• RODEO

19.0

OEM Tires Optional Standard none P245/70R16

Tire Pressures (psi) 26 Rear Front 26 29

Wheel Size 7JJ 7JJ

Ball Joint Inspection U: 4-28 © L: 4-55 U: 4-28 ©

Rodeo 2wd/4wd

P245/70R16

none

29

Passport LX Passport LX Passport EX Passport EX Trooper

P225/75R16 P245/70R16 P245/70R16 P245/70R16 P245/70R15

None None

29 29 29

None None none

29 29 29 29 26

29 26

7JJ

Rodeo Sport

P245/70R16 P245/70R16

none none

26 26

26 26

7JJ 7JJ

Rodeo 2wd/4wd

P225/70R16

P245/70R16

29

29

7JJ

L: 4-55 U: 4-28 ©

P225/75R16 P245/70R16 P245/70R16 P245/70R16 P245/70R15

None

29 29 29 29 26 26

29 29 29 29

7J 7J 6.5-JJ 7-JJ

NS L: NS 4-55

none

Rodeo Sport

P245/60R18 P245/70R16

Axiom

P235/65R17

2wd 4wd 2wd 4wd

VehiCROSS 2001

Passport LX Passport LX Passport EX Passport EX Trooper

2wd 4wd 2wd 4wd

VehiCROSS 2002

None None None none

7J 6.5-JJ 7J 7-JJ

P225/75R16

Passport LX Passport LX Passport EX Passport EX Trooper

P225/75R16 P245/70R16 P245/70R16 P245/70R16 P245/70R15

2wd 4wd 2wd 4wd

U: 4-28© NS L: 4-55 U: 4-28 ©

NS NS

26

7JJ

26

26 26

7JJ 7JJ

none

26

26

7JJ

P245/70R16 P245/60R18 None

26

26 29

L: 4-55 U: 4-28 ©

29 29 26 29

L: NS 4-55 NS NS NS

none

None None None none

29 29 29 29 26

U: 4-28 © L: NS 4-55

7JJ Rodeo 2wd/4wd

L: NS 4-55 NS NS NS

7J 6.5-JJ 7-JJ 7J 7JJ

U: 4-28 © L: 4-55 U: 4-28©

U: 4-28© L: 4-55

L: Lower U: Upper NA: Not available NS: Not specified by manufacturer

© Torque required in inch lbs. to rotate ball joint when

removed

from the knuckle 42356-ISUZ-C1 0

HONDA ISUZU •AND in iO I I U AMIGO AXIOM • RODEO • RODEO SPORT * TROOPER * VEHICROSS « PASSPORT BRAKE

SPECIFICATIONS

All measurements in inches unless noted _ Brake Drum Diameter

Year

2000

2001

Model F Amigo R F Rodeo R F Passport R F Trooper R F VehiCROSS R Rodeo Sport F

R

Rodeo Passport Trooper VehiCROSS

2002

Rodeo Sport Rodeo Axiom Passport Trooper

NA: Not Available

F R F R F R F R F R F R F R F R F R

Brake Caliper

Original Max. Maximum Minimum Bracket Mounting Brake Disc _ _ Original Machine Minimum Maximum Inside Wear Machine Lining Bolts Bolts lbs.) (ft. lbs.) (ft.115 Thickness Thickness Thickness Runout Diameter Limit Diameter Thickness 0.039 0.969 0.983 0.005 1.020 76 32 NA 11.67 11.6 0.005 0.668 115 0.039 0.710 0.654 54 0.969 0.983 1.020 0.005 0.039 0.039 NA 11.67 11.6 0.005 76 0.668 0.710 0.654 0.005 0.039 115 0.983 0.969 1.020 0.039 NA 11.67 11.6 0.668 32 0.654 0.005 0.710 — 0.039 115 54 0.983 0.005 0.969 1.024 0.039 — 76 NA 0.668 0.005 0.710 0.654 — — 0.039 115 54 0.969 0.005 0.983 1.024 — — 32 0.005 115 0.668 76 0.710 0.039 0.654 0.039 54 0.983 0.969 1.020 0.005 11.67 0.005 76 11.6 0.668 0.039 0.654 0.710 115 54 0.039 0.983 NA 1.020 0.969 0.005 11.6 32 NA 0.005 115 0.668 0.710 0.039 11.67 0.654 0.005 1.020 0.983 0.039 0.969 0.005 0.039 32 76 115 0.710 0.668 0.654 54 0.969 0.983 0.039 0.005 1.024 76 0.668 0.005 0.039 0.710 0.654 115 54 0.005 0.039 1.024 0.969 0.983 32 0.005 0.654 0.668 0.039 0.710 115 0.005 54 0.969 0.983 0.039 1.020 32 76 0.005 NA 11.6 76 0.668 0.039 0.654 11.67 0.710 115 0.969 0.983 1.020 0.039 0.005 0.039 11.6 0.005 76 0.668 0.654 0.710 11.67 0.039 115 54 1.020 NA 0.005 0.983 0.969 0.039 32 NA 0.005 0.710 0.654 11.67 0.668 11.6 0.039 115 54 0.005 0.983 0.969 1.020 76 0.005 0.668 0.710 0.039 0.654 115 54 0.039 0.969 0.983 0.005 1.024 32 0.005 0.039 0.668 0.710 0.654 54 32 —

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

—

42356-ISUZ-C11

I

I

TYPE OF r 7.5 SERVICE L

TO BE SERVICED Accelerator linkage ©

S/I R

Battery fluid level ®

S/I L

S/I S/I

37.5

52.5

S/I

Front wheel bearings

S/I R S/I R S/I S/I & L

Fuel lines & tank cap ®

S/I

Inspect for fluid leaks ®

S/I L

Key lock cylinder ® Manual transmission and tranRfpr rasp

✓

✓

y

y

✓

V

y

✓

V

y

✓

y

✓ ✓

✓

y

✓

✓

✓

V

;

✓

✓

✓

S/I

y

y

y

y

y

y

y

y

y

y

y

y

y

y

✓ ✓

y yv'

✓

y

y

✓

y

y

y

y

y

y

y

✓

✓ y

V

y

y

y

y

y

y

✓ ✓ ✓

y

y

y

y

y

y

y

y

y y/ y

✓

y y

y

v'

y

✓

y

y

y

y

y

y y

y

y/

✓

y y

y

y

✓ ✓

y

y

y

y

y

y

/

y

y

y

y

y

y

y

y

✓

y

y

y

y

y

y v'

y

y

y

y V

y y

y

y

y

y

y

y

✓

✓

y

y

V

y

✓

y

y y

y

y

y

✓

y

y

✓

y

y/

✓

V

y

✓

y

yy/ y

y

✓

y

✓

✓

y

y

y

y

y

y y

y

y y

y

y

~

y

y

y y

y

y

y

y

y

y

y

y

y

y

y

y

y

Shift-on-the-fly system gear

✓

✓

y

y

y

S/I & c

tirps

120

y

y

y

y

V

r.nndpnspr

37.5

y

y

R S/I R

|

Parking brake system © Power steering fluid Radiator core and A/C

32.5

y

y

✓

fluid ©

12.5

05

✓

y

S/I R

Engine coolant level ®

90

y

S/I

Engine coolant

75

37.5

✓

S/I

Driveshaft flange torque ® Drum and disc brakes ®

(xIOOO)

✓

✓

✓

®

Engine oil & filter ® Exhaust system ® Front and rear axle lubricant Front and rear driveshafts ©

60

✓

y

S/I S/I

Cooling and heating system

Rntatp

y

45

INTERVAL

y

S/I

Clutch pedal free-play ® Clutch pedal spring, bushing and clevis pin ©

✓

y

S/I

Clutch lines & hose ©

22.5

✓

S/I

Brake pedal play ® Clutch fluid level ®

30

15

Passport

Honda

& vehiCROSS;

MILEAGE

✓

S/I

Body and chassis © Brake fluid level ® Brake lines & hoses ®

VEHICLE

/

Accessory drive belts © Air cleaner filter Auto cruise control linkage & hose ® Automatic transmission fluid level ®

hnsps

Sport, Trooper

Rodeo

Rodeo,

Axiom,

Isuzu — Amigo,

INTERVALS

MAINTENANCE

SCHEDULED

“M

HONDA -I O ISUZU AND * PASSPORT ■

* VEHICROSS

SPORT « TROOPER

• RODEO

AMIGO • AXIOM • RODEO

S/I y

Spark plug wires © Spark plugs

S/I K

Starter safety switch ®

S/I

Steering operation ® Sn^npn^inn

S/I S/I

A stpprinn @

ThrnttlP linkanp © Timing belt _

S/I

_

I

R

nn

y y

~y~ ~7~ y

nn

y

y

y

y

y

y

y

y

y

y

y

y

y

y

y

y

y

y

y

y

y

y

y

y

y

y

V

y

y

y

y

y

y

y

y

y

y

y

V

V

V

y

y

y

y

y

V

y

y 42356 ISUZ-C12

10

iO ISUZU AND HONDA

I C " I C amigo • AXIOM • RODEO • RODEO SPORT • TROOPER • VEHICROSS • PASSPORT SCHEDULED

MAINTENANCE

INTERVALS

Isuzu — Amigo, Axiom, Rodeo, Rodeo Sport, Trooper & vehiCROSS; Honda — Passport TYPE OF SERVICE

TO BE SERVICED Tires and wheels ©

15

22.5 ✓

✓

S/I A

Valve clearance © R: Replace

7.5

VEHICLE MIL EAGE INTERVAL (xIOOO) 90 75 45 52.5 82.5 97.5 105 112.5 60 67.5 37.5

30

S/I: Service or Inspect

L: Lubricate

✓

✓

✓

120

✓

✓ A: Adjust

C: Clean

© Perform this at the mileage indicated or every 6 months, whichever occurs first. © Perform this at the mileage indicated or every 24 months, whichever

occurs first.

© Perform this at the mileage indicated or every 12 months, whichever

occurs first.

©

3.2L V6 engine.

© 2.2L 4 cyl. engine.

FREQUENT

OPERATION

MAINTENANCE

(SEVERE SERVICE)

If a vehicle is operated under any of the following conditions it is considered severe service: - Towing a trailer or using a camper or car-top carrier. - Repeated short trips of less than 5 miles in temperatures below freezing. - Extensive idling or low-speed driving for long distances as in heavy commercial

use, such as delivery, taxi or police cars.

- Operating on rough, muddy or salt-covered roads. - Operating on unpaved or dusty roads. Air cleaner element: replace every 15,000 miles Engine oil and filter: replace every 3000 miles or 3 months, whichever

occurs first.

Automatic transmission fluid, replace every 20,000 miles. Rear axle lubricant: replace every 15,000 miles. 42356-1SUZ-C13

ISUZU AND HONDA

SPOR AMIGO T • AXIOM • RODEO * • PRECAUTIONS RODEO * TROOPER

Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage and important points to take into consideration when servicing a motor vehicle:

• Never open, service or drain the radia¬ tor or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. • Observe all applicable safety precau¬ tions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. • Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. • Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken brake fluid internally, seek medical assis¬ tance IMMEDIATELY.

» VEHICROSS

• The EPA warns that prolonged con¬ tact with used engine oil may cause a number of skin disorders, including can¬ cer. You should make every effort to mini¬ mize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas as soon as pos¬ sible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. • All new vehicles are now equipped with an air bag system, often referred to as a Supplemental Restraint System (SRS) or Supplemental Inflatable Restraint (SIR) system. The system must be disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary system repairs. • Always wear safety goggles when working with, or around, the air bag sys¬ tem. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When plac¬ ing a non-deployed air bag on a work sur¬ face, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the addi¬ tional air bag system precautions later in this section. • Clean, high quality brake fluid from a sealed container is essential to the safe and

« PASSPORT

-10-10

»

^

proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in con¬ tact with a painted surface; it will damage the •paint. Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine damage. • Timing belt maintenance is extremely important. Many models utilize an interfer¬ ence-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing poten¬ tially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this section for the recommended replace¬ ment interval for the timing belt. • Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board com¬ puter system(s) and may require the computer to undergo a relearning pro¬ cess once the negative battery cable is reconnected. • When servicing drum brakes, only dis¬ assemble and assemble one side at a time, leaving the remaining side intact for refer¬ ence. • Only an MVAC-trained, EPA-certified automotive technician should service the A/C system or its components.

ENGINE REPAIR ^Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer system. The computer may undergo a relearning process once the negative battery cable is recon¬ nected.

Distributor REMOVAL

These engines are equipped with a Dis¬ tributorless Ignition System (DIS).

Alternator REMOVAL 2.2L Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Accessory drive belt • Alternator harness connectors • Alternator

3.2L Engine

1 . Before servicing the vehicle, refer to tion. the precautions in the beginning of this sec¬

2. Remove or disconnect the following: • Negative battery cable • Accessory drive belt •• Alternator Alternator harness connectors 3.5L Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

12-14

ISUZU AND HONDA AMIGO • AXIOM • RODEO

SPORT • TROOPER

RODEO

• VEHICROSS

• Heater hoses • Radiator hoses

• Negative battery cable • Accessory drive belt • Alternator wiring connectors • Alternator 2. Re move or discon nect the follow INSTALLATION ing:

• Frame ground cable • Chassis harness connectors at right the enginepump compartment • rear Powerof steering • A/C compressor • Transmission • Exhaust front pipe

2.2L Engine

• Fuel lines and bracket • Clutch fluid line bracket and slave

Install or connect the following: • Alternator. Tighten the long bolt to 26 ft. lbs. (35 Nm) and the short bolt to 15 ft. lbs. (20 Nm). • Alternator harness connectors • Accessory drive belt • Negative battery cable

• cylinder Engine ground cables • Brake booster vacuum line • Engine wiring harness connectors at left rear of the engine compart¬ ment • •• ••

3.2L Engine

Install or connect the following: • Alternator. Tighten the 10mm bolt to 30 ft. lbs. (41 Nm) and the 8mm bolt to 15 ft. lbs. 21 Nm). • Alternator harness connectors • Accessory drive belt • Negative battery cable 3.5L Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Install or connect the following: • Alternator. Tighten the 10mm bolts to 30 ft. lbs. (41 Nm) and the 8mm bolts to 15 ft. lbs. (21 Nm). • Alternator wiring connectors • Accessory drive belt • Negative battery cable

Ignition Timing ADJUSTMENT These engines are equipped with a Dis¬ tributorless Ignition System (DIS). No adjustment is possible.

Engine Assembly REMOVAL & INSTALLATION

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: • Battery

Air intake assembly Accelerator cable Hood Battery Accessory drive belts

8. Fill the cooling system. Left and right motor mounts — 2.2L engine

• Hood

• Accessory drive belt • Accelerator cable • Air intake assembly • Engine wiring harness connectors at left rear of the engine compart¬ ment • Brake booster vacuum line • Engine ground cables • Clutch fluid line bracket and slave • • • • •

cylinder Fuel lines and bracket Exhaust front pipe Transmission A/C compressor Power steering pump

• Chassis harness connectors at right rear of the engine compartment • Frame ground cable • Radiator hoses • Heater hoses • Cooling fan connector •• Cooling Radiator fan and shroud • Left and right engine mounts 5. Lift the engine from the vehicle. To install:

2.2L engines

• PASSPORT

6. Position the engine in the engine compartment. 7. Install or connect the following: • Left and right engine mounts. Tighten the fasteners to 30 ft. lbs. Nm). • (41 Radiator • Cooling fan and shroud • Cooling fan connector

9. Start the engine and check for leaks. 3.2L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. • Battery 3. Relieve the fuel system pressure. 4. •Remove Hood or disconnect the following: • • • • •

Accelerator cable Cruise control cable Air intake assembly Canister vacuum hose Brake booster vacuum hose

• Engine wiring harness connectors • Front axle harness connector, if equipped • Transmission harness connector and bracket • Frame ground cable • Firewall ground cable • Starter harness connectors • Alternator harness connectors • Coolant overflow reservoir hose • Radiator hoses • Cooling fan and shroud •• Accessory drive pump belt Power steering • A/C compressor • • • •

Heated nectors Oxygen (HO2S) sensor con¬ Exhaust front pipes Heater hoses Fuel lines

• Transmission • Left and right engine mounts

ISUZU AND HONDA AMIGO • AXIOM • RODEO

5. Lift the engine from the vehicle. To install:

6. Lower the engine into the vehicle. 7. Install or connect the following: • Left and right engine mounts. Tighten the bolts to 30 ft. lbs. (41 4 Nm) and the nuts to 37 ft. lbs. (50 Nm).

• RODEO

SPORT * TROOPER

• Heater hoses •• Upper Radiatorfan shroud • Cooling fan • Accessory drive belt • Power steering pump • A/C compressor

* VEHICROSS

• • • • • • • • • • •

« PASSPORT

■

1 ^

Air cleaner assembly Canister vacuum line Brake booster vacuum line Engine wiring harness connectors Transmission harness connectors and bracket Engine ground cable Bonding cable connectors Starter harness connector Alternator harness connector Coolant reservoir tank hose Radiator hoses

• Heated Oxygen (HO2S) sensor con¬ nectors • Transmission • Fuel lines • Left and right exhaust front pipes • Fuel lines • Heater hoses • Flywheel dust cover • Exhaust front pipes Upper fanfanshroud • Cooling • Transmission. Refer to the trans¬ • Heated Oxygen (HO2S) sensor con¬ . nectors mission procedure in this section. . •• Accessory drive pump belt and right engine mounts • A/C compressor •• Left Engine Power steering • Power steering pump • A/C compressor To install: • Accessory drive belt • Cooling fan and shroud • Heated • Engine nectors Oxygen (HO2S) sensor con¬ • Radiator hoses • Left and right exhaust front pipes • Coolant overflow reservoir hose • Left and right engine mounts. • Alternator harness connectors •• Flywheel dust cover Nm). the bolts to 30 ft. lbs. (41 Tighten Heater hoses • Starter harness connectors • Fuel lines • Transmission • Firewall ground cable • Flywheel dust cover • Frame ground cable • Transmission. Refer to the trans¬ • Fuel lines • Transmission harness connector Install mission procedure in this section. or c • Accelerator cable and bracket onn • Left and right exhaust front pipes ect • Cruise control cable • Front axle harness connector, if t•he HO2S sensor connectors fol •• Engine l Left and right engine mounts • A/C compressor owi equipped n g:steering pump • Power • Engine wiring harness connectors • Brake booster vacuum hose To install: • Accessory drive belt • Engine • Canister vacuum hose • Cooling fan. Tighten the nuts to 16 ft. lbs. (22 Nm). • Air intake assembly • Radiator • Cruise control cable • Left Nm).and right engine mounts. • Accelerator cable Tighten the bolts to 30 ft. lbs. (41 • Upper fan shroud • Heater hoses • Hood Ins tal • Transmission • Radiator hoses l or • Battery con • Coolant reservoir tank hose nec •• Flywheel dust cover 8. Fill the cooling system. tth Fuel lines • Alternator harness connector e fo 9. Start the engine and check for leaks. llo and right exhaust front pipes • Left • Starter harness connector win 3.5L Engine • HO2S g:sensor connectors • Engine ground cable • A/C compressor • Transmission harness connectors • Power steering pump EXCEPT AXIOM and bracket • Accessory drive belt 1 . Before servicing the vehicle, refer to • Engine wiring harness connectors • Brake booster vacuum line • Cooling fan. Tighten the nuts to 16 the precautions in the beginning of this sec¬ lbs. (22 Nm). tion. • ft. Radiator • Canister vacuum line 2. Drain the cooling system. • Cruise control cable 3. Remove or disconnect the following: • Accelerator cable •• Upper shroud Heater fan hoses • Battery • Air Hoodcleaner assembly • Radiator hoses • Hood • Battery • Air cleaner assembly • Coolant reservoir tank hose • Accelerator cable • Alternator harness connector 5. Fill the cooling system. Check all • Cruise control cable • Starter harness connector fluid levels and adjust as necessary. • Canister vacuum line • Engine ground cable 6. Start the engine and check for leaks. • Brake booster vacuum line • Transmission harness connectors AXIOM • Engine wiring harness connectors and bracket • Transmission harness connectors to refer 1 . Before servicing the vehicle, • Engine wiring harness connectors and bracket • Brake booster vacuum line the precautions in the beginning of this sec¬ • Canister vacuum line • Engine ground cable tion. • Starter harness connector • Cruise control cable 2. Drain the cooling system. • Accelerator cable • Alternator harness connector Battery or disconnect the following: 3. •Remove • Hood • Air cleaner assembly • Coolant reservoir tank hose • Hood • Radiator hoses

1 O I

-f C ISUZU AND HONDA I0

AMIGO • AXIOM • RODEO

• Battery 4 5. Fill the cooling system. Check all fluid levels and adjust as necessary. . 6. Start the engine and check for leaks.

Water Pump REMOVAL & INSTALLATION 2.2L Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Remove or disconnect the following: • Negative battery cable • Radiator hose • Accessory drive belt • Front cover • Timing belt. Refer to the Timing Belt unit repair section. • Water pump

• RODEO

SPORT • TROOPER

• VEHICROSS

• PASSPORT

• Radiator hose • Negative battery cable 5. Fill the cooling system. 6. Start the engine and check for leaks.

• • •

Timing belt. Refer to the Timing Idler Unit pulleyRepair Section. Belt Water pump

To install:

3.5L Engine

1. Before servicing the vehicle, refer to

'♦Apply Loctite® 262 to bolt number 3 prior to installation.

the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Remove or disconnect the following: • Negative battery cable • Upper radiator hose

• Water pump. Tighten the bolts in Installtwo passes, in sequence, to 13 ft. or c(18 onneNm) lbs. 3.2L engines or to ct thfor e Nm) 18 ft. lbs. (25 follofor wing3.5L : engines.

WATER PUMP MOUNTING LUG BOLT

To install:

4. Install a new O-ring and coat the water pump sealing surface with silicone grease. 5. Install or connect the following: • Water pump. Tighten the bolts to 18 ft. lbs. (25 Nm). • Timing belt • Front cover • Accessory drive belt • Radiator hose • Negative battery cable 6. Fill the cooling system. 7. Start the engine and check for leaks.

7924NG03

Exploded view of the water pump mounting, showing the location of the mounting lug— 2.2L engine

3.2L Engines

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Remove or disconnect the following: • Negative battery cable • Radiator hose • Accessory drive belt • Front cover • Timing belt. Refer to the Timing Belt unit repair section. • Timing belt idler pulley • Water pump To install:

4. Install or connect the following: • Water pump. Tighten the bolts in sequence to 18 ft. lbs. (25 Nm). • Timing belt idler pulley. Tighten the bolt to 38 ft. lbs. (52 Nm). • Timing belt • Front cover • Accessory drive belt

Water pump bolt tightening sequence— 3. 2L engines

ISUZU AND HONDA AMIGO • AXIOM • RODEO

• RODEO

• PASSPORT

• VEHICROSS

SPORT • TROOPER

10_17 *

5. Disconnect the cooling system hoses and drain the coolant into a clean container for reuse. Plug the cooling sys¬ tem hoses. 1. 2. 3. 4.

6. Remove the instrument panel by per¬ forming the following procedure: a. Remove the lower center cover screw and pull it out at the clip positions; then, disconnect the cigarette lighter connector. b. Remove both the rear and front console. c. Remove the dash side trim panel

Timing belt Idle pulley Water pump assembly Gasket

sill plates and d. Remove and the glove e. Remove

7924BG41

the panels. the 2 glove box screws box. the 2 hood release screws,

lower panel driver’s the cover6 instrument assembly screws and the cover assembly.

.

f. Remove 5 instrument cluster screws, the 2 clips; then, disconnect the 8 switch connectors and remove the instrument cluster assembly.

g. Remove the 6 driver’s knee bolster assembly bolts and screws and the knee bolster assembly. h. Remove the 4 control lever assem¬ bly bolts; then, disconnect the 3 control cables nectors.(unit side) and the 3 harness con¬ i. Remove the 4 radio/audio sub box screws and the radio/audio sub assembly box assembly. j. Disconnect or remove the following instrument panel harness connectors or items: • The 6 driver’s side connectors •• The side connectors The 32 passenger’s center connectors • Passenger’s inflator module con¬ • nector Radio antenna cable plug • Ground cable bolt on the left dash

3.5L engine Water pump torque sequence. Apply LOCTITE® 262 to bolt number 3 (arrow)

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passenger’s inflator the 42 nuts. a. Remove module bolts and b. Remove the 4 meter assembly screws; then, disconnect the meter wiring harness connectors and remove the meter assembly. c. Remove the 5 vent duct assembly screws and the assembly. d. Remove the 3 lower passenger bracket screws and the bracket.

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block, remove the SRS-1 fuse. c. Disconnect the 2-pin yellow con¬ nector located at the base of the steering column. d. Remove the glove box assembly. e. Disconnect the 2-pin yellow con¬ nector located behind the glove box. 2. Disconnect the negative battery cable. 3. If equipped, discharge and recover conditioning system refrigerant. air the 4. Remove the evaporator lines at the firewall. Plug the air conditioning lines to minimize contamination. m Re

REMOVAL & INSTALLATION

a. Turn the ignition to the LOCK posi¬ tion and remove the key. b. From the lower left dash side fuse

fo

Heater Core

side panel • The 8 instrument panel-to-chassis bolts and the 3 nuts. k. Remove the instrument panel assembly.

r pe by

• Idler pulley • Timing belt • Upper radiator hose • Negative battery cable 5. Fill the cooling system. 6. Start the engine and check tor leaks.

e. Remove the 9 passenger knee bol-

HO HQ ISUZU AND HONDA I L " I 0 AMIGO • AXIOM • RODEO • RODEO SPORT • TROOPER • VEHICROSS • PASSPORT

1

Cross Beam

11

Audio Sub Box

2 3

Vent Duct Assembly Instrument Panel Bracket

4 5 6

Instrument Panel Assembly Passenger Inflator Module Dash Side Trim Panel

12 13 14 15

Control Lever Assembly Front Console Assembly Lower Center Cover Instrument Panel Driver Lower Cover Assembly

7

Passenger Knee Bolster Reinforcement Assembly Glove Box

16 17 18 19 20

Driver Knee Bolster Assembly Meter Cluster Assembly Instrument Panel Center Reinforcement Meter Assembly Instrument Harness Assembly

8 9 10

Passenger Lower Bracket Radio Assembly

93113GB8

Exploded view of the instrument panel — Isuzu Amigo

ISUZU AND HONDA 19.10 AMIGO • AXIOM • RODEO • RODEO SPORT » TROOPER * VEH1CR0SS * PASSPORT

9 ment screws and the rein¬ . ster reinforce forcement. f. Remove the 6 instrument panel center reinforcement screws and the rein¬ forcement. g. Remove the instrument panel wiring harness assembly clips and the wiring harness. h. Remove the 2 instrument panel bracket nuts and 2 bolts for each bracket; then, remove the bracket(s).

nuts, 2 bolts and the 6 lower bolts; then, remove the crossb eam.

. emove

■

nector. 10. DiRemove scon the duct from the heater assembly. nect the resistor wiring con¬ 11. If equipped with air conditioning, remove the evaporator assembly.

remove remove 17. screws 18. case.

the mode control case; do not the link unit. Remove the temperature control case and separate the cases. Remove the heater core from the

12. Remove the driver’s lap vent. 13. Remove the lower ventilation duct. 14. Remove the footrest, the carpet, the 3 clips and the rear heater duct. 15. Remove the heater assembly. 16. Remove the mode control case-totemperature control case screws and

19. Install the heater core to the case. 20. Assemble the temperature control cases and install the case screws. 21. Install the mode control case and the mode control case-to-temperature control case screws. 22. Install the heater assembly.

To install:

the 5 cross beam assem bly

1 2 3 4 5

Instrument Panel Assembly Cross Beam Assembly Instrument Panel Bracket Ventilation Lower Duct Rear Heater Duct

6 Driver Lap Vent Duct 7 Evaporator Assembly (A/C only) 8 Duct 9 Heater Unit Assembly 1 0 Heater Hose 1 1 Resistor Connector 93113GB9

ts— Isuzu Amigo View of the heater and air conditioning housing assemblies and related componen

19 90 ISUZU AND HONDA

3

lt"LU

AMIGO • AXIOM • RODEO • RODEO SPORT • TROOPER • VEHICROSS 0 . bly.27. Install the duct to the heater assem¬ 23. Install the rear heater duct, the footrest, the carpet, and the 3 clips. 24. Install the lower ventilation duct. 28. Connect the resistor wiring connector. 29. Install the crossbeam, the 5 cross¬ 25. Install the driver’s lap vent. 26. If equipped with air conditioning, beam assembly nuts, 2 bolts and the 6 lower bolts. install the evaporator assembly.

• PASSPORT the following procedure: by perfInorstmi alng l thethe inst rument panepanel a. Install instrument l br bracket and the 2 nuts and 2 bolts for eachacket bracket. b. Install the instrument panel wiring

1

Heater Core

4

Mode Door

2 3

Case (Temperature Control) Heater Unit

5 6

Duct Case (Mode Control) 93113GB0

Exploded view of the heater housing assembly — Isuzu Amigo

ISUZU AND HONDA 10_91

6

AMIGO • AXIOM • RODEO • RODEO SPORT * TROOPER • VEHICROSS » PASSPORT

. 33. Refill the cooling system. the wiring harness harness assembly and 34. Install the evaporator lines at the clips. firewall. c. Install the instrument panel center reinforcement and the 6 reinforcement 35. If equipped, evacuate and charge the air conditioning system. screws. 36. Connect the negative battery cable. d. Install the passenger knee bolster ment reinforce 9 the and reinforcement 37. If equipped with an air bag, perform screws. the following procedure: e. Install the lower passenger bracket a. Turn the ignition to the LOCK posi¬ tion and remove the key. and the 3 bracket screws. f. Install the vent duct assembly and b. Connect the 2-pin yellow connec¬ tor located behind the glove box. the 5 vent duct assembly screws. c. Install the glove box assembly. g. Install the meter assembly and the 4 meter assembly screws; then, connect d. Connect the 2-pin yellow connec¬ tor located at the base of the steering the meter wiring harness connectors. column. r’s inflator h. Install e. At the lower left dash side fuse nuts. and2 4passenge bolts the module

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and drain the coolant into a clean container for reuse. Plug the cooling system hoses. formingRemthoev following procedure: e the the instlower a. Remove rumentcenter panel cover by per¬ screw and pull it out at the clip positions; then, disconnect the cigarette lighter connector. b. Remove both the rear and front

console. c. Remove the dash side trim panel sill plates and d. Remove and the glove e. Remove

the panels. the 2 glove box screws box. the 2 hood release screws,

panel driver’s lower 6 instrument the cover assembly screws and the cover assembly.

p t f ng he ollowing rocedure: a. Install the instrument panel assem¬ bly. . b. Connector install the following

block, install the SRS-1 fuse. f. Turn the ignition switch to ON and verify that the AIR BAG warning light flashes 7 times and turns OFF. 38. Run the engine to normal operating

f. Remove 5 instrument cluster screws and the 2 clips. Then, disconnect the 8 switch connectors and remove the instrument cluster assembly.

instrument panel harness connectors or items:

temperatures; then, check the climate con¬ trol operation and check for leaks.

g. Remove the 6 driver's knee bolster assembly bolts .and screws and the knee bolster assembly

formi

• The 6 driver’s side connectors ’s side connectors passenger The 23 center •• The connectors

Passenger’s inflator module con¬ • nector • Radio antenna cable plug • Ground cable bolt on the left dash side panel • The 8 instrument panel-to-chassis bolts and the 3 nuts. c. Install the radio/audio sub box . assembly and the 4 radio/audio sub box e ins assembly screws. trume nd. t paConnect nel b the 3 control cables (unit yp side) and the e3r¬harness connectors. Install the 4 control lever assembly bolts. e. Install the knee bolster assembly and the 6 driver’s knee bolster assembly bolts and screws. f. Install the instrument cluster assembly. Connect the 8 switch connec¬ tors. Install 5 instrument cluster screws and the 2 clips.

g. Install the 2 hood release screws, lower the 6 instrument panel driver’s cover assembly screws and the cover assembly. h. Install the glove box and the 2 glove box screws.

i. Install the dash side trim panel sill plates and the panels. j. Install both the rear and front con¬ sole. k. Connect the cigarette lighter con¬ nector and install the lower center cover screw.

Axiom 1 . Disconnect the battery ground. 2. Drain the coolant.

3. Discharge and recover the refriger¬ ant.

4. Remove the heater unit. 5. Remove the duct. 6. Remove the mix actuator. 7. Remove the mode actuator. 8. Remove the mode control case. 9. Remove the heater case and separate the halves. 10. Remove the core. 1 1 . Installation is the reverse of removal. Rodeo 1. If equipped with an air bag, perform the following procedure: a. Turn the ignition to the LOCK posi¬ tion and remove the key. b. From the lower left dash side fuse

h. Remove the 4 control lever assem¬ bly bolts; then, disconnect the 3 control (unit side) and the 3 harness con¬ cables nectors. i. Remove the 4 radio/audio sub box assembly screws and the radio/audio sub box assembly. j. Disconnect or remove the following instrument panel harness connectors or items: • The 6 driver’s side connectors s side connectors passenger’ • The 23 center connectors • Passenger’s inflator module con¬ nector • Radio antenna cable plug • Ground cable bolt on the left dash side panel • The 8 instrument panel-to-chassis bolts and the 3 nuts. k. Remove the instrument panel assembly.

block, remove the SRS-1 fuse. pr c. Disconnect the 2-pin yellow con¬ the fol by per oc nector located at the base of the steering low fo ed rm Remove the 2inpassenger’s ur inflator a. e: column. g moduleing bolts and 4 nuts. assembly. box b. Remove the 4 meter assembly glove the d. Remove screws. Then, disconnect the meter e. Disconnect the 2-pin yellowRe con¬ mo nector located behind the glove box. v wiring harness connectors and remove the meter assembly. 2. Disconnect the negative battery ethei ns cable. tr c. Remove the 5 vent duct assembly um e npta screws and the assembly. 3. If equipped, discharge and recover ne lbr d. Remove the 3 lower passenger the air conditioning system refrigerant. ack the at lines tor evapora the et screws and the bracket. bracket 4. Remove to lines firewall. Plug the air conditioning e. Remove the 9 passenger knee bol¬ minimize contamination. reinforcement screws and the rein¬ ster forcement. 5. Disconnect the cooling system hoses

19 99 ISUZU AND HONDA I £-~L.L.

1 2 3 4 5 6 7 8 9 10

AMIGO • AXIOM • RODEO • RODEO SPORT • TROOPER • VEHICROSS • PASSPORT

Cross Beam

Vent Duct Assembly Instrument Panel Bracket Instrument Passenger Dash Side Passenger Assembly Glove Box

Panel Assembly Inflator Module Trim Panel Knee Bolster Reinforcement

Passenger Lower Bracket Radio Assembly

11 12 13 14 15 16

Audio Sub Box Control Lever Assembly Front Console Assembly Lower Center Cover Instrument Panel Driver Lower Cover Assembly

17 18 19

Driver Knee Bolster Assembly Meter Cluster Assembly Instrument Panel Center Reinforcement Meter Assembly

20

Instrument Harness Assembly 93113GB8

Exploded view of the instrument panel — Isuzu Rodeo

ISUZU AND HONDA

AMIGO • AXIOM • RODEO • RODEO SPORT * TROOPER * VEHICROSS * PASSPORT f. Remove the 6 instrument panel center reinforcement screws and the rein¬ forcement. g. Remove the instrument panel wiring harness assembly clips and the wiring harness. h. Remove the 2 instrument panel bracket nuts and 2 bolts for each bracket; then, remove the bracket(s). 8. Remove the 5 cross beam assembly nuts, 2 bolts and the 6 lower bolts; then, remove the crossbeam. 9. Disconnect the resistor wiring con¬ nector.

1 2 3 4 5

10. Remove the duct from the heater assembly. 11. If equipped with air conditioning, remove the evaporator assembly. 12. Remove the driver’s lap vent. 13. Remove the lower ventilation duct. 14. Remove the footrest, the carpet, the 3 clips and the rear heater duct. 15. Remove the heater assembly. 16. Remove the mode control case-totemperature control case screws and remove the mode control case; do not remove the link unit.

Instrument Panel Assembly Cross Beam Assembly Instrument Panel Bracket Ventilation Lower Duct Rear Heater Duct

6 7 8 9 10 11

-I9_99 • **

17. Remove the temperature control case screws and separate the cases. 18. Remove the heater core from the case. To install: 19. Install the heater core to the case. 20. Assemble the temperature control cases and install the case screws. 21 . Install the mode control case and the mode control case-to-temperature control case screws. 22. Install the heater assembly. 23. Install the rear heater duct, the footrest, the carpet, and the 3 clips.

Driver Lap Vent Duct Evaporator Assembly (A/C only) Duct Heater Unit Assembly Heater Hose Resistor Connector 93113GB9

components— Isuzu Rodeo View of the heater and air conditioning housing assemblies and related

-i 9

OA

I t"L4

ISUZU AND HONDA AMIGO • AXIOM • RODEO • RODEO SPORT • TROOPER • VEHICROSS • PASSPORT

24. Install the lower ventilation duct.

Install the driver’s lap vent. 3 25. 26. If equipped with air conditioning, 0 install the evaporator assembly. . 27. Install the duct to the heater assem¬ bly. 28. Connect the resistor wiring connector. 29. Install the crossbeam, the 5 cross¬

beam assembly nuts, 2 bolts and the 6 lower bolts.

harness assembly and the wiring harness clips.

by performin the following procedure : g the instrument panel bracket a. Install and the 2 nuts and 2 bolts for each Install th e instrum bracket. ent pa brackwiring b. Install the instrumentnelpanel et

c. Install the instrument panel center reinforcement and the 6 reinforcement screws. d. Install the passenger knee bolster reinforcement and the 9 reinforcement screws.

1

Heater Core

4

Mode Door

2 3

Case (Temperature Control) Heater Unit

5 6

Duct Case (Mode Control) 93113GB0

Exploded view of the heater housing assembly — Isuzu Rodeo

ISUZU AND HONDA

AMIGO • AXIOM • RODEO • RODEO SPORT « TROOPER « VEHICROSS « PASSPORT

and the 3 bracket screws. t. Install the vent duct assembly and the 5 vent duct assembly screws. e. g.In Install the meter assembly and the connect l the lowescrews. 4 meterstalassembly r passenThen, ger bracket the meter wiring harness connectors.

r’s inflator h. Install module bolts the and2 4passenge nuts.

forming the followi procedu ng re: a. Install the instrument panel assem¬ bly. 8 b. Connect or install the following

instrument panel harness connectors or . items: • The 6 driver's side connectors The 3 passenger’s side connec¬ • tors • The 2 center connectors

a. Turn the ignition to the LOCK posi¬ tion and remove the key.

b. Connect the 2-pin yellow connec¬ tor located behind the glove box. c. Install the glove box assembly. d. Connect the 2-pin yellow connec¬ tor located at the base of the steering column. e. At the lower left dash side fuse block, install the SRS-1 fuse. f. Turn the ignition switch to ON and verify that the AIR BAG warning light flashes 7 times and turns OFF. con¬ the che the clim temp andn, chec ck for leaks ate trol eorpaetrur . k ateiso; n

Trooper

|: CAUTION

Run The vehicle is equipped with a Passenger’s inflator module con¬ the e nector ngi driver’sne tside o no and a passenger’s side iRadio nstrumeantenna cable plug rmal panelbolt service pro¬ Before bag. air Ground ntcable on the left dash ostarting pera by per¬ cedures on components, ting especially side panel under the instrument panel and/or • The 8 instrument panel-to-chassis near the steering column, disable the bolts and the 3 nuts. air bag systems. There is sufficient c. Install the radio/audio sub box voltage in the system to cause a assembly and the 4 radio/audio sub box deployment for up to 15 seconds assembly screws. after the battery has been discon¬ d. Connect the 3 control cables (unit nected, the ignition turned OFF or side) and the 3 harness connectors. fuse is removed from the fuse panel.C-21 _ Install the 4 control lever assembly bolts. e. Install the knee bolster assembly

• . Install t h•e •

1

and the 6 driver’s knee bolster assembly bolts and screws. f. Install the instrument cluster

1. If equipped with an air bag, perform the following procedures: a. Disconnect the negative battery

assembly. Connect the 8 switch connec¬ tors. Install 5 instrument cluster screws and the 2 clips. g. Install the 2 hood release screws,

cable, then disconnect the positive bat¬ tery cable. b. Disconnect the yellow 2-pin con¬ nector located at the base of the steering column. c. Remove the glove box and discon¬ nect the yellow 2-pin connector located behind the glove box. 2. Disconnect the negative battery cable. 3. Drain the cooling system. 4. If equipped with air conditioning, discharge and recover the refrigerant. 5. Remove the instrument panel assem¬ bly by performing the following procedure: a. At the front console assembly, dis¬ connect the switch connectors; then, remove the console-to-chassis screws and the console. b. At the lower cluster assembly, remove the cluster-to-instrument panel screws, disconnect the cigarette lighter and light connectors and remove the lower cluster.

lower the 6 instrument panel driver’s cover assembly screws and the cover assembly. h. Install the glove box and the 2 glove box screws. i. Install the dash side trim panel sill plates and the panels. both the rear and front con¬ sole.j. Install

k. Connect the cigarette lighter con¬ nector and install the lower center cover screw. 32. Connect the cooling system hoses. 33. Refill the cooling system. 34. Install the evaporator lines at the firewall. 35. If equipped, evacuate and charge the air conditioning system. 36. Connect the negative battery cable. 37. If equipped with an air bag, perform the following procedure:

-lO OE ■

C-™

c. Remove the glove box and the instrument panel lower cover and the passenger knee bolster reinforcement. d. At the left side, remove the instru¬ panel lower cover and the knee bol¬ ment assembly. ster e. At the top of the instrument panel, pry the 8 claws on the front side toward you, it. raise the defroster grille and remove f. At the SRS adjust bracket and cross beam under the passenger air bag module, remove the 2 fixing bolts and remove the instrument panel assembly. g. Disconnect the air conditioning control cables from the unit. h. Remove the instrument panel har¬ ness connectors (5 on the driver’s side and 3 on the passenger’s side), the pas¬ senger air bag module connector, the radio antenna plug and the center bracket ground cable bolt. i. Remove the passenger’s air bag module nuts, disconnect the connectors and remove the module.

j. Remove the instrument panel clus¬ ter assembly screws, disconnect the switch connectors and the instrument panel assembly. 6. Disconnect the heater hoses from the heater unit. 7. Disconnect the heater resistor con¬ nector and the electro thermo connector (if equipped with air conditioning). 8. Remove the heater duct. 9. If equipped with air conditioning, remove the evaporator assembly by per¬ forming the following procedure: a. Disconnect the drain hose. b. Using a backup wrench, disconnect the refrigerant lines from the evaporator. c. Plug or cap the refrigerant lines. d. Remove the evaporator assembly. 10. Remove the instrument panel center bracket (crossbeam assembly) by perform¬ ing the following procedure: a. Remove the side support bracket bolts and brackets from both sides of the vehicle. b. Remove the crossbeam center bracket nuts, disconnect the electrical connectors and the center bracket. 1 1 . Remove the rear heater duct and heater assembly.

12. Disassemble the heater unit assem¬ following procedure: bly by performing the lower air duct; do not a. Remove the remove the link unit. b. Remove the temperature control case screws and lift the case from the heater unit. c. Remove the heater core.

10

OR

I L ~L 0

ISUZU AND HONDA AMIGO • AXIOM • RODEO • RODEO SPORT • TROOPER • VEHICROSS • PASSPORT

To install: 13. Assemble the heater unit assembly by performing the following procedure: a. Install the heater core into the heater unit. b. Install the temperature control case onto the unit and secure with screws. c. Install the lower air duct. 14. Install the heater unit assembly into the vehicle. 15. Install the rear heater duct.

16. Install the instrument panel cross beam assembly by reversing the removal procedures. 17. If equipped with air conditioning, install the evaporator assembly by perform¬ ing the following procedures: a. If installing a new evaporator assembly, add 1.7 fl. oz. (50mL) of refrigerant oil to the evaporator. b. Using new O-rings and a backup wrench, install the refrigerant lines and torque the outlet line to 18 ft. lbs. (25

(1) Instrument Panel Assembly (2) Instrument Panel Center Bracket (3) Resistor (4) Duct (5) Evaporator Assembly (A/C only) (6) Rear Heater Duct

Exploded view of the heater unit and related components — Isuzu Trooper

Nm). Nm) and the inlet line to 11 ft. lbs. (15

18. Install the heater duct. 19. Connect the heater resistor connec¬ tor and the electro-thermo connector (if equipped with air conditioning). 20. Connect the heater hoses to the heater unit. 21. Install the instrument panel assembly by reversing the removal proc¬ edures. 22. If equipped with air conditioning,

(7) Heater Unit Assembly (8) Center Ventilation Lower Duct (9) Driver Lap Vent Nozzle

(10) Water Hose (11) Electro Thermo Connector (With A/C) (12) Resistor Connector

93113G01

ISUZU AND HONDA 10.97 AMIGO • AXIOM • RODEO • RODEO SPORT • TROOPER « VEHICROSS * PASSPORT evacuate and charge and leak-test the sys¬ tem. 23. Refill the cooling system. 24. Connect the negative battery cable.

CAUTION

2

Never use an air bag assembly from 5 another vehicle and/or different .

model year. Starting in 1999, the air

bag assemblies are equipped with identification colors on the bar code label as follows: YELLOW for the driver’s air bag assembly, WHITE the passenger’s air bag assem¬ for bly_ _ the follow p ing rocedur

e:

connect the yellow 2-pin connector. d. Install the air bag fuse C-21 (if removed) or connect the negative battery cable. e. Turn the ignition switch ON and

e the air ba gs by perfo rming

Exploded view of the heater unit — Isuzu Trooper

1

a. Connect the passenger’s side air . connector bagb.yellow Install2-pin the glove box. c. At the base of the steering column,

Enabl

(1) Case (Temperature Control) (2) Mode Door (3) Duct

1

(5) Case (Mode Control) (6) Heater Core 93113G02

(

HO OQ ISUZU AND HONDA I L "L. 0 AMIGO • AXIOM • RODEO • RODEO SPORT • TROOPER • VEHICROSS • PASSPORT

)

9

(8) Instrument Panel Passenger Lower Cover Assembly Exploded view of the instrument panel and accessories — Isuzu Trooper

(10) Lower Cluster Assembly (11) Front Console Assembly x vBeo

Vent Duct Assembly Instrument Harness Assembly Instrument Panel Assembly Side Defroster Grille Passenger Inflator Module Control Lever Assembly Passenger Knee Bolster Reinforcement Assembly

Glo

(1 ) (2) (3) (4) (5) (6) (7)

(12) Radio Assembly (13) Assembly Instrument Panel Driver Lower Cover (14) Driver Knee Bolster Assembly (15) Instrument Panel Cluster Assembly (16) Meter Assembly (17) Front Defroster Grille

93113G03

ISUZU AND HONDA AMIfiO « AXIOM * RODEO * RODEO SPORT • TROOPER * VEHICROSS • PASSPORT verify that the AIR BAG warning light flashes 7 times and then turns OFF. 26. Run the engine to normal operating | temperatures and check for leaks. Check the I systems for correct operation.

VehiCROSS C CAUTION The vehicle is equipped with a driver’s side and a passenger’s side air bag. Before starting service pro¬ cedures on components, especially under the instrument panel and/or , near the steering column, disable the air bag systems. There is sufficient voltage in the system to cause a deployment of the air bags for up to 15 seconds after the battery has been disconnected. _ 1. If equipped with an air bag, perform the following procedures: a. Disconnect the negative battery cable, then disconnect the positive bat¬ tery cable. b. Disconnect the yellow 3-pin con¬ nector located at the base of the steering column. 2. Disconnect the negative battery cable. 3. Drain the cooling system. 4. If equipped with air conditioning, discharge and recover the refrigerant. 5. Remove the instrument panel

assembly by performing the following procedure: a. Remove the front lower console cover screws and cover. b. Remove the glove box door and box. c. At the passenger’s side, remove the instrument panel lower cover screws and d. At the driver’s side, disconnect the panel. accelerator cable from the pedal and instrument panel lower cover the remove screws and panel. e. Remove the lower cluster. f. At the meter cluster assembly, dis¬ connect the switch connectors, then remove the screws, clips and the meter assembly.

g. At the driver’s side, disconnect the data link connector, then remove the bolts and the knee bolster. h. At the lower cluster cover, remove the cover-to-instrument panel screws, disconnect the cigarette lighter and remove the lower cover. i. Disconnect the air conditioning control cables from the unit.

j. Remove the instrument panel clus¬ ter assembly screws, disconnect the switch connectors and the instrument panel assembly. k. Remove the instrument harness connectors, the radio antenna plug. l. Remove the side defroster grille. Remove the instrument panel nuts,

1 9_9Q 1

bolts and screws and the instrument

6. Remove the passenger’s air bag rein¬ forcement screws and the reinforcement. panel. 7. At the meter assembly, disconnect the electrical connector, then remove the screws and the meter assembly. 8. Remove the radio and the vent duct assembly. the passenger’s knee bolster 9. Remove screws and bolster. 10. Remove the instrument panel center bracket bolts, nuts and bracket. 1 1 . Remove the heater resistor connec¬ tors and the electro thermo connector (if equipped with air conditioning). 12. Remove the blower motor assembly. 13. If equipped with air conditioning, remove the evaporator assembly by per¬ forming the following procedure: a. Disconnect the drain hose. b. Using a backup wrench, disconnect the refrigerant lines from the evaporator. c. Plug or cap the refrigerant lines. d. Remove the evaporator assembly. 14. Remove the driver’s side lap vent duct. 15. Remove the center and lower vent ducts. 16. Remove the heater assembly.

17. Disassemble the heater unit assem¬ bly by performing the following procedure: a. Remove the lower air duct; do not remove the link unit. b. Remove the temperature control

1 Instrument Panel Assembly 2 Center & Lower Vent Duct

3 Instrument Panel Center Bracket 4 Evaporator Assembly 5 Heater Unit Assembly 6 Heater Hose 7 Blower Unit

93113G04

Exploded view of the heater unit and related components

Isuzu VehiCROSS

19 c

on ISUZU AND HONDA

I L "OU AMIGO • AXIOM • RODEO • RODEO SPORT • TROOPER • VEHICROSS • PASSPORT . case screws and lift the case from the heater unit. c. Remove the heater core.

To install: by performin the following procedure g the heater core into the: a. Install heater unit. b. Install the temperature control case onto the unit and secure with screws.

8. Assemble

19. Install Ins the heater unit assembly into the vehicle.tall the lower ai r duct. 20. Install the center and lower vent ducts. 21. Install the driver’s side lap vent duct. 22. Install the instrument panel cross beam assembly by reversing the removal procedures. 23. If equipped with air conditioning,

install the evaporator assembly by perform¬ ing the following procedures: a. If installing a new evaporator assembly, add 1.7 fl. oz. (50mL) of refrigerant oil to the evaporator. b. Using new O-rings and a backup wrench, install the refrigerant lines and Nm). the outlet line to 18 ft. lbs. (25 torque Nm) and the inlet line to 11 ft. lbs. (15

the heate r unit as sembly

(1) Case (Temperature Control) (2) Mode Door (3) Duct Exploded view of the heater unit — Isuzu VehiCROSS

(5) Case (Mode Control) (6) Heater Core 93113G02

ISUZU AND HONDA AMIGO • AXIOM • RODEO • RODEO SPORT * TROOPER * VEHICROSS * PASSPORT

1 Vent Duct Assembly

-f 0_Q1 ■

12 Lower Cluster

2

Passenger Air Bag Reinforcement

13 Instrument Panel Lower Center Cover

3

Instrument Panel Assembly

14 Instrument Panel Driver Lower Cover

4

Passenger Air Bag Assembly

15 Driver Knee Bolster

5 Glove Box Cover

6

Passenger Knee Bolster

16 Meter Cluster Assembly 17 Meter Assembly

7 Glove Box Assembly

18 Instrument Harness Assembly

8

Radio Assembly

19 Brake Pedal & Bracket Assembly

9

Air Conditioner Control Lever Assembly

20 Instrument Panel Center Bracket

10 Instrument Panel Passenger Lower Cover

21 Cross Beam Assembly

11 Front Lower Console Cover 93113G05

VehiCROSS Exploded view of the instrument panel and accessories— Isuzu

u 1

Q9

HO

I C~OC

ISUZU AND HONDA AMIGO • AXIOM • RODEO • RODEO SPORT • TROOPER • VEHICROSS • PASSPORT

1

Cross Beam

11

Audio Sub Box

2 3 4 5 6 7

Vent Duct Assembly Instrument Panel Bracket

12 13 14 15

Control Lever Assembly Front Console Assembly Lower Center Cover Instrument Panel Driver Lower Cover Assembly

16 17 18 19 20

Driver Knee Bolster Assembly Meter Cluster Assembly Instrument Panel Center Reinforcement Meter Assembly Instrument Harness Assembly

8 9 10

Instrument Passenger Dash Side Passenger Assembly Glove Box

Panel Assembly Inflator Module Trim Panel Knee Bolster Reinforcement

Passenger Lower Bracket Radio Assembly

93113GB8

Exploded view of the instrument panel — Honda Passport

OO ISUZU AND HONDA -19 ■

AMIGO • AXIOM • RODEO • RODEO SPORT • TROOPER • VEHICROSS • PASSPORT

3

2 24. Install the blower motor. : CAUTION . ¬ connec 25. Connect the heater resistor Never use an air bag assembly from tors and the electro-thermo connector (if and/or different vehicle another equipped with air conditioning). model year. _ the to hoses 26. Connect the heater heater unit. . 27. Install the instrument panel assembly followi proced by reversing the removal procedures. ure: of the steering column, ng At the base a. 28. If equipped with air conditioning, evacuate and recharge the system. connect the yellow 3-pin connector. b. Connect the negative battery 29. Refill the cooling system. 31 Ecable. nable 30. Connect the negative battery the r cable. bagignition c. Turn aithe by per switch ON and formin g the

1 2 3 4 5

Instalment Panel Assembly Cross Beam Assembly Instrument Panel Bracket Ventilation Lower Duct Rear Heater Duct

6 7 8 9 10 11

verify that the AIR BAG warning light flashes 7 times and then turns OFF.

temperaRtuunrethe and check for leaks. Check the s eng systems for correcitneoptoerantoiromna.l operat ing

Passport 1 . If equipped with an air bag, perform the following procedure: a. Turn the ignition to the LOCK posi¬ tion and remove the key. b. From the lower left dash side fuse

block, remove the SRS-1 fuse.

Driver Lap Vent Duct Evaporator Assembly (A/C only) Duct Heater Unit Assembly Heater Hose Resistor Connector 93113GB9

and related components— Honda Passport View of the heater and air conditioning housing assemblies

19

04

ISUZU AND HONDA

c. Disconnect the 2-pin yellow con¬

I

firewall. Plug the air conditioning lines to

b. Remove both the rear and front

t"04 • AXIOM console. T • RODEO • minimize RODEO contamination. nector located AMIGO at the base of the steering SPORT • TROOPER • VEHICROSS • PASSPOR

a

column. d. Remove the glove box assembly.

e. Disconnect the 2-pin yellow con¬ . nector located behind the glove box. 2. Disconnect the negative battery cable. 3. If equipped, discharge and recover the air conditioning system refrigerant. 4. Remove the evaporator lines at the

5. Disconnect the cooling system hoses and drain the coolant into a clean container for reuse. Plug the cooling system hoses. 6. Remove the instrument panel by per¬ forming the following procedure: screw and pull it out at the clip posit io then, disco the cigar light ns; e e nnect r tte conne Remcotor. ve t he lo wer c enter cover

c. Remove sill plates and d. Remove and the glove e. Remove

the dash side trim panel the panels. the 2 glove box screws box. the 2 hood release screws,

the 6 instrument panel driver’s lower cover assembly screws and the cover assembly. f. Remove the 5 instrument cluster

1

Heater Core

4

Mode Door

2 3

Case (Temperature Control) Heater Unit

5 6

Duct Case (Mode Control) 93113GB0

Exploded view of the heater housing assembly— Honda Passport

ket

ISUZU AND HONDA

RODEO • RODEO SPORT • TROOPER • VEHICROSS • PASSPORT screws and the 2 clips. Disconnect the 8 switch connectors and remove the instru¬ ment cluster assembly.

g. Remove the 6 driver’s knee bolster assembly bolts and screws and the knee bolster assembly. h. Remove the 4 control lever assem¬ bly bolts; then, disconnect the 3 control side) and the 3 harness con¬ cables nectors.(unit i. Remove the 4 radio/audio sub box assembly screws and the radio/audio sub box assembly. j. Disconnect or remove the following instrument panel harness connectors or items: • The 6 driver’s side connectors r’s side connectors passengeconnectors The 23 center •• The

Passenger’s inflator module con¬ • nector • Radio antenna cable plug • Ground cable bolt on the left dash side panel • The 8 instrument panel-to-chassis bolts and the 3 nuts. k. Remove the instrument panel assembly. pro the foll by per ced for owin u mRemove g ing : er’s reinflator 2 passeng the a. module bolts and 4 nuts. b. Remove the 4 meter assembly screws. Then, disconnect the meter wiring harness connectors and remove the meter assembly. c. Remove the 5 vent duct assembly screws and the assembly.

d. Remove the 3 lower passenger’s bracket screws and the bracket.

19. Install the heater core to the case. 20. Assemble the temperature control cases and install the case screws. 21. Install the mode control case and the mode control case-to-temperature control case screws. 22. Install the heater assembly. 23. Install the rear heater duct, the footrest, the carpet, and the 3 clips. 24. Install the lower ventilation duct. 25. Install the driver’s lap vent. 26. If equipped with air conditioning, install the evaporator assembly. bly.27. Install the duct to the heater assem¬

28. Connect the resistor wiring connec¬ tor. 29. Install the crossbeam, the 5 cross beam assembly nuts, 2 bolts and the 6 lower bolts. 30. Install the instrument panel bracket by performing the following procedure: a. Install the instrument panel bracket and the 2 nuts and 2 bolts for each bracket. b. Install the instrument panel wiring harness assembly and the wiring harness clips. c. Install the instrument panel center reinforcement and the 6 reinforcement screws. d. Install the passenger knee bolster reinforcement and the 9 reinforcement screws. e. Install the lower passenger bracket and the 3 bracket screws. f. Install the vent duct assembly and the 5 vent duct assembly screws. g. Install the meter assembly and the 4 meter assembly screws; then, connect the meter wiring harness connectors.

h. Install the 2 passenger’s inflator module bolts and 4 nuts. pro

fol the

ure

ced

ing

low

bly.a. Install the instrument panel assem¬

g min

b. Connect or install the following instrument panel harness connectors or items: :

12. Remove the driver’s lap vent.

To install:

for

e. Remove the 9 passenger’s knee bolster reinforcement screws and the reinforcement. f. Remove the 6 instrument panel center reinforcement screws and the rein¬ forcement. g. Remove the instrument panel wiring harness assembly clips and the wiring harness. h. Remove the 2 instrument panel bracket nuts and 2 bolts for each bracket; then, remove the bracket(s). 8. Remove the 5 cross beam assembly nuts, 2 bolts and the 6 lower bolts; then, remove the crossbeam. 9. Disconnect the resistor wiring con¬ nector. 10. Remove the duct from the heater assembly. 11. If equipped with air conditioning, remove the evaporator assembly.

13. Remove the lower ventilation duct. 14. Remove the footrest, the carpet, the 3 clips and the rear heater duct. 15. Remove the heater assembly. 16. Remove the mode control case-totemperature control case screws and remove the mode control case; do not remove the link unit. 17. Remove the temperature control case screws and separate the cases. 18. Remove the heater core from the case.

12-35

• The 6 driver’s side connectors

’s side connectors passenger The 23 center •• The connectors • Passenger's inflator module con¬ nector antenna cable plug • Radio • Ground cable bolt on the left dash side panel • The 8 instrument panel-to-chassis bolts and the 3 nuts. c. Install the radio/audio sub box assembly and the 4 radio/audio sub box assembly screws. d. Connect the 3 control cables (unit side) and the 3 harness connectors. Install the 4 control lever assembly bolts. e. Install the knee bolster assembly and the 6 driver’s knee bolster assembly bolts and screws. f. Install the instrument cluster assembly. Connect the 8 switch connec¬ tors. Install 5 instrument cluster screws and the 2 clips.

g. Install the 2 hood release screws, t panel driver’s lower the 6 instrumen cover assembly screws and the cover assembly. h. Install the glove box and the 2 glove box screws. i. Install the dash side trim panel sill plates and the panels. j. Install both the rear and front con¬ sole. k. Connect the cigarette lighter con¬ nector and install the lower center cover

screw. 32. Connect the cooling system hoses. 33. Refill the cooling system. 34. Install the evaporator lines at the firewall. 35. If equipped, evacuate and charge the air conditioning system. 36. Connect the negative battery cable. 37. If equipped with an air bag, perform the following procedure: Turn the ignition to the LOCK posi¬ tiona.and remove the key.

b. Connect the 2-pin yellow connec¬ tor located behind the glove box. c. Install the glove box assembly. d. Connect the 2-pin yellow connec¬ tor located at the base of the steering column. e. At the lower left dash side fuse block, install the SRS-1 fuse. f. Turn the ignition switch to ON and verify that the AIR BAG warning light flashes 7 times and turns OFF. 38. Run the engine to normal operating climate con¬ temperatures; then, check fortheleaks. trol operation and check

10

QC

Il"OU

ISUZU AND HONDA

AMIGO • AXIOM • RODEO • RODEO SPORT • TROOPER • VEHICROSS • PASSPORT • Engine wiring harness connectors at left rear of the engine compart¬ ment

Cylinder Head REMOVAL & INSTALLATION

• Power steering pump pressure switch connector • Front cover

2.2L Engine 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: • Negative battery cable • Intake Air Temperature (IAT) sensor connector • Positive Crankcase Ventilation (PCV) valve and hose • Air intake assembly • Upper radiator hose • Accessory drive belt • Exhaust front pipe • Alternator and brackets • Crankshaft Position (CKP) sensor connector • Knock sensor connector • Heater hoses • Water bypass hose • Fuel lines • Evaporative Emissions (EVAP) valve connector • Canister hose • Intake manifold

7

3

• Spark plugs and wires • Camshaft Position (CMP) sensor • Valve cover • Timing belt. Refer to the Timing Belt unit repair section. • Timing belt idler pulleys • Timing belt rear cover • Oil pressure switch connector • Camshafts • Cylinder head. Remove the bolts in reverse of the tightening sequence. To install:

^Use new cylinder head bolts for assembly. 5. Install the cylinder head with a new gasket. Tighten the bolts in sequence as fol¬ lows: a. Step 1: 18 ft. lbs. (25 Nm) b. Step 2: Plus 90 degrees c. Step 3: Plus 90 degrees d. Step 4: Plus 90 degrees 6. Install or connect the following: • Camshafts • Oil pressure switch connector • Timing belt rear cover

15

9

• • • •

Timing belt idler pulleys. Tighten the boltsbelt to 18 ft. lbs. (25 Nm). Timing Valve cover CMP sensor

•• Spark plugs and wires Front cover • Power steering pump pressure switch connector • Engine wiring harness connectors at left rear of the engine compart¬ ment • Intake manifold • Canister hose •• EVAP valve connector Fuel lines • Water bypass hose • Heater hoses • • • •

Knock sensor connector CKP sensor connector Alternator and brackets Exhaust front pipe

• Accessory drive belt • Upper radiator hose • Air intake assembly • PCV valve and hose • IAT sensor connector • Negative battery cable 7. Fill the cooling system. 8. Start the engine and check for leaks.

3.2L Engines 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. •Remove Hood or disconnect the following: • Negative battery cable • Engine cover • Mass Air Flow (MAF) sensor con¬ nector • Intake Air Temperature (IAT) sensor connector • Positive Crankcase Ventilation (PCV) valve assembly and hose • Air cleaner • Manifold Absolute Pressure (MAP) sensor connector • Vacuum Switching Valve (VS V) connector and vacuum line • Fuel injector connectors • Throttle Position (TP) sensor con¬ nector • Idle Air Control (IAC) valve con¬ nector • Ignition coils • Brake booster vacuum line • Canister purge vacuum line • Duty solenoid valve

Cylinder head torque sequence— 2. 2L (VIN D) engine

ISUZU AND HONDA 12 -37

• • • • • • • • • • • • • • • •

Fuel lines Intake manifold Radiator hoses Engine coolant manifold Upper fan shroud Accessory drive belt and tensioner Cooling fan and pulley Alternator Idler pulley Power steering pump and bracket A/C compressor Crankshaft pulley Oil cooler hoses Timing belt cover Valve covers Timing belt. Refer to the Timing Belt Unit Repair Section. • Left and right exhaust front pipes • Oil dipstick tube • Cylinder heads

To install:

c*>Use new head bolts when installing the cylinder head.

^The left and right cylinder head gas¬ kets are not interchangeable. 5. Install the cylinder heads with new gaskets. Tighten the bolts in sequence as follows: a. Step 1:21 ft. lbs. (29 Nm) b. Step 2: 47 ft. lbs. (64 Nm) 6. Install or connect the following: • Oil dipstick tube • Left and right exhaust front pipes • Timing belt • Valve covers • Timing belt cover • Oil cooler hoses . Crankshaft pulley. Tighten the pul¬ ley bolt to 123 ft. lbs. (167 Nm). • A/C compressor • Power steering pump and bracket. Tighten the bolts to 34 ft. lbs. (46 Nm). • Idler pulley • Alternator • Cooling fan and pulley • Accessory drive belt and tensioner • Upper fan shroud • Engine coolant manifold • Radiator hoses • Intake manifold • Fuel lines • Duty solenoid valve • Canister purge vacuum line • Brake booster vacuum line • Ignition coils • IAC valve connector • TP sensor connector • Fuel injector connectors • VSV connector and vacuum line

7924NG11

ns— 3.2L DOHC engine Right (1) and left (2) head gasket identification mark locatio

5

2

4

8 7924NG12

3.5L engines Cylinder head torque sequence — 3.2L DOHC and

HO I

QQ O • • • • • • •

ISUZU AND HONDA AMIGO • AXIOM • RODEO • RODEO SPORT • TROOPER • VEHICROSS • PASSPORT

MAP sensor connector Air cleaner assembly PCV valve and hose IAT sensor connector MAF sensor connector Engine cover Hood

• Negative battery cable 7. Fill the cooling system. 8. Start the engine and check for leaks.

3.5L Engine EXCEPT

AXIOM

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Remove or disconnect the following: • Negative battery cable • Hood • Engine cover • Mass Air Flow (MAF) sensor con¬ nector • Intake Air Temperature (IAT) sensor connector • Positive Crankcase Ventilation (PCV) valve and hose • Air cleaner assembly • Manifold Absolute Pressure (MAP) sensor connector • Vacuum Switching Valve (VSV) connector and vacuum line • Fuel injector connectors • Throttle Position (TP) sensor con¬ nector • Idle Air Control (IAC) valve con¬ nector • Ignition coils • Brake booster vacuum line • Canister purge vacuum line • Duty solenoid valve • Fuel lines • Intake manifold • Radiator hoses • Engine coolant manifold • Upper fan shroud • Accessory drive belt and tensioner • Cooling fan and pulley • Alternator • Idler pulley • Power steering pump and bracket • A/C compressor • Crankshaft pulley • Oil cooler hoses • Timing belt cover • Valve covers • Timing belt. Refer to the Timing Belt Unit Repair Section. • Left and right exhaust front pipes • Oil dipstick tube • Cylinder heads

To install: K»Use new head bolts when installing the cylinder head. Do not apply oil to the head bolt threads. all-joint 9357NG21

Exploded view of the front hub and bearing assembly— Rio

assembly, using an appropriate hub-puller • Bearing inner race from the front wheel hub the bearing inner race still remains on the hub assembly, grind a section of the bearing inner race until about 0.02 in. (0.50mm) remains. Remove with a chisel. • Retaining ring from within the knuckle • Front wheel bearing from the knuckle, using a wheel bearing removal tool to press it out 6. Clean and inspect all parts but do not wash or clean the wheel bearing. To install: 7. Install or connect the following: • New wheel bearing into the

knuckle assembly, using the press tools Wheel bearing retaining ring Front wheel hub, using a press and the correct bearing driver New oil seal using the appropriate seal driver and a hammer. Tap the oil seal in evenly until the special tool contacts the steering knuckle. Coat the lip of the oil seal with

• Halfshaft to the knuckle assembly • Wheel speed sensor, if equipped with ABS and tighten the bolts to 12-17 ft. lbs. (16-23 Nm) • Tie rod end to the knuckle and tighten the nut to 22-32 ft. lbs. (29-41 Nm) for Rio, Sephia and Spectra or to 18-25 ft. lbs. (24-34 • Nm) New for cotter pin Optima • New wheel hub locknut. Tighten the

grease. Bearing/hub and knuckle assembly in place. Loosely tighten the knuckle to shock absorber bolt. Lower arm ball joint to the knuckle. Tighten the nut to 32-40 ft. lbs. (43-54 Nm) for Sephia and Spec¬ tra, to 40-50 ft. lbs. (54-68 Nm) for Rio or to 74-88 ft. lbs. (100-120 Nm) for Optima.

nut to 155-200 ft. lbs. (214-279 Nm) for Sephia and Spectra, to 116-174 ft. lbs. (157-235 Nm) for Rio or to 148-192 ft. lbs. (200-260 Nm) for Optima. 8. Check the end-play of the wheel bearing by installing a dial indicator against the wheel hub and tire to move the brake disc back and forth. There should be no

K,A 1Q-7Q SEPHIA • SPECTRA • RIO • OPTIMA

J

■

1. Oil seal (Replace) 2. Front wheel hub 3. Retaining ring (Replace) 4. Wheel bearing

.

5. Dust shield 6. Steering knuckle 7. Wheel stud 7923KG47

Exploded view of the front hub and bearing assembly— Sephia and Spectra

more than 0.002 in. (0.05mm) of tree-play present. ing it into the gro ve. 10. Install or oconnect the following: • Brake caliper(s) and tighten the bolts to 33-50 ft. lbs. (45-67 Nm)

• Front wheels and lower the vehicle 1 1 . With the vehicle lowered check all of the bolts and retighten as necessary. 12. Inspect the front end alignment and adjust as is necessary. Rear

View of the special tool need to remove the inner and outer bearing outer races— Rio

Rio

RIO

lithium grease, using a hammer and seal installation tool • ABS sensor rotor using a flat plate to press it into place

• Inner bearings from the bearing hub

a

h

wit

are

ad sh the in l fil

• Brake drum bearings and hub on ed

• Outer bearing race using a hammer. Tap the race in until it is fully seated in the hub. . Inner bearing in the bearing hub • Oil seal after lubricating it with

. aseely grleet mp co um hi

• Inner and outer bearing outer races using special tool 0K68A 173 002 To install:

oth

ert

Ref

In

i ny

pa

m co

eac

• Anti-lock Brake System (ABS) sen¬ sor rotor using a suitable puller • Bearing oil seal and discard

^lf the bearings will be reused, they must be matchmarked so they can be installed in their original positions.

andlit

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Rear wheels • Hubcap 3. Use a small chisel to raise the staked edge of the hub lock nut. • Drum, washer and bearings as an assembly

Keep the drum cen¬ the spindle. on the spindle to prevent tered damage to the oil seal and spindle threads. • Outer bearing and washer • New hub lock nut

© (1) (2) (3) (4) (5) (6) (7)

Hubcap Locknut Washer Outer bearing Outer bearing outer race Brake drum Inner bearing outer race

(8) Inner bearing (9) (10) (11) (12)

Oil seal Sensor rotor(for ABS) Brake assembly Back plate

(13) Spindle 9357NG22

Exploded view of the rear wheel bearings and related components— Rio

6. Adjust the bearing preload to 5.6— 8.6 Hubcap Nm). ft. lbs.•(0.63-0.98 • Hub lock nut to the groove firmly SEPHIA, SPECTRA AND OPTIMA 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec2. •Remove or disconnect the following: Rear wheels • Hubcap. Hold the brake to remove the center axle nut. • Drum, if equipped with drum • Disc brake caliper, if equipped with disc brakes without disconnecting the hydraulic hose and hang it from the body. Do not let it hang by the hose. Slide the disc off the spindle. • Hub and bearing assembly off the Fill in the shaded areas with lithium grease— Rio

spindle. The hub and bearing can-

65-87 ft-lb (88-118 N*m)

7. 1.

Wheel and tire Dust cap Locknut (Replace) Brake drum (or disc) 5. Hub with bearing assembly 6. Brake line

8.

2. 3. 4.

10. 9. 11. 12.

Rear brake assembly (drum or disc) Dust cover Spindle Brake rotor Hub bolt ABS sensor rotor 7923KG48

Exploded view of the rear axle assembly— Sephia and Spectra

• Brake caliper, if equipped • New spindle nut and tighten to 131-173 ft. lbs. (177-235 Nm) for disk brakes and 155-200 ft. lbs. (209-279 Nm) for drum brakes.

not be separated and must be replaced as 1 piece. To install: 3. Install or connect the following: • Hub and drum or rotor

^

■

Brake Caliper REMOVAL & INSTALLATION Front

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Wheels • Brake hose from the caliper • Caliper guide pin bolts and caliper

BRAKES To install: 3. Install or connect the following: • Caliper and tighten the guide pin bolts to 19-21 ft. lbs. (26-28 Nm) • Brake hose and tighten to 9-13 ft. lbs. (13-18 Nm) 4. Bleed the brakes and fill the master with clean brake fluid. cylinder• Wheels Rear

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

Stake the nut into place. Replace the hubcap. • Wheel and tire assembly

• Wheels • Parking brake cable and clip • Brake hose banjo bolt

• Caliper lock bolts and the caliper To install: 3. Install or connect the following: • Caliper and tighten the lock bolts to 22-29 ft. lbs. (29-39 Nm) • Brake hose and tighten the banjo bolt to 16-22 ft. lbs. (22-29 Nm) • Park brake cable and clip 4. Bleed the brakes and fill the master • Wheels cylinder with clean brake fluid.

13-82 SEPHIA • SPECTRA • RIO • OPTIMA

(1) (2) (3) (4)

Flexible hose Bolt Cap, bolt (square head) and bushing Spring

(5) Cap and bleeder screw

(6) (7) (8) (9)

Caliper Supporting plate Brake rotor (Disc) Mounting screws 93016G15

Exploded view of the front brakes

(1) (2) (3) (4)

Parking cable, clip Connecting bolt Brake hose Lock bolt

(5) Caliper (6) V-spring (7) Disc pad

(9) Guide plate (11) Bolt Mounting support (10) (12) Caliper piston

(8) Shim

9301 6G1 6

Exploded view of the rear disc brakes

Disc Brake Pads REMOVAL & INSTALLATION Front

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Wheels • Caliper guide pin bolts and lift the caliper away from the rotor • Brake pads and retainer spring from the caliper To install: 3. Compress the caliper piston into the bore. 4. Install or connect the following: • Brake pads and retainer spring to the caliper • Caliper in position on the caliper support bracket • Guide pin bolts • Wheels

Rear

Brake Drums

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. ing:2. Remove or disconnect the follow¬ • Wheels • Parking brake cable and clip • Caliper lock bolts and remove the caliper • V-springs from the brake pads • Brake pads and shims To install: 3. Compress the caliper piston into the bore by rotating the piston with special tool OK9A4 263 001. 4. Install or connect the following: •• V-springs New pads and shims

. Caliper and tighten the lock bolts to 22-29 ft. lbs. (29-39 Nm) • Park brake cable and clip • Wheels

REMOVAL & INSTALLATION

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. • Wheels 2. Remove or disconnect the following:

• Retaining screws and brake drum. Two 8mm x 1.25 bolts can be used to press the drum from the hub. To install: 3. Install or connect the following: • Wheels Brake drum to the hub

Brake Shoes REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section.

13-84

KIA SEPHIA • SPECTRA • RIO • OPTIMA

Remove or disconnect the following: • Wheels • Retaining screws and brake drum. Two 8mm x 1.25 bolts can be used to press the drum from the hub. • Top return spring • Shoe retainer springs and pins • Adjuster spring and anti-rattle spring from the operating lever assembly

(1) (2) (3) (4) (5) (6) (7) (8)

Mounting screws Brake drum Drum pulling threads Return springs Spring clips Hold down pins Adjuster spring Brake shoe-leading

Exploded view of the rear drum brakes

To 3. above 4.

5.

• Bottom return spring • Parking brake cable from the rear shoe and remove the brake shoes install: Position the operating lever assembly the hub. Install or connect the following: • Parking brake cable to the rear shoe Fit the operating lever assembly

between the front and rear shoes and install the bottom return spring. • Shoe retainer pins and springs • Top return spring • Adjuster spring and the anti-rattle assembly spring to the operating lever • Brake drum • Wheels and adjust the brakes.

(9) Brake shoe-trailing (10) 01) Brake line (12) (13) (14) (15) 93016617

14-29 BRAKES . 14-22 DRIVE TRAIN . 14-8 . ENGINE REPAIR 14-21 FUEL SYSTEM . 14-8 PRECAUTIONS . SPECIFICATION CHARTS . 14-2 STEERING AND 14-25 SUSPENSION . A Air Bag . Disarming . Precautions . Alternator . Removal .

14-25 14-25 14-25 14-8 14-8

Brake Caliper . Removal & Installation . Brake Drums . Removal & Installation . Brake Shoes . Removal & Installation .

14-29 14-29 14-29 14-29 14-29 14-29

Camshaft and Valve Lifters . Removal & Installation . Coil Spring . Removal & Installation . CV Joint . Overhaul . Cylinder Head . Removal & Installation .

14-16 14-16 14-26 14-26 14-24 14-24 14-12 14-12

Disc Brake Pads . ation . Removal & Install E

14-29 14-29

B

C

D

Engine Assembly . Removal & Installation .

14-8 14-8

Exhaust Manifold . Removal & Installat F ion .

14-15 14-15

Front Crankshaft Seal . Removal & Installation . Fuel Filter . Removal & Installation .

14-16 14-16 14-21 14-21 14-22 14-22 14-22 14-22

Fuel Injector . Removal & Installation . Fuel Pump . Removal & Installation . Fuel System Pressure . Relieving . Fuel System Service Precautions . H

14-21 14-21 14-21

Halfshaft . Removal & Installation . Heater Core . Removal & Installa I tion .

14-22 14-22 14-11 14-11

Ignition Timing . Intake Manifold . Removal & Installa L tion .

14-8 14-14 14-14

Lower Ball Joint . Removal & Installation . Lower Control Arm . Control Arm Bushing

14-27 14-27 14-28

Replacement . Removal & Installa 0 tion .

14-28 14-28

Oil Pan . Removal & Installation . Oil Pump . Removal & Installation .

14-17 14-17 14-18 14-18

P Piston and Ring . Positioning . . . Rack and Pinion Steering Removal & Installation Rear Main Seal . Removal & Installation Rocker Arms . S ion Removal & Installat

14-21 14-21

Gear. ...14-25 14-25 . 14-18 14-18 . 14-13 14-13 .

Shock Absorber . Removal & Installation . Starter Motor . Removal & Installation . Strut . T tion . Removal & Installa

14-25 14-25 14-17 14-17 14-25 14-25

Timing Belt . Removal & Installation . Transaxle Assembly . U tion . Removal & Installa

14-19 14-19 14-22 14-22

. l Arm Contro Upper Control Arm Bushing

14-27

Replacement . V tion . Removal & Installa Valve Lash .

W Adjustment . Water Pump . Removal & Installation . Wheel Bearings . Adjustment . Removal & Installation .

14-28 14-27 14-17

14-17 14-10 14-10 14-28 14-28 14-28

Year

2002 2003

Model

Sedona Sedona

Engine Displacement Liters (cc)

3.5 (3497) 3.5 (3497)

Net

Fuel Engine VIN

1 1

Horsepower System TyPe

Borex

Torque @ rpm

Pressure

Stroke

218(5)3500

3.66x3.88

Ratio 10:01 pression

218@3500

3.66x3.88

10:01 Com¬

(ft lbs.)

195@5500 @rpm 195(9)5500

EGI EGI

Net

(in.)

43-57(5)3000 43-57(5)3000

EGI: Electronic Gasoline Injection

@ rpm

MFI: Multi-port Fuel Injection

42356-SEDO-C02

ENGINE

Year

2002 2003

Engine Displacement Liters (cc)

3.5 (3497) 3.5 (3497)

Engine VIN

1 1

Plug Gap Spark (in.)

0.039-0.043 0.039-0.043

TUNE-UP

Pump

SPECIFICATIONS

Ignition Timing

Fuel

MT —

Clearance

(rpm)

(deg.) —

Valve

Idle Speed

© AT ©

4649 4649

(psi)

MT

AT

Intake

Exhaust

600-800 | HYD 1 HYD 600-800 HYD HYD

NOTE: The Vehicle Emission Control Information label often reflects specification changes made during production. The label figures must be used if they differ from those in this chart B: Before top dead center HVD: Hydraulic

©

Computer controled, no adjustment possible 42356- SEDO-C03

3.5L engine Firing order: 1-2-3-4-5-6 Distributorless ignition system

93581 GY2

Accessory serpentine belt routing — 3.5L engine

KIA Cooling

CAPACITIES

Year 2002 2003

Model Sedona Sedona

Engine Displacement Liters (cc)

Engine VIN 1 1

3.5 (3497) 3.5(3497)

Fuel Tank

Transaxle

Engine Oil with 4.3 Filter 4.3

Manual — —

(Elii Auto. 8.5

19.8

8.5

19.8 (gal.)

System (qts.) 8.2 8.2

level is obtained. NOTE: All capacities are approximate. Add fluid gradually and ensure a proper

42356-SEDO-C04

VALVE SPECIFICATIONS Spring Maximum Engine Displacement

Engine

Seat Angle 45

2002

3.5 (3497)

2003

3.5 (3497)

Face Angle 45

1 1

45

out of Square 2 2

45

Stem-to-Guide Clearance

Free

(in.)

Length

Year 2002 2003 ©Step

Engine Displacement Liters (cc) 3.5 (3497) 3.5 (3497)

Engine VIN 1 1

Cylinder Head Bolts

1.8268

77-85 77-85

0.0020 0.00090.0020

0.0039 0.00200.0039

0.0009-

0.0020-

(in.) Intake

Exhaust

0.259

0.258

0.2580.259

0.258 0.257-

0.258-

Lug 0.25742356-SEDO-C05

SPECIFICATIONS Rod Bearing

Bolts

Bolts

Crankshaft Damper Bolts

52-59 52-59

© ©

130-138 130-138

Bearing Main

Intake

Exhaust

1.8268

NA: Not Available

TORQUE

Stem Diameter

Flywheel Bolts 54-57 54-57

Manifold Exhaust Intake © 30-37 © 30-37

Plugs Nuts Spark 15-22 15-22

65-79 65-79

1:24-27 ft. lbs.

Step 2: Plus 90-94 degrees ©Upper

15-17 ft. lbs.

Lower: 15-22 ft. lbs. 42356-SED0-C06

Top Ring

Top Ring Gap

Year 2002

Engine Displacement Liters (cc)

Engine VIN

Bottom Compression

1

3.5(3497)

~T~

2003 3.5(3497)

Piston Clearance

"

0.0020 0.00120.0020 0.0012-

0.0118 0.00790.0118 0.0079-

Compression 0.0236 0.01770.0236 0.0177-

e

Side Clearanc Bottom

Oil Control

Compression

Compression

0.0276

0.0315

0.0024

0.0016-

0.0008-

0.0079-

0.0276 0.0079-

Oil Control SNUG

0.0315

0.0016-

0.0024 0.0008-

SNUG

42356-SEDO-C07

14-6

KIA SEDONA

OEM: Original Equipment Manufacturer PSI. Pounds Per Square Inch STD: Standard OPT: Optional

©

Replace if any measurable movement

is found

BRAKE SPECIFICATIONS All measurements in inches unless noted

2002 2003

Sedona Sedona

F R F R

Original

Brake Disc Minimum Thickness

1.020

0.940

Run-out 0.0020

—

—

_

1.020 —

0.940 —

Maximum

0.0020 —

Lining

Original Inside Diameter

Max. Wear Limit

Maximum Machine Diameter

—

—

—

10.00 —

10.00

10.05 —

10.05 —

10.05

10.05

Minimum Thickness 0.100 0.040 0.100

7.2-9.4 —

18-26 —

7.2-9.4

18-26

—

—

0.040

F: Front R: Rear 42356-SED0-C11

KIA SEDONA

MAINTENANCE Kia — Sedona

SCHEDULED

VEHICLE TYPE OF SERVICE

TO BE SERVICED Accessory drive belts Air cleaner element

S/I l/R

Air conditioner system

S/I

15

7.5

Y

Y

Y

y

y

Y

Y

V Y Y

S/I R R

Enqine oil and filter

Y

Y

Exhaust system heat S/I Front and rear brakes

S/I

Front ball joints S/I

S/I R

Fuel filter Fuel lines and hoses

Locks and hinges

L

Spark pluqs

R

Y

Y

INTERVAL 75 67.5

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y Y Y

Y

Y

Y

FREQUENT

OPERATION

L: Lubricate

Y

Y

V Y Y

Y

Y

120

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y Y Y

/

Y

Y

Y Y

Y Y Y Y Y Y Y

Y Y

Y Y Y Y Y Y Y

A: Adjust

(SEVERE

Y

112. 5

ally.

Y

Y

Y

Y

Y

Y

Y Y

MAINTENANCE

Y

it annt

105

Y

R

S/I: Inspect and service, if needed

Y

97.5

Y

Y

S/I

R- Replace

90 82.5

✓

Y

Y

Steering operation and

Timing belt

(xIOOO)

Y

Y Y Y Y

S/I A

Idle speed

Y Y

MILEAGE 60 52.5

Y

Y

S/I Engine coolant

45

Inspect the system operation and refrigerant amout

Y

Cooling system hoses and CV-joint boots

37.5

Y

✓

S/I T

22.5

Y

Brake lines, hoses and Chassis and body

30

14-7

INTERVALS

Y

Y

Y Y Y Y

Y

Y

Y

✓

Y Y

T: Tighten

SERVICE)

severe service If a vehicle is operated under any of the following conditions it is considered carrier. - Towing a trailer or using a camper or car-top or trips of less than 10 miles in any temperature. • Repeated short trips of less than 5 miles in temperatures below freezing, use, such as delivery, taxi or police cars. - Extensive idling or low-speed driving for long distances as in heavy commercial - Operating on rough, muddy or salt-covered roads. - Operating on unpaved or dusty roads.

- Driving in extremely hot (over 90°F) conditions. occurs first. Engine oil and filter: replace every 5000 miles or 5 months, whichever every 30,000 miles or 30 months, whichever occurs first. Air cleaner element: inspect ever 15,000 miles or 15 months and replace miles. Fuel system hoses (California models only): replace every 105,000

miles or 55 months, whichever occurs first. Emission system hoses (non-California models): inspect every 55,000 miles or 60 months, whichever occurs first. Emission system hoses (California models): inspect every 60,000 whichever occurs first. Front and rear disc brakes: inspect every 1 5,000 miles or 15 months, whichever occurs first. Chassis and body fasteners: tighten every 15,000 miles or 15 months, occurs first. Locks and hinges: lubricate every 5000 miles or 5 months, whichever 42356-SEDO-C12

14-8 £Adona PRECAUTIONS Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle:

• Never open, service or drain the radia¬ tor or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. • Observe all applicable safety precau¬ tions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. • Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. • Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken

brake fluid internally, IMMEDIATELY seek medical assistance. • The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer. You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas as soon as possible after expo¬ sure to used engine oil. Soap and water, or waterless hand cleaner should be used. • All new vehicles are now equipped with an air bag system, often referred to as a Supplemental Restraint System (SRS) or Supplemental Inflatable Restraint (SIR) sys¬ tem. The system must be disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling proce¬ dures could result in accidental air bag deployment, possible personal injury and unnecessary system repairs. • Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a nondeployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section. • Clean, high quality brake fluid from a sealed container is essential to the safe and

proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in con¬ tact with a painted surface; it will damage the paint. • Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine damage. • Timing belt maintenance is extremely important. Many models utilize an interfer¬ ence-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing poten¬ tially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts for the recom¬ mended replacement interval for the timing belt. • Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer sys¬ tem^) and may require the computer to undergo a relearning process once the neg¬ ative battery cable is reconnected. • When servicing drum brakes, only dis¬ assemble and assemble one side at a time, leaving the remaining side intact for refer¬ ence. • Only an MVAC-trained, EPA-certified automotive technician should service the air conditioning system or its compo¬ nents.

ENGINE REPAIR Alternator

Accessory drive belt Negative battery cable

Ignition Timing

REMOVAL

This vehicle is equipped with a Distribu¬ torless Ignition System (DIS). No adjust¬ ment is necessary or possible.

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Accessory drive belt • Alternator mounting bolts • Alternator To install: 3. Install or connect the following; • Alternator • Alternator electrical connectors. Tighten the battery terminal con¬ nector nut to 60 inch lbs. (7 Nm).

Engine Assembly REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Drain the transaxle fluid. ing:4. Relieve Batterythe fuel system pressure. 5. Remove or disconnect the follow9358HG01

Alternator mounting exploded view

KIA SEDONA

14-9

No. 3 Engine mounting 66.7-93.2 (6.8-9.5,49.2-68.7)

No.2 Engine mounting

No.4 Engine mounting

Subframe

36.3-53.9 (3.7-5.5,26.8-39.8)

TORQUE

: N*m (kg*m, lb*ft)

9358HG02

Engine mount locations and torque specifications

• • • •

• • • •

• • • •

Engine cover Air cleaner assembly Engine wiring harness connectors Alternator wiring harness connec¬ tors Oil pressure switch connector Oil pressure sensor connector Starter motor wiring harness con¬ nectors Transaxle oil cooler hose Upper and lower radiator hoses Radiator Engine ground cable Brake booster vacuum hose

EVAP canister hose Fuel lines Heater hoses Throttle and cruise control cables Transaxle shift cable Power steering pump hose Oil pan shie Exhaust frontld pipe Outer tie rod ends Sway bar links Lower ball joints Axle halfshafts Intermediate shaft bolt No. 3 and 4 engine mounts

6. Support the front subframe with a suitable powertrain jack. • Subframe bolts • Impact bar bolts 7. Lower the powertrain and subframe away from the vehicle. To install: 8. Installation is the reverse of the

removal procedure, while using the follow¬ ing torque values: bolts: 88-101 ft. lbs. • Subframe (120-137 Nm) 115 Nm) • Impact bar bolts: 69-85 ft. lbs. (93-

*

N

7

2

14-10 Zom

120-137(12.2-14, 88-101)

69-85)

Impact bar

93-115(9.5-11.7,69-85)

Control link

m

*

93-115(9.5-11.7.

68.6-78.5(7.0-8.0, 50.6-57.9)

TORQUE

: N*m (kg-m, lb*ft)

Front subframe bolt locations and torque specifications

20

• Engine mount bolts: 49-69 ft. lbs. (67-93 Nm) • Engine mount through-bolts: 63-86 ft. lbs. (85-117 Nm) Nm)rod ends: 51-58 ft. lbs. (69-79 • Tie

9358HG03

-

Water Pump REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Remove or disconnect the following: • Negative battery cable • Engine cover • Accessory drive belt • Idler pulley • Crankshaft pulley

15-22N*m Water pump bolt locations and torque specifications

9358HG04

KIA SEDONA • Power steering pump pulley • Tensioner pulley

Upper and lower timing belt cov¬ • ers • • • •

No. 3 engine mount Timing belt Timing belt tensioner Water pump

To install: 4. Installation is the reverse of the removal procedure, while using the follow¬ ing torque values: • Water pump bolts: refer to the illus¬ tration • Crankshaft pulley: 130-138 ft. lbs. (180-190 Nm)

14-11

Heater Core REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

cs— (D

(1) Speaker assembly

(9) Audio panel

(2) Side cover

(10) Heater control panel

(3) Instrument cluster trim (4) Instrument cluster (5) A-pillar lower trim (6) Lower LH panel

(11) Audio (12) Glove box (13) Lower RH panel

(7) Center upper tray

(14) Center console (15) Mounting bolt

(8) Multi box

(16) Instrument panel 9358HG29

Instrument panel exploded view

14-12

.

KIA SEOONA

9358HG30

Heater unit mounting exploded view

2. Drain the cooling system. 3. Remove or disconnect the follow¬ ing:

s

nes

Bottom mounting bolts T-bar mounting bolts Side covers

har

ing

wir

tal

ng:

owi oll hef ectt

onn

lorc

Audio system speakers and mount¬ ing bolts from the top of the instru¬ ment panel Side covers T-bar mounting bolts

To install: el el pan pan t uni nt nt rs ume me to ter tr trunec Hea Ins Inscon

Ins

Negative battery cable Heater hoses Driver air bag module Steering wheel Turn signal assembly Upper and lower steering column covers A pillar upper trim Instrument cluster trim Instrument cluster A pillar lower trim Hood release handle Left lower trim panel Multi box Audio panel Ventilation control panel Radio Glove box Center console

• Bottom mounting bolts • Instrument panel wiring harness connectors • Instrument panel • Heater unit

Upper mounting bolts and audio system speakers Center console Glove box Radio Ventilation control panel Audio panel Multi box Left lower trim panel Hood release handle A pillar lower trim Instrument cluster Instrument cluster trim

• A pillar upper trim • Upper and lower steering column covers • Turn signal assembly • Steering wheel • Driver air bag module • Heater hoses • Negative battery cable 5. Fill the cooling system. Start the engine and check for leaks and proper heater operation. 6.

Cylinder Head REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: • Negative battery cable • Engine cover • Timing belt • Intake manifold • Exhaust manifolds

SEDONA Rocker arm

eflB ©

©

8-

© -

Valve spring er Lash adjust Spring seat Valve guide

Cylinder head bolt 105-115

Cylinder head (LH)

(1050-1150, 77.46 - 84.84)

Intake vafve

Cylinder block

9358HG05

Cylinder head exploded view

• Cylinder head covers • Camshafts • Rocker arms and lash adjusters ^Keep all valvetrain components in order for assembly.

• Cylinder head bolts • Cylinder heads To install:

Cylinder head bolt torque sequence

5. Install the cylinder heads with new gaskets. Tighten the bolts in sequence to 78-85 ft. lbs. (105-115 Nm). 6. Installation is the reverse of the removal procedure.

Rocker Arms

REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.2. Remove or disconnect the following: • Negative battery cable • Engine cover • Timing belt •• Cylinder Camshaftshead covers • Rocker arms and lash adjusters

14-14

KIA SEDONA

'•Keep all valvetrain components in order tor installation.

3. Inspect the roller visually. If any dam¬ age is found, replace it. 4. Check that the roller operates smoothly. If there is excessive clearance, replace it.

To install:

5. Installation is the reverse of the removal procedure.

TORQUE

: N«m (kg*cm, lb»ft)

Intake manifold exploded view

Intake Manifold

• Negative battery cable • Engine cover

REMOVAL & INSTALLATION

• Upper radiator hose • Positive Crankcase Ventilation

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

hose vacuum hose (PCV) booster • Brake • Surge tank stays • Fuel lines

2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following:

• Upper intake manifold (surge tank) • Fuel injector harness connectors

9358HG07

3 Fuel supply manifold with injectors • Upper intake manifold bolts: 11-15 attached ft. lbs. (15-20 Nm) . Engine Coolant Temperature (ECT) sensor connector Exhaust Manifold Coolant temperature gauge sensor connector REMOVAL & INSTALLATION • Thermostat • Lower intake manifold 1 . Before servicing the vehicle, refer to To install: 5. Installation is the reverse of the the precautions in the beginning of this sec¬ tion. removal procedure, while using the follow¬ 2. Remove or disconnect the following: ing torque values: Heated Oxygen (HO2S) sensor con¬ • nectors • Lower intake manifold nuts: 15-22 • Exhaust Y pipe ft. lbs. (20-30 Nm)

Oxygen sensor 40 - 50 (400 - 500, 29.51 - 36.89)

• Exhaust manifold heat shields • Exhaust manifolds To install:

nuts for ^Use only y. new gaskets and assembl

manifolds with new gas¬ Ins•talExhaust l or co nnect the fasteners to 30-37 kets. Tighten followi ft. lbs. (40-50theNm) ng: • Exhaust manifold heat shields. the bolts to 106-132 inch • Tighten Exhaust Y pipe lbs. (12-15 Nm)

1 2 - 1 5 (1 20 - 1 50, 8.85 -11.06)

9358HG08

Exhaust manifold mounting exploded view

K,AONA i SED d-lflu II4* Breather hose

• Heated Oxygen (HO2S) sensor con¬ nectors

Cylinder head cover bolt T: 5-6(50-60,3.69-4.42)

Front Crankshaft Seal REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Negative battery cable • Engine cover • Accessory drive belts • Idler pulley • Crankshaft pulley • Power steering pump pulley • Belt tensioner pulley • Upper and lower timing belt covers • No. 3 engine mount • Timing belt • Timing belt crankshaft sprocket • Crankshaft Position (CKP) sensor tone ring • Front crankshaft seal To install:

3. Install or connect the following: • Front crankshaft seal. Use Seal Driver 09214-33000 or similar. • CKP sensor tone ring • Timing belt crankshaft sprocket • Timing belt • No. 3 engine mount • Upper and lower timing belt covers • Belt tensioner pulley • Power steering pump pulley • Crankshaft pulley • Idler pulley • Accessory drive belts • Engine cover • Negative battery cable

Blow - by hose

L>

Cylinder head cover

Camshaft (EX) Bearing cap (front)

Cylinder head (LH)

T : 90- 110 (900-1100,66.39

- 81.14)

Camshaft sprocket

TORQUE

: N*m (kg-cm, lb*ft) 9358HG09

Camshaft mounting exploded view

Cylinder head (RH)

Camshaft and Valve Lifters REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Negative battery cable • Engine cover • Valve covers • Accessory drive belts • Idler pulley • Crankshaft pulley • Power steering pump pulley • Belt tensioner pulley • Upper and lower timing belt covers • No. 3 engine mount • Timing belt • Camshaft sprockets

Oil filler cap

Cylinder head (LH)

Camshaft installation alignment

N

*

^Keep all valvetrain components in order for assembly.

• • • • • •

Front bearing caps* Rear bearing caps Center bearing caps m Camshafts Rocker arms ( Hydraulic lifters

To install:

3. Set the No. 1 cylinder to Top Dead Center of the compression stroke. 4. Install the lifters and rocker arms in their original positions. 5. Install the camshafts aligned accord¬ ing to the illustration. 6. Install the bearing caps. Tighten the

bolts evenly in several passes to the follow¬ ing torque specifications: • Front and rear bearing caps: 16-19 ft. Lbs. (21 -26 Nm) • Center bearing caps: 88-106 inch lbs. (10-12 Nm) 7. Install or connect the following: • Camshaft sprockets. Tighten the bolts to 67-81 ft. Lbs. (90-110 Nm). • Timing belt • No. 3 engine mount • Upper and lower timing belt covers • Belt tensioner pulley • Power steering pump pulley • Crankshaft pulley • Idler pulley • Accessory drive belts • Valve covers. Tighten the bolts to 44-53 inch lbs. (5-6 Nm). • Engine cover • Negative battery cable

k

g

*

m

,

lb*

ft) 9358HG11

Starter motor mounting exploded view

• Starter motor. Tighten the bolts to 20-24 ft. Lbs. (27-33 Nm). • Starter heat shield • Starter motor electrical connectors. Tighten the battery terminal nut to 106-141 inch lbs. (12-16 Nm). • Shift cable • Negative battery cable

Oil Pan Valve Lash REMOVAL & INSTALLATION

3. Remove or disconnect the following: • Negative battery cable • Starter motor • Oil filter • Lower oil pan • Upper oil pan To install:

Nm) 4. Apply silicone sealant to the grove of the oil pan flange. 5. Install the upper oil pan and tighten the bolts in sequence as follows: a. Bolts 1-14: 14-20 ft. lbs. (19-28

ADJUSTMENT

This vehicle is equipped with hydraulic valve lifters. No adjustment is necessary.

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the engine oil.

Starter Motor REMOVAL & INSTALLATION

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Shift cable • Starter motor electrical connectors • Starter heat shield • Starter motor To install:

3. Install or connect the following:

Upper oil pan torque sequence

Bolts 15 and 16: 44-62 inch lbs. (5-7b. Nm)

c. Upper oil pan-to-transaxle mount¬ ing bolts: 22-33 ft. lbs. (30-42 Nm)

KIA

14-18

SEDONA

• Lower oil pan

Oil Pump

• • •• •

REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: • Negative battery cable • Engine cover • Valve covers

6. Install the lower oil pan and tighten the bolts in sequence to 86-104 inch lbs. (10-12 Nm). 7. Install or connect the following: • Oil filter • Starter motor • Negative battery cable 8. Fill the crankcase to the correct level with engine oil. 9. Start the engine and check for leaks.

•• Accessory Idler pulley drive belts • Crankshaft pulley • Power steering pump pulley • Belt tensioner pulley

• Upper and lower timing belt covers • No. 3 engine mount • Timing belt • Crankshaft sprocket • tone Crankshaf ringt Position (CKP) sensor • Oil filter • Starter motor

Upper oil pan Oil pick-up tube Oil bracket Oil filter pump valve plug Oil relief

To install:

4. Install the oil pump with a new gasket Tighten the oil pump case bolts to 106-133 inch lbs. (12-15 Nm). Tighten the oil pump cover screws to 71-106 inch lbs. (8-12 Nm) 5. Install or connect the following: • Oil relief valve plug. Tighten the

to 30-37 plugfilter bracketft. lbs. (40-50 Nm). Oil Oil pick-up tube. Tighten the bolts to 11 -16 ft. lbs. (15-22 Nm). Lower oil pan Upper Starter motor Oil filter CKP sensor tone ring Crankshaft sprocket Timing belt No. 3 engine mount Upper and lower timing belt covers Belt tensioner pulley Power steering pump pulley Crankshaft pulley Idler pulley Accessory drive belts Valve covers Engine cover Negative battery cable 6. Fill the crankcase to the correct level with engine oil. 7. Start the engine and check for leaks.

Oil pump outer rotor Oil pump inner rotor

Oil pressure switch

8-15 (80-150, 5.90-11.06) 12-15 (120-150,8.85-11.06)

Rear Main Seal

^

REMOVAL & INSTALLATION Upper baffle plate 10 - 12 (100 - 120, 7.38 - 8.85)

Gasket Sensing blade

£^ -

Crankshaft sprocket

Relief valve spring Relief valve plug

_Oil screen

40 - 50 (400 - 500, 29.51 - 36.88)

Lower baffle plate

Upper oil pan

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Front wheels Starter motor Axle halfshafts Transaxle Flexplate Oil seal housing Oil seal To install:

3. Install the oil seal to the seal housing Lower oil pan Drain plug

TORQUE

: N-m (kg -cm, Ib-ft)

30 - 45 (300 - 450, 22.13 - 33.19)

10-12(100-120,

7.38 - 8.85) 9358HG12

Oil pump and oil pan mounting exploded view

using special tool 09231-33000 or similar seal driver. 4. Apply silicone sealant to the oil seal housing flange. 5. Install the seal housing and tighten the bolts to 94-106 inch lbs. (10-12 Nm).

KIA SEDONA

14-19

Tensioner

6. Install or connect the following: • Flexplate. Tighten the bolts to 5457 ft. lbs. (73-77 Nm) • Transaxle • Axle halfshafts • Starter motor • Front wheels • Negative battery cable 7. Fill the crankcase to the correct level with engine oil. 8. Start the engine and check for leaks.

pulley socket

Timing Belt

9358H627

REMOVAL & INSTALLATION

Adjusting the tensioner pulley-Kia 3.5L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

ing:

2. Remove or disconnect the follow¬

• Negative battery cable • Engine cover • Accessory drive belts • Idler pulley • Crankshaft pulley • Power steering pump pulley • Belt tensioner pulley • Upper and lower timing belt covers 3. Support the engine with a floor jack and remove the engine mount. Water pump pulley Timing mark Timing mark

Camshaft sprocket

Cam Position Sensor(CPS) Idler pulley

Tensioner arm Tensioner pulley

Engine support tower bracket

Crank Angle Sensor(CAS)

Auto tensioner

Crankshaft sprocket

IS

Engine Timing belt routing and timing marks-Kia 3.5L

Timing mark 9358HG25

14-20 KIA

SEDONA 9

. 4. Rotate the engine to align the lation by compressing it in a vise and installing a retaining pin. camshaft sprocket timing marks with the 8 cylinder head cover timing marks. . 5. Remove or disconnect the follow¬ ing order: ing: a. Crankshaft sprocket b. Idler pulley • Auto tensioner Install th e timiexhaust ng belt camshaft c. Left bank sprocket • Timing belt in the low¬ To install: d. Left bank intake camshaftfolsprocket e. Water pump pulley 6. Ensure that the engine is set to Top Dead Center (TDC). f. Right bank intake camshaft 7. Prepare the auto tensioner for instal¬ sprocket

g. Right bank exhaust camshaft h. Tensioner pulley sprocket

remove the retaining pin at this time. 10. InCheck crankshaft and stall ththat e autthe o t e sionealigned camshaft timing marks nare r. Do ncorrectly ot 1 1 . Rotate the crankshaft 14 turn Coun¬

terclockwise

12. Rotate the crankshaft 14 turn Clock wise to return the engine to TDC.

Camshaft sprocket 90-110(900-1100,

65-80)

20-27 (200 - 270, 14-20)

43 - 55 (430 - 550, 31 - 39)

Timing belt upper cover

Crankshaft pulley

Timing belt lower cover

180-190 (1800-1900, 130-138)

50 - 60 (500 - 550, 31 - 39)

TORQUE

: N*m (kg*cm, lb*ft) 9358HG26

Timing belt exploded view-Kia 3.5L Engine

13. Loosen the tensioner pulley center bolt. 14. Apply 44 inch lbs. (5 Nm) torque to the tensioner pulley as shown and tighten the center bolt to 32-41 ft. lbs. (43-55 Nm). 15. Remove the auto tensioner retaining

fl

pin. 16. Rotate the crankshaft 2 revolutions Clockwise, then wait 5 minutes for the

auto tensioner to adjust. 17. Measure the auto tensioner rod as shown. It the measurement is not 3. 8-4.5 mm, then repeat the belt tensioning proce¬ dure. 18. When the auto tensioner measure¬ ment is correct, install or connect the fol-

jlowing: • • • • • • • • •

Engine mount Upper and lower timing belt covers Belt tensioner pulley Power steering pump pulley Crankshaft pulley Idler pulley Accessory drive belts Engine cover Negative battery cable

Piston and Ring

ring gap

rail gap Upper side

Front side of engine

No.2 ring gap and spacer expender gap 9358HG16

POSITIONING

Piston ring end gap spacing

FUEL SYSTEM Fuel System Service Precautions Safety is the most important factor when performing not only fuel system mainte¬ nance, but any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle’s fuel system components can be accomplished safely and effectively by the following rules and guide¬ adherin lines. g to • To avoid the possibility of fire and per¬ sonal injury, always disconnect the negative battery cable unless the repair or test proce¬ dure requires that battery voltage be applied. • Always relieve the fuel system pres¬ sure prior to disconnecting any fuel system component (injector, fuel rail, pressure reg¬ ulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may pene¬

trate the skin or any part of the body that it contacts. • Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suit¬ able waste container. • Always keep a dry chemical (Class B) fire extinguisher near the work area. • Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame.

• Always use a back-up wrench when loosening and tightening fuel line connec¬ tion fittings. This will prevent unnecessary stress and torsion to fuel line piping.

Fuel System Pressure RELIEVING

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the rear seat. 3. Remove the access cover 4. Disconnect the fuel pump electrical connector. 5. Start the engine and allow it to run until it stalls. 6. Turn the ignition switch to the OFF

the electrical connections 7. Restore . position after fuel system repairs are completed.

Always follow the proper torque specifica¬ tions.

REMOVAL & INSTALLATION

• Always replace worn fuel fitting Fi¬ rings with new. Do not substitute fuel hose or equivalent where fuel pipe is installed.

The fuel filter is located inside the fuel tank and is replaced with the fuel pump as an assembly.

KIA 9 SEDONA d-9CL. IIH

9

Fuel Pump

• Fuel lines

• Access cover • Rear seat

• Upper intake manifold (surge tank) • Fuel injector harness connectors • Fuel supply manifold with injectors attached

5 REMOVAL & INSTALLATION .

1. Before servicing the vehicle, refer to . the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: 1 • Rear seat • Access cover • Fuel pump electrical connector 3. Relieve the fuel system pressure. 0 • Fuel lines • Fuel pump and filter assembly

To install:

4. Install or connect the following: • Fuel pump . and filter assembly • Fuel lines • Fuel pump electrical connector

Fuel Injector

To install:

Start th ngine an REMOVAL e& eINSTALLATION d check for leaks.

4. Replace all injector seals. 5. Install or connect the following: • Fuel supply manifold with injectors attached • Fuel injector harness connectors Upperlines intake manifold (surge tank) • Fuel

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: • Negative battery cable • Engine cover • Positive Crankcase Ventilation

• Surge tank stays • Brake booster vacuum hose • Positive Crankcase Ventilation (PCV) hose • Engine cover • Negative battery cable 6. Start the engine and check for leaks.

hose vacuum hose • (PCV) Brake booster • Surge tank stays

DRIVE TRAIN Transaxle Assembly REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Drain the transaxle fluid. 4. Remove or disconnect the following: • Battery and tray • Engine wiring harness • Transaxle wiring harness • Air filter assembly • Shift cable • Transaxle cooler lines • Radiator hoses • Radiator • Heater hoses • Steering intermediate shaft • Power steering pressure and return lines from the steering gear • Engine upper roll stopper and bracket • Front wheels • Heated Oxygen (HO2S) sensor con¬ nector • Front muffler • Outer tie rod ends • Lower ball joints • Axle halfshafts • Steering tube mounting bolt 5. Support the engine from below. • Front subframe • Starter motor • Transaxle housing cover

6. Support the transaxle with a trans¬ mission jack. • Torque converter bolts • Transaxle flange bolts • Transaxle

Fill

lin

g sy ste REMOVAL & INSTALLATION m.

To install:

7. Install or connect the following: • Transaxle. Tighten the flange bolts to 29-38 ft. lbs. (42-54 Nm) • Torque converter bolts • Transaxle housing cover • Starter motor • Front subframe • • • • •

Steering tube mounting bolt Axle halfshafts Lower ball joints Outer tie rod ends Front muffler

• Heated Oxygen (HO2S) sensor con¬ nector • Front wheels • Engine upper roll stopper and bracket • Power steering pressure and return lines from the steering gear • Steering intermediate shaft • Heater hoses • Radiator • • • • • • •

Radiator hoses Transaxle cooler lines Shift cable Air filter assembly Transaxle wiring harness Engine wiring harness Battery and tray 8. Fill the transaxle to the correct level with the proper transmission fluid.

t

he c Halfshaft oo

Star

t th 1. Before servicing the vehicle, refer to e en gin the precautions in the beginning of this sec¬ e an d c tion. hec k ftransaxle 2. Drain the fluid. or l e a ks 3. Remove or disconnect the following: • Front wheels . • Hub retaining nuts

• Sway bar links • Outer tie rod ends • Lower ball joints 4. Using a prybar, remove the left half¬ shaft from the transaxle. Separate the right halfshaft from the intermediate shaft. 5. Remove the axle halfshafts from the front hubs. It may be necessary to tap the stub shaft with a brass hammer to remove the axles. To install: ^Use new circlips for assembly.

6. Install the left halfshaft to the transaxle. 7. Install the right halfshaft to the inter¬ mediate shaft. 8. Install the halfshaft stub shafts to the wheel hubs. 9. Install or connect the following: • Lower ball joints. Tighten the pinch bolts to 69-85 ft. lbs. (93-115 Nm). • Outer tie rod ends. Tighten the nuts to 43-58 ft. lbs. (59-78 Nm).

(1) (2) (3) (4)

Wheel nut Driveshaft(RH) Circlip Center bearing bracket

Halfshaft mounting exploded view

(5) (6) (7) (8)

constant velocity shaft Automatic transaxle Driveshaft(LH) Circle pin 9358HG17

KIA

14-24

SEDONA

• Sway bar links. Tighten nuts to 6985 ft. lbs. (93-115 Nm). • Hub retaining nuts. Tighten the hub nuts to 177-1 99 ft. lbs. (240-270 Nm). • Front wheels. Tighten the lug nuts to 65-79 ft. lbs. (88-108 Nm). 10. Fill the transaxle to the correct level with the proper fluid. 11. Start the engine and check for leaks.

Inner Tripod Joint

CV Joint OVERHAUL Outer CV Joint

The outer CV joint is serviced only with the axle halfshaft as an assembly. The outer CV joint boot can be serviced by first removing the inner Tripod joint.

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the axle halfshaft from the vehicle and place it in a vise. 3. Remove or disconnect the following: • Tripod joint boot clamps. Slide the boot on the axle shaft to expose the • Circle pin

joint.

Driveshaft(LH)

(1) (2) (3) (4) (5)

BJ assembly BJ inner race and ball Snap ring BJ boot BJ boot band

(6) Driveshaft(LH)

(7) UTJ boot band (8) UTJ boot (9) Circle pin

(10) Spider assembly (11) Snap ring (12) UTJ assembly (13) Circlip Driveshaft(RH) (14) (15) (16) (17)

UTJ assembly Snap ring Spider assembly Circle pin

(18) UTJ boot (19) UTJ boot band (20) Driveshaft(RH) (21) BJ boot band (22) BJ bootring (23) Snap (24) BJ inner race and ball (25) BJ assembly

Caution

a) b) c) d)

Install a protective material in a vice, and secure joint in the vice. Keep dust or foreign material from joint during procedure. Do not disassemble wheel side ball joint. Do not wash joint unless disassembling it. 9358HG18

Inner and outer CV Joint exploded view and parts identification

5 • • • •

. Tripod joint housing Tripod joint snapring Tripod joint Inner Tripod joint boot

Inner Tripod joint boot Tripod joint Tripod joint snapring Tripod joint housing. Fill with 7.5 ounces of CV Joint grease. Circle pin

To install:

STEERING AND SUSPENSION Air Bag ** CAUTION

Some vehicles are equipped with an . Install o r system. connect The system must be air bag the follo ing service wing: disarmed before perform on, or around, system components, the steering column, instrument panel components, wiring and sen¬ sors. Failure to follow the safety pre¬ cautions and the disarming procedure could result in accidental air bag deployment, possible injury and unnecessary system repairs.

PRECAUTIONS

Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible per¬ sonal injury. • Never carry the inflator module by the wires or connector on the underside of the i module. • When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed away. • Place the inflator module on a bench or other surface with the bag and trim cover facing up. • With the inflator module on the bench, never place anything on or close to the module which may be thrown in the event of an accidental deployment.

Rack and Pinion Steering Gear REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the power steering fluid. ing:3. Remove or disconnect the follow¬ • • • •

Negative battery cable Front wheels Outer tie rod ends Power steering fluid pressure and return lines • Steering intermediate shaft • Steering rack brackets and fasten¬ ers 4. Remove the steering gear through the right wheel opening. To install:

5. Install the steering gear through the right wheel opening. 6. Install or connect the following:

• Steering rack brackets and fasten¬ ers. Tighten the fasteners to 55-69 ft. lbs. (74-93 Nm). • Steering intermediate shaft. Tighten 26 pinch bolt to 16-20 ft. lbs. (21the Nm). • Power steering fluid pressure and return lines. Tighten the bolts to 17-26 ft. lbs. (24-35 Nm). • Outer tie rod ends. Tighten the Nm). nuts to 43-58 ft. lbs. (59-78 • Front wheels

DISARMING

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Position the vehicle with the front wheels in a straight-ahead position. 3. Disconnect both battery cables. 4. Wait at least 1 minute for the air bag back-up power supply to deplete its stored energy before continuing. 5. Proceed with the repair. 6. Reconnect both battery cables once the repair is complete.

• Negative battery cable

Strut REMOVAL & INSTALLATION Front

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Front wheel

• Tripod joint boot clamps. Pull on the clamp end with pliers and fold the locking tabs over to lock the clamp in place.

vehiclIen.stall the axle halfshaft

to the

• Brake hose from the bracket • Wheel speed sensor cable • Steering knuckle mounting bolts • Upper strut mount nuts 3. Remove the strut from the vehicle. To install:

4. Install the strut to the vehicle. 5. Install or connect the following: • Upper strut mount nuts and 62 Nm). tighten them to 33-46 ft. lbs. (46• Steering knuckle mounting bolts and tighten them to 88-101 ft. lbs. (119-137 Nm). • Wheel speed sensor cable • Brake hose to the bracket • Front wheel

6. Check the front end alignment and adjust as necessary.

Shock Absorber REMOVAL & INSTALLATION Rear

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Support the rear axle on jack stands. ing: 3. Remove or disconnect the follow¬ • Rear wheel • Shock absorber upper nut and washer • Shock absorber lower nut and washer • Shock absorber To install:

4. Install or connect the following: • Shock absorber . Shock absorber lower nut and

washer. Tighten the nut to 55-69 ft. lbs. (74-93 Nm). • Shock absorber upper nut and washer. Tighten the nut to 41-47 ft. lbs. (55-64 • Rear wheel Nm).

14-26

KIA SEDONA

Coil Spring REMOVAL & INSTALLATION Front

• Upper mount retaining nut and 137 Nm). tighten it to 88-101 ft. lbs. (1206. Install the strut to the vehicle. 7. Check the front end alignment and adjust as necessary.

To install:

5. Install or connect the following: • Lower spring seat • Bump stopper • Dust boot • Coil spring

Rear

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the vehicle with jackstands forward of the lower control arm mounting.

• Upper spring isolator

©

)

0

1

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the strut from the vehicle and attach Service Tool 0K2A1 341 001 or other suitable spring compressor. 3. Compress the coil spring. 4. Remove or disconnect the following: • Upper mount retaining nut

• Upper spring seat • Mounting block

• Mounting block • Upper spring seat Uppersprspring • Coil ing isolator • Dust boot • Bump stopper • Lower spring seat

(1) Piston retaining nut (2) Washer (3) Mounting block

(6) (7) (8) (9)

(4) Upper spring seat

(5) Upper spring isolator

Dust boot Bump stopper Coil spring Lower spring isolator 9358HG19

Front strut and coil spring exploded view

Sho c

3. Support the rear axle with jackstands. 4. Support the lower control arm with a oor jack. 5. Remove or disconnect the following: • Rear wheel • Sway bar link • Parking brake cable • Lower control arm bolts 6. Carefully lower the floor jack and ;emove the lower control arm, coil spring, tnd spring seats from the vehicle. To install:

7. Install or connect the following: • Spring seats • Coil spring • Lower control arm. Tighten the

(1) (2) (3) (4)

Stabilizer bar Shock absorber Panhard rod Upper arm assembly

Nm). bolts to 87-101 ft. lbs. (118-137

Upper Control Arm

• Parking brake cable. Tighten the bracket 23 Nm). bolts to 14-19 ft. lbs. (16-

REMOVAL & INSTALLATION

• Sway bar link. Tighten the locknut to 17-20 ft. lbs. (24-28 Nm). • Rear wheel

Rear

Lower Ball Joint REMOVAL & INSTALLATION

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the vehicle with jackstands forward of the lower control arm mounting. 3. Support the rear axle with jackstands. 4. Remove or disconnect the following: • Rear wheel

The ball joint is serviced with the lower control arm as an assembly.

• Upper control arm mounting bolts • Upper control arm

(5) Lower arm assembly (6) Coil spring (7) Rear casing 9358HG20

Rear suspension exploded view

14-28 SEDONA

To install: 4 . • Upper control arm • Upper control arm mounting bolts. Tighten the bolts to 55-69 ft. lbs. (74-93 Nm). 5. • Rear wheel Install or connect t he folREPLACEMENT lowing: CONTROL ARM BUSHING

The upper control arm bushings are ser¬ viced with the control arm as an assembly.

Lower Control Arm REMOVAL & INSTALLATION Front

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Front wheel • Sway bar link • Tension rod bolts • Lower ball joint • Lower control arm subframe bolt • Lower control arm To install:

3. Install or connect the following: • Lower control arm. Tighten the subframe bolt to 88-101 ft. lbs. (120-137 Nm). • Lower ball joint. Tighten the pinch bolt to 69-85 ft. lbs. (93-115 Nm). • Tension rod bolts and tighten them to 88-101 ft. lbs. (120-137 Nm) • Sway bar link. Tighten the nut to 69-85 ft. lbs. (93-115 Nm).

• Front wheel

Wheel Bearings

adjust as necessary

ADJUSTMENT

RearCheck th e front e nd align ment

Front

.

nd to 1 . Before servicing the vehicle, arefer the precautions in the beginning of this sec¬ tion. 2. Support the vehicle with jackstands forward of the lower control arm mounting. 3. Support the rear axle with jackstands. 4. Support the lower control arm with a floor jack. 5. Remove or disconnect the following: • Rear wheel • Sway bar link • Parking brake cable • Lower control arm bolts 6. Carefully lower the floor jack and remove the lower control arm, coil spring, and spring seats from the vehicle.

The front wheel bearings are not adjustable. Replace the wheel bearings if play exceeds 0.002 inches (0.05 mm). Rear

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. •Remove or disconnect the following: Rear wheel • Brake drum • Hub cover • Cotter pin • Lock nut cover 3. Adjust the locknut to achieve wheel

To install:

bearingmm). play of 0.001-0.006 inches (0.0250.152

7. Install or connect the following: • Spring seats • Coil spring

REMOVAL & INSTALLATION

• Lower control arm. Tighten the Nm). bolts to 87-101 ft. lbs. (118-137 • Parking brake cable. Tighten the 23 Nm). bolts to 14-19 ft. lbs. (IBbracket • Sway bar link. Tighten the locknut to 17-20 ft. lbs. (24-28 Nm). • Rear wheel

Front '■►The front wheel bearings are ser¬ viced with the steering knuckle as an assembly.

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Front wheel

CONTROL ARM BUSHING REPLACEMENT

• Brake caliper and rotor •• Wheel Hub nutspeed sensor harness

The lower control arm bushings are ser¬ viced with the control arm as an assembly.

• Lower ball joint • Strut mounting bolts • Steering knuckle To install:

3. Install or connect the following: • Steering knuckle Nm). • Strut mounting bolts and tighten them to 88-1 01 ft. lbs. (119-137 • Lower ball joint. Tighten the pinch bolt to 69-85 ft. lbs. (93-115 Nm). • Hub nut and tighten it to 177-199 ft. lbs. (240-270 Nm). • Wheel speed sensor harness • Brake caliper and rotor • Front wheel 4. Check the alignment and adjust as necessary. (1) (2) (3) (4)

Knuckle Shock absorber Tie rod end Stabilizer bar

Rear

(5) Stabilizer control link (6) Tension rod (7) Lower arm 9358HG21

Front suspension exploded view

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

KIA SEDONA

• • • • • • •

Rear wheel Brake drum Hubcap Cotter pin Lock nut cover Lock nut Wheel bearing retainer washer and the outer wheel bearing • Hub assembly • Grease seal

• Inner wheel bearing

14-29

• Hub assembly

3. Clean and inspect the wheel bearings and races for unusual wear or damage. Replace parts as necessary.

• Lock nut. Adjust the locknut to achieve wheel bearing play of mm). 0.001-0.006 inches (0.025-0.152

4. Pack the wheel bearings with grease for assembly. 5. Install or connect the following: • Inner wheel bearing • Grease seal

•• Lock nutpincover Cotter Hubcap

To install:

• Brake drum • Rear wheel

BRAKES Brake Caliper REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Front wheel • Brake fluid hose • Caliper mounting bolts • Brake caliper To install:

3. Install or connect the following: • Brake caliper. Tighten the mount¬ ing bolts to 18-26 ft. lbs. (24-35 Nm). • Brake fluid hose • Front wheel 4. Bleed the brake system. 5. Before attempting to move the vehicle, pump the brake pedal to seat the pads against the rotors. Make sure the vehicle has a firm brake pedal. Check the level of the brake fluid and add DOT 3 or 4 brake fluid if necessary.

Disc Brake Pads REMOVAL & INSTALLATION

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Front wheel • Brake hose from the support bracket • Outer brake pad retaining clip • Brake caliper • Inner and outer brake pads To install:

3. Compress the caliper piston into the caliper bore. 4. Install or connect the following: • Inner and outer brake pads

• Brake caliper. Tighten the mount-

Nm). ing bolts to 18-26 ft. lbs. (24-35 Brake hose to the support bracket Front wheel

Brake Drums REMOVAL & INSTALLATION

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

ing:2. Remove or disconnect the follow¬ • Rear wheel • Brake drum retaining screws • Brake drum To install:

3. Install or connect the following: • Brake drum • Brake drum retaining screws • Rear wheel

Brake Shoes REMOVAL & INSTALLATION

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. ing: 2. Remove or disconnect the follow¬ • Rear wheels • Brake drum • • • • •

Brake adjuster spring Adjuster lever Strut spring and retracting spring Upper return spring Hold-down spring and pins

• Leading (primary) brake shoe • Trailing (secondary) brake shoe • Parking brake cable To install:

3. Transfer the parking brake lever to the new trailing (secondary) brake shoe. 4. Install or connect the following:

KIA NA iIHd-^OUn SEDO • • • • • • • • • •

Parking brake cable Trailing (secondary) brake shoe Leading (primary) brake shoe Hold-down spring and pins Upper return spring Strut spring and retracting spring Adjuster lever Brake adjuster spring Brake drum Rear wheels

5. Work the parking brake control sev¬ eral times to complete the brake shoe adjustment and to check the parking brake adjustment as well. 6. Pump the brake pedal several times to assure a good pedal. 7. Road test the vehicle and check for proper brake system operation.

Brake adjuster assembly

Strut spring

Retracting spring 9358HG24

Brake strut spring and retracting spring

P

15-39 BRAKES . 15-25 DRIVE TRAIN . 15-9 ENGINE REPAIR . 15-23 FUEL SYSTEM . 15-9 PRECAUTIONS . SPECIFICATION CHARTS . 15-2 STEERING AND 15-33 SUSPENSION . A Air Bag . Arming . Disarming . Precautions . Alternator . Removal . Axle Shaft Bearing and Seal . Removal & InstalBlation .

15-33 15-33 15-33 15-33 15-9 15-9 15-32 15-32

Brake Caliper . Removal & Installation . Brake Drums . Removal & Installation . Brake Shoes . Removal & InstalClation .

15-39 15-39 15-39 15-39 15-39 15-39

Camshaft . Removal & Installation . Clutch . Adjustment . Removal & Installation . Coil Spring . Removal & Installation . Cylinder Head . Removal & InstalDlation .

15-18 15-18 15-27 15-27 15-28 15-35 15-35 15-14 15-14

Disc Brake Pads . Removal & Install Eation .

15-39 15-39

Engine Assembly . Removal & Installation .

15-10 15-10

Exhaust Manifold . Fation . Removal & Install

15-17 15-17

Front Crankshaft Seal . Removal & Installation . Fuel Filter . Removal & Installation . Fuel Injector . . . Removal & Installation . Fuel Pump . Removal & Installation . Fuel System Pressure . Relieving . . . Fuel System Service

15-18 15-18 15-24 15-24 15-25 15-25 15-24 15-24 15-23 15-23

H Precautions .

15-23

Halfshaft . Removal & Installation . Heater Core . Removal & Installation . Hydraulic Clutch System . Bleeding .

15-30 15-30 15-12 15-12

Ignition Timing . Adjustment . Intake Manifold . Removal & InstalLlation .

15-9 15-9 15-16 15-16

Locking Hubs . Removal & Installation . Lower Ball Joint . Removal & Installation . Lower Control Arm . Lower Control Arm Bushing

15-30 15-30 15-36 15-36 15-37

Replacement . Removal & Instal0lation .

15-38 15-37

Oil Pan . Removal & Installation . Oil Pump . Removal & Installation .

15-28 15-28

Adjustment . R ation . Removal & Install

15-33 15-33 15-23 15-23 15-33 15-33 15-33

Rear Main Seal . Sation . Removal & Install

15-21 15-21

Shock Absorber . Removal & Installation . Spindle Bearings . Removal & Installation . Starter . T ation . Removal & Install

15-34 15-34

Timing Belt . Removal & Installation . Transfer Case Assembly . Removal & Installation . Transmission Assembly . U ation . Removal & Install

15-22 15-22 15-29 15-29 15-25 15-25

Upper Ball Joint . Removal & Installation .

15-36 15-36

Upper Control Arm . Removal & Installation . Upper Control Arm Bushing

15-37 15-37

Replacement .

15-37

Pinion Seal . Removal & Installation . Piston and Ring . Positioning . Power Steering Gear .

Valve Lash .

15-19 15-19 15-20 15-20

W

Adjustment . Water Pump . Removal & Installation . Wheel Bearings . Adjustment . Removal & Installation .

15-32 15-32 15-19 15-19

15-19

15-19 15-12 15-12 15-38 15-38 15-38

SPORTAGE

2KIA

SPECIFICATION CHARTS

ENGINE AND VEHICLE IDENTIFICATION Model Year

Engine Code ©

Liters (cc)

3

2.0(1998)

Cu. In.

Cyl.

Fuel Sys.

122

4

MFI

Engine Type

Code®

Eng. Mfg.

DOHC

KIA

MFI: Multi-port Fuel Injection

Y

DOHC:

1

©8th ©10th

Double Overhead Camshafts digit of VIN digit of VIN

2002

Year

2003

ENGINE SPECIFICATIONS Net

Fuel Engine VIN

Displacement Liters (cc)

Model

2002

2003

3

Engine

2001

2001

2

GENERAL

2000

Year 1999 2000

X

Spoilage

2.0(1998)

3

Sportage

2.0(1998)

3

Spoilage

2.0(1998)

3

Sportage

2.0(1998)

3

Horsepower @ rpm

System TVPe MFI MFI MFI MFI

42356-KSPO-COI

Oil

Borex

Net Torque @ rpm (ft. lbs.)

Stroke

Pressure @ rpm

Ratio (in.)

130 @5500

127 @4000

3.39x3.39

13005500

127 0 4000

3.39x3.39

130 @5500

127 @4000

3.39x3.39

13005500

127 @4000

3.39x3.39

pression 9.2:1 Com¬ 9.2:1 9.2:1

43-57© 43-57© 43-57© 43-57©

9.2:1

MFI: Multi-port Fuel Injection

©The

manufacturer does not provide an engine speed specification for oil pump pressure.

42356-KSPO-C02

ENGINE TUNE-UP SPECIFICATIONS Ignition Engine Year

Displacement Liters (cc)

2000

2.0(1998)

2001

2.0(1998)

2002

2.0(1998)

Spark Plug Engine -

— -

Gap (iH)

4B

0.043 0.039-

4B

(deg.)

Pump

4B AT

38

(psi)

4B

4B

38 4B

(rpm) MT AT

750-850

750-850

750-850

750-850

4B

3

3

Speed

Valve Clearance Intake Exhaust HYD. HYD.

38

3

0.043 0.0392.0(1998)

Fuel

3

0.043 0.039-

2003

Timing

idle

750-850

4B 38

750-850

HYD. HYD.

750-850

HYD. HYD.

750-850

HYD.

HYD.

0.043 0.039B: Before Top Dead Center HYD: Hydraulic lash adjusters 42356-KSP0-C03

KIA SPORTAGE

15-3

22 lb (98 N)

Generator

Front of the Vehicle

i

79243G63 79244G57

Firing order: 1-3-4-2 Distributorless ignition system (one coil on each cylinder)

Accessory drive belt routing

and check to be sure a proper fluid level is obtained. NOTE: All capacities are approximate. Add fluid gradually

15-4

KIA SPORTAGE

CRANKSHAFT

AND CONNECTING

All measurements are given in inches. Crankshaft

Engine

Main Brg. Engine

Year

Displacement Liters (cc)

2000

2.0(1998)

3

Journal Dia.

VIN

Main Brg. Oil

© 2.35972.3604

2002

2.0(1998)

3

2.0(1998)

©Journals

3

Oil Clearance

Side Clearance

2.0061 2.0055-

0.0021

0.0103

0.00900.0021

0.00400.0103

2.0061 2.0055-

3 0.0071 0.0031-

© 2.35972.3604

Journal Diameter

3 0.0071 0.0031-

©

3

Thrust

0.0071 0.0031-

2.3604 2.35972003

Connecting Rod

on No.

©

3

2.0(1998)

Shaft End-play

Clearance

2.35972.3604 2001

ROD SPECIFICATIONS

3 0.0071 0.0031-

0.0090-

2.0061 2.0055-

0.0021 0.0090-

2.0061

0.0021

2.0055-

0.0090-

1, 2 and 4: 0.0010 - 0 0017 in.

0.00400.0103 0.00400.0103 0.0040-

Journal 3: 0.0012 - 0.0019 in. 42356-KSPO-C05

VALVE SPECIFICATIONS Spring

Stem Diameter

Stem-to-Guide Engine

Seat

Face

Engine VIN

Angle

Year

Displacement Liters (cc)

Angle (de9)

2000

2.0(1998)

3

45

(deg.)

45 45

Spring Test Pressure

Installed Height

(lbs. 9 in.)

(in.)

©

©

45 2001

2.0(1998)

3

45

©

©

45 2002

2.0(1998)

3

©

45

©

45 2003

2.0(1998)

3

©

©

Clearance (in.) Intake Exhaust 0.0024 0.00100.0024 0.00100.0024 0.00100.0024 0.0010-

©

Spring test pressure or installed height not provided by the manufacturer.

0.0026 0.0012-

(in.) Intake Exhaust 0.2356

0.2354

0.2350-

0.0026

0.2356

0.23480.2354

0.00120.0026

0.23500.2356

0.23480.2354

0.23500.2356

0.23480.2354

0.2350-

0.2348-

0.00120.0026 0.0012-

Valve Spring Free Length: Outer spring: 1.524-1.539 in. Inner spring: 1.484-1.496 in. 42356-KSPO-C06

KIA SPORTAGE

Top

15-5

T

op SPECIFICATIONS PISTON AND RING

_

All measurements are given in inches.

Year 2000

Displacement Liters (cc)

Engine VIN

2.0(1998)

3

_

Piston Clearance

Compression

2.0(1998)

2.0 (1998)

3

3

2.0(1998)

0.012 0.006-

TORQUE

0.003

0.0010.003

SNUG

0.0010.003 SNUG

0.008-

0.014 0.008-

3

0.00190.0024

0.0080.028

0.014 0.008-

0.012 0.006-

0.003

0.028

0.014 0.008-

0.012 0.006-

0.00190.0024

2003

Control Oil

0.012 0.006-

0.00190.0024

2002

Compression

Compression

SNUG 0.00190.0024

2001

Ring Side Clearance Bottom

Ring Gap _ Bottom Oil Control Compression

0.014 0.008-

0.028

0.0010.003

0.0080.028

0.0010.003

0.003 0.001SNUG 0.003 0.001-

Lug

0.008-

0.001-

42356-KSP0-C07

0.001-

SPECIFICATIONS

All readings in ft. lbs. Engine Displacement Liters (cc)

Engine VIN

2000

2.0(1998)

3

2001

2.0(1998)

3

2002

2.0(1998)

3

| 2003

2.0(1998)

3

Year

Cylinder Head Bolts

Main Bearing Bolts

Rod Bearing Bolts

Crankshaft Damper Bolts 11

63 62 62 62 62

63

Flywheel Bolts

11

50

63

50

11

63

50

11

Plugs

Manifold Intake

73

16

73 73 73

16

Exhaust

16

11-17

16

31

11-17 11-17

ALIGNMENT

Caster Range Year

Model

Range

+3.58

0.75

+3.58

0.75

+3.58

0.75

+3.58

0.75

Sportage

0.75

2001

Sportage

0.75

2002

Sportage

0.75

2003

Sportage

0.75

Axis

(Deg)

(Deg)

(Deg.)

2000

Setting Preferred

(+/-Deg.)

(+/-Deg.)

42356-KSP0-C08

Steering Camber

Preferred Setting

73 73

31

31

WHEEL

73

Spark 11-17

31

50

73

Nuts

inclination (in.) Toe-in

+0.44

0.10+/-0.10 0

+0.44

0.10+/-0.10

+0.44

0.10+/-0.10

+0.44

0.10+/-0.10 0 42356-KSP0-C09

15-6

KIA SPORTAGE

TIRE, WHEEL

AND BALL JOINT SPECIFICATIONS Tire Pressures (psi) Rear 26 Front

OEM Tires Year

Model

Standard

2000

Spoilage

P205/75R15

Optional none

2001

Spoilage

P205/75R15

none

2002

Spoilage

P205/75R15

none

2003

Spoilage

P205/75R1 5

none

26 26

26 26 26

6-JJ Wheel 6-JJ Size 6-JJ 6-JJ

26

Ball Joint Inspection © © ©

26

OEM: Original Equipment Manufacturer PSI: Pounds Per Square Inch STD: Standard OPT: Optional ©

Replace if any measurable movement

is found. 42356-KSP0-C10

BRAKE SPECIFICATIONS All measurements

in inches unless noted Brake Drum

Brake Disc Year

Model

2000

Spoilage

Original Thickness

Minimum

Maximum

Thickness

Run-out

0.880

0.004 0.004

2001

Spoilage

0.940 0.940

2002

Spoilage

0.940

0.880

2003

Sportage

0.940

0.880

0.880

0.004 0.004

Original Inside Diameter NA NA NA NA

Max.

Maximum

Wear Limit

Machine

9.89 9.89

Brake Caliper

Minimum Thickness

Rear

Diameter NA

Front 0.080

NA

0.080 0.080

0.060

0.080

0.060

9.89

NA

9.89

NA

0.060

0.060

Bolts (ft. lbs.) 72 72 72 72

NA: Not Available 42356-KSP0-C11

KIA

SPORTAGE

'.

15-7

\

KIA

15-8

■/

SPORTAGE

SCHEDULED

INTERVALS

MAINTENANCE Kla— Spoilage

TO BE SERVICED

TYPE OF SERVICE

Transfer case fluid Transmission fluid R: Replace

15

✓ S/I

✓

30 V

✓

INTERVAL 75

60 ✓

V

✓

✓

MILEAGE

52.5

37.5

22.5

7.5

120

VEHICLE 45

✓

67.5 ✓

(xIOOO) 82.5

97.5

✓

105 112.5

✓

/ ✓

90

✓

/

✓ ✓

S/I

S/I: Inspect and service, if needed

L: Lubricate

FREQUENT OPERATION MAINTENANCE (SEVERE SERVICE) If a vehicle is operated under any of the following conditions it is considered severe service:

- Towing a trailer or using a camper or car-top carrier. 10 miles in any temperature. - Repeated short trips of less than 5 miles in temperatures below freezing, or trips of less than taxi or police cars. - Extensive idling or low-speed driving for long distances as in heavy commercial use, such as delivery,

- Operating on rough, muddy or salt-covered roads. - Operating on unpaved or dusty roads. - Driving in extremely hot (over 90°) conditions.

Engine oil & filter replace every 5000 miles or 5 months, whichever occurs tirst. Air cleaner filter: inspect and replace if necessary, every 15,000 miles or 15 months, whichever occurs first. whichever occurs first. Transfer case fluid: inspect the level every 5000 miles or 5 months, and replace every 15,000 miles or 15 months, whichever occurs first. Transmission fluid: inspect the level every 5000 miles or 5 months, and replace every 15,000 miles or 15 months, months, whichever occurs first. Front differential fluid: inspect the level every 5000 miles or 5 months, and replace every 1 5,000 miles or 1 5 whichever occurs first. Rear differential fluid: inspect the level every 5000 miles or 5 months, and replace every 1 5,000 miles or 1 5 months, 42356-KSPO-C13

KIA SPORTAGE

15-9

PRECAUTIONS Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a : motor vehicle: • Never open, service or drain the radia¬ tor or cooling system when the engine is ! hot; serious burns can occur from the steam and hot coolant. • Observe all applicable safety precau¬ tions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. • Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. • Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance.

• The EPA warns that prolonged con¬ tact with used engine oil may cause a number of skin disorders, including can¬ cer! You should make every effort to mini¬ mize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas as soon as pos¬ sible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. • All new vehicles are now equipped with an air bag system, often referred to as a Supplemental Restraint System (SRS) or Supplemental Inflatable Restraint (SIR) sys¬ tem. The system must be disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling proce¬ dures could result in accidental air bag deployment, possible personal injury and unnecessary system repairs. • Always wear safety goggles when working with, or around, the air bag sys¬ tem. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When plac¬ ing a non-deployed air bag on a work sur¬ face, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the addi¬ tional air bag system precautions later in this section. • Clean, high quality brake fluid from a sealed container is essential to the safe and proper operation of the brake system. You

should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in con¬ tact with a painted surface; it will damage the •paint. Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine damage. • Timing belt maintenance is extremely important! Many models utilize an interfer¬ ence-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing poten¬ tially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this section for the recommended replace¬ ment interval for the timing belt, and to the timing belt procedure in this section for belt replacement and inspection. • Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer sys¬ tem^) and may require the computer to undergo a relearning process once the neg¬ ative battery cable is reconnected. • When servicing drum brakes, only dis¬ assemble and assemble one side at a time, leaving the remaining side intact for refer¬ ence. • Only an MVAC-trained, EPA-certified automotive technician should service the A/C system or its components.

ENGINE REPAIR • • • •

Alternator REMOVAL

1 . Before servicing the vehicle, refer to s in the beginning of this sec¬ the precaution . tion

l

fol etchte onn

alolrc

Inst

2. Remove or disconnect the following: • Negative battery cable • Air cleaner inlet pipe front bolts • Top hose from the resonance chamber • Air cleaner inlet pipe • Alternator electrical connectors • Loosen the pivot and tensioner mounting bolts, do mot remove them

Drive belt from the alternator pulley Drive belt tensioner Alternator pivot bolt Loosen the bolt at the base of the adjusting bracket upbracket and rotate the

• Alternator To install: • Alternator • Pivot bolt and hand tighten • Rotate the bracket down on top of the alternator • Belt tensioner on the adjustment bracket • Tensioner mounting bolt and hand • tighten Drive belt it

• Torque the tensioner bolt to 19 ft. lbs. (26 Nm). • Torque the pivot bolt to 38 ft. lbs. Nm). electrical connectors • (51 Alternator clamp inlet pipe and tighten • the Air cleaner

• Hose to the resonance chamber • Air inlet pipe bolts and tighten • Negative battery cable Ignition Timing ADJUSTMENT The 2.0L engine in the Sportage is equipped with a distributorless ignition sys-

1 5"1 0 SPORTAGE tem. The ignition timing is controlled by the Powertrain Control Module (PCM) through the input ot engine control system sensors. The ignition timing is set at 4 degrees BTDC for vehicles equipped with manual or automatic transmissions. The ignition tim¬ ing cannot be adjusted.

Engine Assembly REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. Properly relieve the fuel system pressure. 3. Drain the cooling system. 4. Drain the engine oil. 5. Drain the transmission fluid. 6. Remove or disconnect the following: • Both battery cables • Windshield washer hose from the hood • Hood

• Brake booster vacuum hose from the dynamic chamber • Fuel lines and fuel pressure regula¬ tor from the rear of the dynamic chamber • Vacuum hose from the bottom of the EGR valve • Purge solenoid valve vacuum hose from dynamic chamber • Vacuum hoses from the top of the charcoal canister and slide the charcoal canister up and out of the bracket • Lower radiator hose • Cooling lines from the radiator, if equipped with an automatic trans¬ mission • Radiator and raise and safely sup¬ port the vehicle • Lower splash panel • Drive belt • A/C pulley assembly • A/C compressor mounting bolts and of themove way the A/C compressor out

• 2 air duct mounting bolts from the top of the radiator. Loosen the clamp at the air intake housing and remove the duct

• • ••

• Accelerator cable by pulling the throttle back and rotating the cable until it aligns with the slot in the pulley • Transmission control cable • Resonance chamber mounting bolt, chamber bolt and air silencer

• Front exhaust pipe from the exhaust manifold • Bracket bolt from the front exhaust

• Idle Air Control (IAC) air hose, breather hose and vacuum line from the air intake tube • Manifold Air Flow (MAF) sensor connector • Loosen the air inlet hose clamp from the MAF sensor • 3 bolts from the air intake tube to the throttle body • Air intake hose and tube as an assembly • • • • • • • •

Upper radiator hose Clutch fan nuts Cooling fan shroud bolts Fan and shroud at the same time Alternator drive belt Fan pulley Alternator electrical connectors Exhaust Gas Recirculation (EGR) solenoid valve connector on the intake manifold in front of the dynamic chamber • Both heater hoses from the pipes • Engine-to-body ground wire from the intake manifold and the harness bracket

Power steering drive belt Intake manifold support bracket Starter Starter wiring harness

• Exhaust-to-clutch (manual trans¬ pipe mission) or converter (automatic transmission) housing bolts and the bracket • Clutch housing (manual transmis¬ sion) or converter (automatic trans¬ mission) housing bolts. • Drive plate-to-torque converter bolts, if equipped 7. Support the transmission from underneath the vehicle. 8. Connect the engine hoist to the engine assembly. • Left and right side engine mounting bolts 9. Lift the engine up and forward slightly to provide access to three electrical connectors on the rear of the cylinder head. • Electrical connectors from the Camshaft Position (CMP) sensor, coil and condenser on the rear of the cylinder head • Engine from the vehicle To install: 10. Lower the engine enough to connect the three electrical connectors to the CMP sensor, coil and condenser on the rear of the cylinder head. 1 1 . Position the engine to the transmis¬

sion. Install the transmission bolts and tighten the bolts. Torque according to bolt size: • 14mm bolts to 80 ft. lbs. (108 Nm) • 10mm bolts to 28 ft. lbs. (38 Nm) • 6mm bolts to 60 inch lbs. (7 Nm) • Right and left side engine mounting bolts. Torque the bolt s to 38 ft. lbs. (52 Nm). 12. Disconnect the engine hoist from the engine assembly. 13. Raise and safely support the vehicle. • Drive plate-to-torque converter bolts, if equipped. • Connect the front exhaust pipe to the exhaust manifold. Torque the flange bolts to 24 ft. lbs. (31 Nm). • Front exhaust pipe. Torque the • Starter bolts to 20 ft. lbs. (27 Nm). • Connect the starter wiring harness • Intake manifold support bracket bolts and the bracket. 14. Install the power steering pump lock and mounting bolts. Install the power steer¬ ing drive belt. Torque the bolts to 30 ft. lbs. (42 Nm). Nm). compressor mounting bolts. A/C Torque the bolts to 18 ft. lbs. (24 A/C belt pulley assembly and drive belt. Install the two A/C idler pulley bracket bolts and torque to 24 ft. lbs. (32 Nm). Lower splash panel Radiator Cooling lines to the radiator, if equipped Lower radiator hose Slide the charcoal canister in the bracket Vacuum hoses to the top of the charcoal canister Engine-to-body ground wire to the intake manifold and the harness bracket Brake booster vacuum hose to the dynamic chamber Fuel lines and fuel pressure regula¬ tor to the rear of the dynamic chamber Vacuum hose to the bottom of the EGR valve Purge solenoid valve vacuum hose to dynamic chamber EGR solenoid valve connector on the intake manifold in front of the dynamic chamber Heater hoses Electrical terminal connectors to the alternator Fan pulley

SPORTAGE

14-22

47-66

ft-lb (19-30

N»m)

ft-lb (64 - 89 N«m)

14 -22 ft-lb (19- 30 N»m)

14-22

22-29

ft-lb (19-30

N»m)

ft-lb (29 - 39 N«m)

25 - 36 ft-lb (34 - 49 N«m

14 - 22 ft-lb (19-30

1. 2. 3. 4. 5.

N»m)

7. 8. 9. 1 0. 11.

Oil Level Gauge Thermo-Modulated Fan Bracket EGR Pipe Exhaust Manifold Heat Shield Exhaust Manifold

6. Coolant Inlet Pipe and Bypass Pipe

Engine Hanger Generator Generator Strap and Bracket Intake Manifold Assembly Intake Manifold Support Bracket

13. Oil Cooler 14. Oil Pressure Switch

12. Oil Filter

7924QG36

Exploded view of some peripheral engine component mountings

• Alternator drive belt. Torque the adjusting bolt 16 ft. lbs. (22 Nm) and the mounting bolt to 32 ft. lbs. (45 Nm). • Fan and shroud as an assembly. Torque the five cooling fan shroud bolts to 72 inch lbs. (8 Nm) • Clutch fan nuts. Torque the nuts to 27 ft. lbs. (37 Nm). • Upper radiator hose • Air intake hose and tube as an assembly • Air intake tube to the throttle body

and tighten the air inlet hose clamp to the MAF sensor MAF sensor electrical connector Resonance chamber mounting bolt, chamber bolt and air silencer IAC air hose, breather hose and vacuum line to the air intake tube Accelerator cable by pulling the throttle back and rotating the cable until it aligns with the slot in the pulley Transmission control cable Air duct mounting bolts to the top

the radiator. Torque the clamp at • of Hood the air intake housing • Windshield washer hose to the hood 15. Fill the engine with clean engine oil. 16. Connect the battery cables. 17. Fill the cooling system. 18. Fill the transmission fluid. 19. Recharge the A/C system. 20. Start the vehicle. Check for leaks, repair if necessary. 21 . Road test the vehicle to check engine performance.

KIA 1IJC_1 lLO SPORTAGE • Timing belt • Loosen ley the tensioner lockbolt and allow the tensioner to rest against

2 Water Pump

d REMOVAL & INSTALLATION . e

the belt. Torque the tensioner lockbolt to 32 ft. lbs. (43 Nm). • Upper and lower timing belt covers • Fan bracket assembly and fan pul¬

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. Drain the cooling system. 3. Remove or disconnect the following: . • Negative battery cable • Lower splash shield . • Upper and lower radiator hoses • Coolant reservoir tank hose • Fresh air duct • Fan and shroud • Loosen the alternator mounting and adjusting bolts • Alternator belt • Fan pulley and bracket • Upper and lower timing belt covers and turn the crankshaft until No. 1 cylinder is at Top Dead Center (TDC). • Loosen the tensioner lockbolt and pry the tensioner away from the belt • Timing belt • Loosen the tensioner bolt • Water pump • Tensioners from the water pump To install: 4. Clean the surface of any old gasket material. 5. Install or connect the following: • Tensioners on the water pump • Water pump and gasket. Torque the bolts to 19 ft. lbs. 25 Nm).

• Drive belt • Cooling fan and shroud • Position the radiator and torque the Nm). bracket bolts to 89 inch lbs. (10 • Torque the shroud bolts to 89 inch lbs. (10 Nm) and torque the alter¬ nator adjusting and mounting bolts • Position the fresh air duct over the radiator and tighten the retaining bolt 89 inch lbs. (10 Nm) • clamps Radiator hoses and tighten the • Lower splash shield • Negative battery cable 6. Fill the cooling system. 7. Start the vehicle and bring the engine to operating temperature. Check for leaks and repair if necessary.

Heater Core REMOVAL & INSTALLATION

** CAUTION After disconnecting the negative bat¬ tery cable, wait for at least 10 min¬ utes for the air bag module to deplete its stored energy.

t f steerin wheel by perfor ming he ollowing g RemovPosition the front wheels in the e proceda. ure: the driver’ s side straight-ahead position. air bag and b. Remove the 4 steering wheel-to-air bag module bolts. c. Carefully, lift the air bag module and disconnect the electrical connector.

** CAUTION Place the air bag module in a safe location with the front facing upward.

stee

le.

cab

c nut. ring olumn may be necessary to mark the Rem steering ove wheel to steering column th alignment.e stee ring whe elt whe o- fro the stee pre the ste e ss m el r¬ rin g in3. cDrain olu the cooling system into a clean g Usi mn. reuse. container for ng a st 4. eDischarge and recover the air condi eri ngw hee refrigerant. tioning system l pu lle instrument panel by per¬ 5. Remove the r forming the following, procedure: a. Remove both the rear and front consoles. b. Remove the knee bolster assembly.

1

c. Remove the “T” bar section. d. Remove the relay bracket. e. Remove the turn signal assembly and the upper/lower steering column covers. f. Remove the hood release handle lockscrew, the hood release handle and the cable assembly nut. g. Remove the left side front pillar trim and the lower left side cover.

Di on

sc e att ivbe gat ene ctth

ne ry

bar-to-chassis bolts. h. Remove the 2 left side of the “T” i. At the left side of the instrument

32 Ib-ft (45 N«m) 1 TIMING BELT COVERS, GASKETS AND TIMING BELT 2 IDLER PULLEY

3

COOLANT

PUMP

4 GASKET 7924QG01

Exploded view of the water pump mounting

panel, remove chassis bolts. the 3 instrument panel-to j. Remove the ashtray. k. Remove the center panel trim. l. Remove the ventilation control panel m. At the center of the windshield next to the windshield, remove the cap and the mounting bolt. n. Remove the right side front pillar trim and the lower right side cover.

h

. ve the 2 right side of the “T" Remossis o.o-cha bar-t bolts. side of the instrument right the At p. the 3 instrument panel-topanel, remove chassis bolts.

q. Remove the steering column-toinstrument panel bolts and lower the steering column. r. Disconnect the instrument panel electrical connectors. s. Remove the instrument panel.

housing by performing the following proce¬ dure: a. Disconnect the air conditioning refrigerant lines trom the evaporator core and discard the gaskets. Plug the open¬ ings to prevent contamination. b. Disconnect the fresh air control cable from the blower/evaporator hous¬ ing inlet duct. c. Disconnect the 5 connectors from the bottom of the blower/evaporator housing. ve t he bl d. Move the carpeting from the bulk¬ ow /evgain headerto apor access to the hole cover ator plate. e. Remove the 4 hole cover plate nuts and the plate. f. Remove the 2 upper blower/evapo¬ rator housing bolts. g. Remove the 2 lower blower/evapo¬ rator housing-to-bulkhead nuts.

ing. a. Install the heater core to the hous¬

housing. Remove tt the heater hoses from the 7. Disconnec he blower /evaporat or heater core. 8. Remove the temperature control cable from the heater housing. 9. Remove the 2 lower heater housing

b. Assemble the housings and install the 8 remaining heater housing clips.

c. Install the heater core tube mount¬ ing bracket and the 4 bracket screws. d. Install the 6 heater housing assem¬ bly clips. e. Install the left side of the heater housing.

the upper heater housing-to-bulknuts and head nut. 10. Remove the heater housing. 11. Disassemble the heater housing by performing the following procedure: a. Remove the seal from the heater core tube connections. b. Remove the vent seal.

f. Install the 8 heater housing clips located on the servo side (left side).

the 2 wiring harness-toc. Remove servo screws. heater d. Remove the 8 heater housing clips located on the servo side (left side). e. Remove the left side of the heater housing. f. Remove the 6 heater housing assembly clips. g. Remove the 4 heater core tube mounting bracket screws and the bracket. h. Remove the 8 remaining heater

2 wiring harness-tog. Install screws. servo the heater h. Install the vent seal. i. Install the seal to the heater core tube connections. 13. Install the heater housing. 14. Install the 2 lower heater housing housing-to-bulk¬ nuts and head nut. the upper heater 15. Install the temperature control cable to the heater housing. 16. Connect the heater hoses to the heater core. 17. Install the blower/evaporator housing performing the following procedure: by ing. a. Install the blower/evaporator hous¬

clips and disassemble the hous¬ housing ings. i. Remove the heater core from the housing.

b. Install the 2 lower blower/evapora¬ tor housing-to-bulkhead nuts. c. Install the 2 upper blower/evapora¬ tor housing bolts.

To install: 12. Assemble the heater housing by per¬ forming the following procedure: Oblong Hole

Clockspring Assembly

Combination Switch Steering Wheel Air Bag Module

Steering Wheel

93113GI4

y Exploded view of the steering wheel and air bag module assembl

Kia Spoilage

15-14

SPORTAGE d. At the right side of the instrument panel, install chassis bolts. the 3 instrument panel-tobar-to-chassis e. Install thebolts. 2 right side of the “T” f. Install the right side front pillar trim and the lower right side cover. g. At the center of the windshield next to the windshield, install the cap and the mounting bolt. h. Install the ventilation control panel. i. Install the center panel trim. j. Install the ashtray. k. At the left side of the instrument panel, install the 3 instrument panel-tochassis bolts.

93113GI5

View of the blower/evaporator housing assembly— Kia Sportage

l. Installbolts. the 2 left side of the “T” barto-chassis m. Install the lower left side cover and the left side front pillar trim. n. Install the cable assembly nut, the hood release handle and the hood release handle lockscrew. o. Install the turn signal assembly and the upper/lower steering column covers. p. Install the relay bracket. q. the knee “T” barbolster section. r. Install Install the assembly. s. Install both the rear and front con¬ soles. 19. Evacuate and charge the air condi¬ tioning system refrigerant. 20. Refill the cooling system. 21. Install the driver’s side air bag and steering wheel by performing the following procedure: a. Install the steering wheel to the steering column. b. Install the steering wheel-to-steer¬ ing column nut and torque the nut to 33 ft. lbs. (45 Nm). c. Carefully, install the air bag mod¬ ule and connect the electrical connector.

93113GI6

Exploded view of the heater core and heater housing assembly— Kia Sportage

temperatures; then, check the climate con¬ trol operation and check for leaks.

conditioning refrigerant lines to the evap¬ orator core.

pro

fol the

for

Cylinder Head REMOVAL & INSTALLATION

: ure

ced

g

ing

low

a. Install the instrument panel. b. Connect the instrument panel elec¬ trical connectors. c. Install the steering column and lower the steering column-to-instrument panel bolts. Torque the bolts to 15 ft. lbs. (20 Nm).

min

d. Install the hole cover plate and the 4 plate nuts. e. Move the carpeting over the bulk¬ head. f. Connect the 5 connectors to the bottom of the blower/evaporator hous¬ ing. g. Connect the fresh air control cable to the blower/evaporator housing inlet duct. h. Using new gaskets, connect the air

d. Install the 4 steering wheel-to-air bag module bolts and torque to 72-106 inch lbs. (8-12 Nm). 22. Connect the negative battery cable. 23. Run the engine to normal operating

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion . sure.2. Properly relieve the fuel system pres¬

15-15

KIA

SPORTAGE

1. 2. 3. 4. 5. 6.

Ignition Coils and High Tension Leads Cylinder Head Cover Camshaft Position Sensor Seal Plate Camshaft Caps Camshafts

13. 7. 8. 10. 9. 11,

Hydraulic Lash Adjuster Cylinder Head Bolt Cylinder Head Cylinder Head Gasket Valve Locks

14.

12.

Upper Spring Seat

18.

16. 15. 17.

Outer Valve Spring Inner Valve Spring Lower Spring Seat Valve Valve Stem Seal Valve Guide 7924QG37

Exploded view of the cylinder head assembly

3. Drain the cooling system. 4. Remove or disconnect the following: • Negative battery cable • Brake booster vacuum hose from the dynamic chamber • Fuel line from the pressure regula¬ tor and the return line from the rear of the dynamic chamber • Ground wire from the intake mani¬ fold • Purge solenoid valve vacuum hose • Upper radiator hose • Intake manifold support bracket • Converter flange inlet pipe

• Timing belt • Cylinder head cover • Cylinder head with the intake and exhaust manifolds attached • 3 wire harness connectors at the rear of the cylinder head To install: 5. Place the new head gasket on the

engine block. 6. Install or connect the following: • Cylinder head with the intake and exhaust manifolds attached • 3 wiring connectors at the rear of the cylinder head

• Cylinder head bolts in the proper sequence. Torque the bolts to 64 ft. lbs. (87 Nm). •• Timing Cylinderbelt head cover • Converter inlet pipe flange nuts. Torque the nuts to 24 ft. lbs. (33 Nm). • Upper radiator hose • Vacuum hose from the intake mani¬ fold to the charcoal canister • Purge solenoid vacuum hose • Ground wire and harness bracket to the intake manifold. Torque the bolts to 18 ft. lbs. (25 Nm).

K,A II RJ-lflUi SPORTAGE

t

2. Properly relieve the fuel system pres¬ sure. 3. Drain the coolant. 4. Remove or disconnect the following: • Negative battery cable • Accelerator cable bracket bolts from the valve cover • Air intake tube to cylinder head cover bolts • Air intake tube to throttle body bolts

• Loosen the clamp attaching the air tube to the Mass Air Flow (MAF) sensor • Idle Air Control (IAC) valve, breather hose and vacuum line from the air intake tube • Air intake tube • Positive Crankcase Ventilation hose (PCV) from the dynamic chamber • Purge solenoid valve vacuum hose from the dynamic chamber • Throttle Position (TP) sensor elec¬ trical connector • IAC valve electrical connector • Heater hoses

• Engine-to-body ground strap from the intake manifold and the harness bracket below it • Brake booster vacuum line • Vacuum hose from the fuel pres¬ sure regulator hose • Dynamic chamber support bracket bolts • Fuel injector electrical connectors • Fuel pressure and return lines Intake • Oil filtermanifold support bracket • Intake manifold bolts • Bypass pipe from the heater hose • Intake manifold and discard the To install: 5. Install or connect the following: gasket • Intake manifold with a new gasket to the cylinder head • Fuel line to the pressure regulator and the return line to the fuel rail • Brake booster vacuum hose • Negative battery cable 7. Properly fill the cooling system. 8. Start the engine and check for leaks, repair if necessary..

Intake Manifold REMOVAL & INSTALLATION

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section .

Intake manifold mounting bolt locations. Be sure to connect the ground cable

KiA

SPORTAGE • Heater hose to the bypass pipe • Bolts and nuts attaching the intake manifold to the cylinder head. Torque the bolts to 14-22 ft. lbs. (19-30 Nm). • New oil filter • Intake manifold support bracket. Torque the bolts to 27-38 ft. lbs. (37-52 Nm) • Fuel lines • Fuel injector electrical connectors • Engine to body ground wire. Torque the bolt to 18 ft. lbs. (25 Nm). • Dynamic chamber support bracket. Torque the bolts to 18 ft. lbs. (25 Nm). • Purge solenoid valve vacuum hose to the dynamic chamber

• Vacuum hose to the fuel pressure • • • • • •

• • • • •

regulator Coolant hoses to the throttle body IAC valve electrical connector Brake booster vacuum hose Heater hoses TP sensor electrical connector Air intake tube and hose to the throttle body. Torque the bolts to 16 ft. lbs. (22 Nm).

PCV hose to the dynamic cham¬ ber Accelerator cable to the throttle body pulley Accelerator cable bracket. Torque the bolts to 10 ft. lbs. (15 Nm). Air intake hose to the MAF sensor Resonance chamber

15-17

• IAC hose, breather hose and vac¬ uum line to the intake manifold • Negative battery cable 6. Properly fill the cooling system. 7. Start the engine and check for leaks, repair if necessary. Exhaust Manifold REMOVAL & INSTALLATION

1 . Before servicing the vehicle, refer to ns in the beginning of this sec¬ the precautio . tion 2. Remove or disconnect the following: • Negative battery cable • Air intake hose • Exhaust manifold heat shield

& ^

0®*

1. 2. 3. 4.

Oil Level Gauge Thermo-Modulated Fan Bracket Exhaust Manifold Heat Shield Exhaust Manifold 5. Coolant Inlet Pipe and Bypass Pipe

6. Engine Hanger 7. Generator 8. Generator Strap and Bracket 9. Intake Manifold Assembly 10. Intake Support Bracket

11. Oil Filter 12. Oil Cooler

1 3. Oil Pressure Switch

9308QG01

nts Exploded view of the intake, exhaust manifold and related compone

O-Ring

15-18

KIA SPORTAGE

Exploded view of the exhaust manifold assembly

. Converter inlet pipe flange locknuts . Exhaust manifold and discard the gasket 3. Clean the mating surfaces. To install: 4. Install or connect the following: • Exhaust manifold with a new gas¬ ket. Torque the bolts to 31 ft. lbs. (42 Nm). • New flange gasket and install the converter inlet pipe. Torque the bolts to 24 ft. lbs. (33 Nm). • Exhaust manifold heat shield. Torque the bolts to 18 ft. lbs. (25 Nm). • Air intake hose • Negative battery cable 5. Start the vehicle and check for leaks, repair if necessary.

ley

• Pulley lock bolt. Torque the bolt to 18 ft. lbs. (25 Nm). • Timing belt • Engine under cover. Torque the bolts to 18 ft. lbs. (25 Nm). • Negative battery cable 5. Start the engine and check for leaks, repair if necessary.

Camshaft

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. Remove or disconnect the following: • Negative battery cable • Engine under cover • Timing belt 1 Be • Timing belt pulley folock res bolt • Timing belt pulley ervi cin • Pulley woodruff key tghe veith out of cutting y carefull by • Oil seal icl e,re the oil pump housing fer to To install: 3. Lubricate the lip of the new seal with clean engine oil. 4. Install or connect the following: • New oil seal into the oil pump housing by hand • Press the oil seal into pump until it is flush with the edge of the oil pump body • Timing belt pulley • Pulley woodruff key

• Upper timing belt cover • Timing belt from the camshaft pul¬ • Camshaft pulleys . Camshaft cap bolts in the proper

REMOVAL & INSTALLATION

• sequence Camshaft caps • Camshafts

Front Crankshaft Seal REMOVAL & INSTALLATION

2. Properly relieve the fuel system pres¬ sure. 3. Drain the coolant into a suitable con¬ tainer. 4. Remove or disconnect the following: • Negative battery cable

To install:

ttihoe pr. ec aut n ion s

in the beg i

nn

of thi sec s ¬ in

g

Camshaft cap bolt removal sequence

5. Install or connect the following:

• Camshafts into the cylinder head.

• Starter into position. When aligned properly torque the bolts to 40 ft. lbs. (54 Nm). • Torque the intake manifold bracket bolts to 40 ft. lbs. (54 Nm).

• Properly position the clutch release cylinder, if equipped. Torque the bolts to 40 ft. lbs. (54 Nm). • Torque the intake manifold bracket upper bolts to 40 ft. lbs. (54 Nm). • Negative battery cable

Oil Pan REMOVAL & INSTALLATION

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion . 2. Drain the engine oil. ing: 3. Remove or disconnect the follow¬ 7924QG16

Camshaft journal bolt tightening sequence

The exhaust camshaft has a steel dowel pin at the rear for the • Negative battery cable camshaft position sensor • Intake manifold bracket upper bolts and • Clean engine oil to the journals bearings • Clutch release cylinder and move it aside, if equipped • Camshaft oil seal • Silicone sealant to the front • Intake manifold bracket lower bolts and remove the bracket camshaft camshaft cap and the • Starter from the clutch, manual R position sensor mounting cap emo )■ only v transmissions • Camshaft caps in the proper e or d • Starter from the torque converter, sequence. Torque the bolts in threeiscon n automatic transmissions only e steps to 20 ft. lbs. (26 Nm). ctth e • • Camshaft pulleys fol Starter electrical connectors low • Timing belt •- Move the transmission wire har¬ ness aside • Timing belt cover • Starter • Negative battery cable To install:

Valve Lash ADJUSTMENT

fo ctthe nne lrco talo

g:

win

REMOVAL & INSTALLATION

llo

Starter

1 . Before servicing the vehicle, refer to ons in the beginning of this sec¬ the precauti . tion 2. Drain the engine oil.

• • • ••

Both gusset plates from the engine Transmission under cover Engine under cover pan mounting bolts and using a Oil pan Oil scrapper tool separate the oil pan

• Oil strainer assembly • Oil baffle To install: 4. Clean the engine block, oil pan and baffle pan surfaces of any gasket material. 5. Apply a continuous bead of Loctite Ultra Blue 587® silicone sealant around the baffle pan. 6. Install or connect the following: • Oil baffle. Torque the bolt to 84 inch lbs. (9.5 Nm). • Oil strainer. Torque the bolts to 84 inch lbs. (9.5 Nm).

7. Apply a continuous bead of Loctite Ultra Blue 587® silicone sealant around the oil pan. • Oil pan. Torque the bolts to 84 inch lbs. (9.5 Nm). • Transmission under cover. Torque the bolts to 84 inch lbs. (9.5 Nm). • Gusset plates to the engine. Torque the bolts to 33 ft. lbs. (45 Nm). • Engine under cover • Front axle housing into position.

Ins

The DOHC engine uses Hydraulic Lash Adjusters (HLA’s), which automaticallylash. maintain the proper amount of valve Therefore, the DOHC engine does not need manual valve lash adjustment.

• Starter to the engine well • Starter electrical connectors • Lower intake manifold bracket and install the upper bolts

• Negative battery cable • 2 Top intake manifold bracket bolts • Front 3 axle housing mounting bolts, 4WD only • Left front bushing from the axle mount and lower the front housing axle housing

Exploded view of the starter

When properly aligned, torque the bolts to 48 ft. lbs. (65 Nm).

15 “20 SMRTAGE 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion . 2. Properly relieve the fuel system 3. Drain the engine oil. pressure. 4. Drain the cooling system. 5. Remove or disconnect the following: • Negative battery cable • Alternator belt • Fresh air duct from the radiator • • • • • • •

0 •

• ••

Upper radiator hose Clutch fan and shroud Splash guard Loosen the A/C drive belt Power steering belt Timing belt covers Lower timing belt pulley and lock bolt and place a support under the front axle Axle attaching bolts and lower the axle enough to gain access to the oil Oil pan pan Transmission undercover Oil pump

To install: 6. Clean the engine block, oil pan and baffle pan surfaces of any gasket material. 7. Apply a continuous bead of silicone sealant around the oil pump.

.

f»Do not allow sealant to get in the oil passages when applying sealant to the contact surface. 8. Install or connect the following: • New O-ring and mount the oil pump to the engine. the “A” bolts to 16 ft. lbs.Torque (22 Nm) Nm). and the “B" bolts to 33 ft. lbs. (45 9. Remove the upper and lower A/C compressor mounting bolts. • Power steering pump bracket and hand tighten the bolts • A/C compressor bracket • A/C compressor. Torque the O-RING

Lo

os

• Intake manifold bracket bolts. Torque the bolts to 34 ft. lbs. (65 Nm). • Negative battery cable 8. Fill the engine with clean oil. 9. Start the vehicle and check for leaks, repair if necessary.

ent

he A

Oil Pump

/C

co

mp

re

ss

obrr ac

ket

.

REMOVAL & INSTALLATION f^The oil pump is externally-mounted, but still requires the removal of the oil pan to disconnect the oil pump strainer.

Be sure the oil pump O-ring is in the proper location prior to installation

Backing

mounting bolts to 17 ft. lbs. (23 Nm). • Torque the power steering pump bracket bolts to 24 ft. lbs. (33 Nm). • Power steering pump. Torque the bolts to 43 ft. lbs. (58 Nm). • Timing belt gear on the crankshaft. Torque the large crank bolt to 119 ft. lbs. (162 Nm). • Oil baffle after applying sealant to the mating surface. Torque the bolt to 84 inch lbs. (9.5 Nm). • Oil strainer. Torque the bolts to 84 inch lbs. (9.5 Nm). • Oil pan • Transmission under cover. Torque the bolts to 84 inch lbs. (9.5 Nm). • Both gusset plates. Torque the bolts to 33 ft. lbs. (45 Nm). • Raise the front axle into position. When aligned properly, torque the bolts to 123 ft. lbs. (167 Nm). • Timing belt and cover • Alternator belt • A/C and power steering belt and adjust as needed • Splash shield • Upper radiator hose • Clutch fan and shroud as an assembly • Air duct to the top of the radiator • Engine under cover. Torque the bolts to 18 ft. lbs. (25 Nm). • Negative battery cable 11. Properly fill the cooling system. 12. Fill the engine with clean oil. 13. Start the engine, check for leaks, and repair if necessary.

A/T

Rear Main Seal REMOVAL & INSTALLATION

1 . Before servicing the vehicle, refer to ns in the beginning of this sec¬ the precautio tion . 2. Drain the transmission fluid. 3. Remove or disconnect the following: • Negative battery cable • Transmission • Clutch cover and disc, if equipped • Flywheel, if equipped • Rear cover • Rear main oil seal To install:

16-24

M/T

ft-lb

(22 - 32 N»m) 7924QG38

Exploded view of the rear main seal and related components

• Rear cover

et orn.n aloolrcve Inst c the o int l sea the

ss

pre

• Flywheel onto the crankshaft. While holding the flywheel torque the bolts in sequence: a. Step 1:30 ft. lbs. (41 Nm). b. Step 2: 60 ft. lbs. (81 Nm). c. Step 3: 73 ft. lbs. (99 Nm).

. Clutch disc and cover. Torque the bolts to 16 ft. lbs. (22 Nm). • Transmission • Negative battery cable 6. Fill the transmission to the proper level. 7. Start the vehicle and check for leaks, repair if necessary.

O IC U.O tt 1

kia SPORTAGE

Timing Belt REMOVAL & INSTALLATION 1. Disconnect the negative battery cable. 2. Properly relieve the fuel system pressure. 3. Remove the alternator drive belt. 4. Remove the fresh air duct from the top of the radiator. 5. Remove the upper radiator hose. 6. Remove the 4 attaching nuts to the clutch fan. 7. Remove the 5 fan shroud bolts. Remove the fan and shroud as an assembly. 8. Remove the 4 splash guard mount¬ ing bolts and the splash guard. 9. Loosen the lockbolts and loosen the air conditioning drive belt. 10. Loosen the power steering lock and mounting bolt. Remove the power steering belt. 11. Remove the 5 upper timing belt cover bolts and remove the cover. 12. Remove the 2 lower timing belt cover bolts and remove the cover. 13. Align the timing marks. ^When the seal pulley I on the E

N-m (kgf-cm, ft-lbf) |: Specified torque 93025G25

Align the crankshaft marks before removing the timing belt — KIA Spoilage 2.0L (DOHC) engine

aligning the cam pulleys with plate marks, align the left cam mark and the right cam pulley mark.

:: WARNING When aligning the timing marks, do not turn the timing gear counterclock¬ wise. Damage to the engine will occur. 14. Loosen the tensioner bolt. Pry the tensioner away from the belt. Tighten the tensioner bolt to relieve the pressure against the timing belt. 15. Remove the timing belt. 16. Remove the camshaft pulley attach¬ ing bolts. Use a driver placed through one of the holes in the pulley to prevent it from moving when the attaching bolt is removed. Remove and mark the pulleys. 17. Remove the lower timing belt pulley and locking bolt. To install: 18. Install the camshaft pulleys. Tighten the bolts to 35-48 ft. lbs. (47-65 Nm). 19. Install the lower timing belt pulley and locking bolt. Tighten the bolt to 120 ft. lbs. (162 Nm). 20. If necessary, align the timing marks. "••When aligning the cam pulleys with the seal plate marks, align the left cam pulley “I” mark and the right cam pul¬ ley on the “E” mark.

Proper alignment of the intake and exhaust camshaft pulley timing marks — KIA Spoilage 2.0L (DOHC) engine

: WARNING When aligning the timing marks, do not turn the timing gear counterclock¬ wise. Damage to the engine will occur. 21. Loosen the tensioner bolt. Pry the tensioner away from the belt. Tighten ten¬ sioner bolt to relieve the pressure against the timing belt. 22. Install the timing belt.

** WARNING If any binding is felt when adjusting the timing belt tension by turning the

crankshaft, STOP turning the engine, because the pistons may be hitting the valves. 23. Loosen the tensioner bolt and allow the tensioner to tighten the timing belt. Tighten the tensioner bolt 27 - 38 ft. lbs. (37-52 Nm). 24. Check the timing belt deflection. If there is more than 0.30 - 0.33 in. (7.5 8.5mm) replace the tensioner spring. 25. Install the 2 lower timing belt cover bolts to the cover. 26. Install the 5 upper timing belt cover bolts to the cover.

27. Install and adjust the air condition¬ ing and power steering drive belts. 28. Install the splash guard. 29. Install and tighten the alternator belt. 30. Install the upper radiator hose. 31. Install the fan and shroud as an assembly. 32. Install the 4 attaching nuts to the clutch fan. 33. Install the 5 fan shroud bolts. 34. Install the fresh air duct to the top of the radiator. 35. Properly fill the cooling system. 36. Connect the negative battery cable. 37. Start the engine and check for leaks. 38. Road test the vehicle.

SPACER

TANG

UPPER

RAIL

yy?

OIL RING SPACER ENDS LOWER RAIL PISTON

Piston and Ring POSITIONING

tioning mark locations

7924AG05

Kia 2.0L engine— oil control ring rail and spacer positioning

Kia 2.0L engine— piston ring end-gap spacing

FUEL SYSTEM

Fuel System Service Precautions Safety is the most important factor when performing not only fuel system mainte¬ nance but any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle’s fuel system components can be accomplished safely and effectively by following rules and guide¬ adherin lines. g to the • To avoid the possibility of fire and per¬ sonal injury, always disconnect the negative battery cable unless the repair or test proce¬ dure requires that battery voltage be applied. • Always relieve the fuel system pres¬ sure prior to disconnecting any fuel system component (injector, fuel rail, pressure reg¬ ulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving

fuel system pressure to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may pene¬ trate the skin or any part of the body that it contacts. • Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suit¬ able waste container. • Always keep a dry chemical (Class B) fire extinguisher near the work area. • Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. • Always use a back-up wrench when loosening and tightening fuel line connec¬ tion fittings. This will prevent unnecessary stress and torsion to fuel line piping.

• Always replace worn fuel fitting fi¬ rings with new. Do not substitute fuel hose or equivalent where fuel pipe is installed.

Fuel System Pressure RELIEVING

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the fuel pump harness connector located behind the rear seat. 3. Start the engine and allow the engine to run out of fuel. 4. Once the engine has stalled, turn the key to the OFF position and connect the electrical connector. 5. Disconnect the negative battery cable so pressure cannot build up until work has been completed.

. OA iK 13

KIA SPORTAGE

REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pres¬ sure. 3. Remove or disconnect the following: • Negative battery cable • Fuel pump connector • Fuel hoses from the fuel filter • Fuel filter from the bracket To install: 4. Install or connect the following: • Fuel filter in the bracket • Fuel filter. Torque the bolts to 95 ft. lbs. (129 Nm). • Fuel hoses on the filter and make certain that the hoses are seated properly • Fuel pump connector • Negative battery cable 5. Start the engine and check for fuel leaks, repair if necessary.

• Hoses from the fuel pump • Screws securing the fuel pump to the fuel tank • Gradually lift the fuel pump from the tank • Plastic retaining bracket from the fuel pump assembly • Fuel hose from the fuel pump • Fuel tank pressure sensor 6. Wrap the fuel pump assembly in a rag before removing the assembly from the vehicle. 7. Cover or seal the fuel tank until installing the fuel pump assembly. To install:

Removing the fuel pump through the access panel

fuel pump • the 8 screws around the top surface of

^The fuel pump is part of the assem¬ bly and is replaced as a complete unit.

• with Fuel clamps hoses to the pump and secure

8. Install or connect the following: • Plastic mounting bracket to the fuel pump and secure the bracket to the

• Fuel tank pressure sensor • Fuel pressure sensor electrical con¬ nector

pump with 4 screws • Fuel hose to the pump and secure with a new clamp

• Ground wire and fuel pump electri¬ cal connector • 2 halves of the fuel pump electrical connector • Access plate and reposition the carpet at seat • Negative battery cable

• Fuel pump into the access port on top of the fuel tank • Twist the fuel pump as necessary to properly position it in the fuel tank

Fuel filter underhood mounting location

Fuel Pump REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion . 2. Properly relieve the fuel system pres¬ sure. 3. Release the catch for the back seat and tilt the seat out of the way. 4. Move the carpet behind the seat that covers the fuel pump access panel. 5. Remove or disconnect the following: • Negative battery cable • Fuel pump electrical connectors • Bolt securing the ground wire • Fuel pump access panel • Hose clamps connecting the fuel hoses to the fuel pump

1 FUEL HOSE 2 RETAINING CLIP 3 FUEL PUMP 7924QG22

Exploded view of the fuel pump assembly

body

.

• Coolant hoses from the throttle

Fuel Injector REMOVAL & INSTALLATION —

1. Before servicing the vehicle, refer to : the precautions in the beginning of this sec| tion . 2. Properly relieve the fuel system presi sure. 3. Drain the cooling system. 4. Remove or disconnect the following: • Negative battery cable • Air intake hose assembly • Breather hoses from the air intake duct

• Mass Air Flow (MAF) sensor elec¬ trical connector • Air intake hose bracket • Accelerator cable • Vacuum hose from the intake mani¬ fold to the vacuum pipe . Throttle Position (TP) sensor and Idle Air Control (IAC) valve electri¬ cal connectors

• Clamp and hoses from the IAC valve • Brake booster vacuum hose from the dynamic chamber • Cruise control vacuum hose, if equipped • Bracket from the dynamic chamber • Manifold bracket • Heater inlet hose • Dynamic chamber • Fuel hose from the pressure regu¬ lator • Fuel injector rail clips • Fuel rail • Fuel injector insulators • Pressure regulator • Fuel injectors To install: 5. Install or connect the following: • Fuel injectors to the fuel rail • New insulators • New injector clips • Fuel rail

SPORTAGE ■ w • Clamps and air hose to the fuel rail • Fuel hose to the pressure regulator

• Dynamic chamber with a new gas¬ ket. Torque the bolts to 16 ft. lbs. (22 Nm). • IAC valve bracket bottom bolt • IAC valve and TP sensor electrical connectors • Heater inlet hose • Cruise control hose, if equipped • Vacuum hose to the pressure regu¬ lator • Air hose and clamp to the air rail • IAC valve vacuum hose • Manifold bracket bolts • Coolant hoses to the throttle body • Vacuum hose to the vacuum pipe • MAF sensor bracket • MAF sensor electrical connector • Accelerator cable • Breather hoses • Negative battery cable 6. Fill the cooling system. 7. Start the vehicle and check for leaks, repair if necessary.

DRIVE TRAIN Transmission Assembly REMOVAL & INSTALLATION

•

Manual

**The removal of the manual transmis¬ sion is virtually the same for 4WD and 2WD vehicles.

efol etcht

onn

alolrc

Inst

1. Before servicing the vehicle, refer to s in the beginning of this sec¬ the precaution . tion 2. Drain the transmission fluid. 3. Drain the transfer case. 4. Remove or disconnect the following: • Negative battery cable • Rear portion of the center console • Shift lever and transfer lever knobs • Slide the boot cover over the shifters and remove the center con¬ sole • Shift lever • Transfer lever • Front driveshaft by removing the bolts at the front differential and the bolts at the transfer case, if equipped • Bolts from the rear differential flange and the center support. Pull the driveshaft out of the tail shaft housing, if equipped with a 4 x 4 • Bolts from the rear differential

• • • •

flange and center support. Pull the driveshaft out of the tail shaft hous¬ ing, if equipped with a 4 x 2 Back-up light electrical connector and the Vehicle Speed Sensor (VSS) electrical connectors and move the wire harness aside Crankshaft Position (CKP) sensor from the transmission housing Clutch release cylinder and move it aside Front exhaust pipe bracket Front lower transmission housing

bolts • Transfer case side mount, if

• • • •

equipped and properly support the transmission Transmission crossmember Transmission mount bolts Starter from the front housing Transmission and transfer case, if

equipped To install:

• Transmission into position at the rear of the engine . Wire harness along the right side of the transmission and route the VSS wire over the transmission to the rear of the control rod extension • Transmission to engine 14mm mounting bolts. Torque the bolts to 80 ft. lbs. (108 Nm).

Transmission to engine 10mm mounting bolts. Torque the bolts to 29 ft. lbs. (39 Nm). Transmission to engine 6mm bolts. Torque the bolts to 5mounting ft. lbs. (7 Nm).

Exhaust pipe to the bracket. Torque the bolts to 20 ft. lbs. (27 Nm). Starter and ground wire. Torque the bolts to 29 ft. lbs. (39 Nm). Nm). ion crossmember mount. Transmiss Torque the bolts to 80 ft. lbs. (108 Crossmember to the chassis. Torque the bolts to 32 ft. lbs. (44 Nm). CKP sensor. Torque the bolt to 5 ft. lbs. (7 Nm). 4WD indicator switch connector Back-up light electrical connector VSS electrical connector Clutch release cylinder. Torque the bolts to 29 ft. lbs. (39 Nm). Driveshaft to the rear differential flange, 4x4 only Forward end of the driveshaft into the extension housing and attach the center support to the chassis Nm). to the rear differential flange. Shaft Torque the bolts to 27 ft. lbs. (36

Front driveshaft at the transfer case dif¬ the bolts and install4x4 only to the front ferential,

low

15 "2 6 SMRTAGE • Transfer case side mount, if equipped. Torque the bolts to 38 ft. lbs. (52 Nm). • Transfer case side mount to the chassis. Torque the bolts to 38 ft. lbs. (52 Nm). • Shift lever assembly. Torque the shift lever bracket bolts to 18 ft. lbs. (25 Nm). • Transfer lever assembly, if equipped. Torque the bolts to 18 ft. lbs. (25 Nm). • Dust cover plate over the shifter lever handles. Torque the bolts to 15 ft. lbs. (20 Nm). • Front console • Shifter lever knobs • Negative battery cable • Fill the transfer case. 6. Fill the transmission assembly. 7. Start the vehicle and check for leaks, repair if necessary.

Vehicle

Automatic transmission wiring connections

Radiator Side

.

Automatic 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion . 2. Drain the transmission fluid. 3. Drain the cooling system. 4. Remove or disconnect the following: • Negative battery cable • Automatic transmission control cable from the throttle body 5. Slide the front seats forward and remove the 2 rear shift console mounting screws and set the parking brake. • Rear console and slide the front seats rearward • Front console mounting screws and untie the shifter boot draw strings • Loosen the transfer case lock nut and remove the transfer case shifter lever knob • Power/economy switch electrical connector • Front console and shift the transfer lever to the 4L position • transfer shift lever cover plate • transfer case shift lever assembly and place the transmission in the park position • Selector lever nuts • Split pin from the shift selector lever • Shift selector rod and spring wash¬ ers

• Electrical connectors from the base of the selector lever

7924QG24

Exploded view of the oil cooler pipe connections

• Selector lever assembly • Control cable from the throttle link¬ age and slide the cable from the bellcrank • Upper dipstick tube from the lower dipstick tube • Input/Turbine speed sensor from the top rear of the transmission • Shift solenoids from the lower left side of the transmission • Vehicle Speed Sensor (VSS) from the center of the transfer case • nectors Input speed sensor electrical con¬ • Matchmark the front and rear driveshafts. Remove the attaching bolts from both flanges and remove the driveshafts Oil cooler pipes at the transmission • Starter

• Transfer case mounting bolts

• Transfer case nuts from the cross¬ member and support the transmis¬ sion • Crossmember • Transmission to engine mounting bolts • Front lower splash shield • Left side lower gusset • Torque converter inspection cover • Torque converter to drive plate bolts • Slide the transmission away from sion engine slightlyand lower the transmis¬ the • Crankshaft Position (CKP) sensor attaching bolt and sensor • 4WD, 4WD LOW indicator switches and the VSS from the transfer case g e in sur bind Be t hou wit d. out ecte n con dis come ing yth and aens blto arca cle is le n ott chi thr tta ing a wir the or

^There is a fifth wire connection (Park Position). This wire is hard-wired, do not disconnect it.

Passenger Side

To install: 7. Install or connect the following: • Transmission into position to attach the sensor and indicator switch wiring. Be sure the throttle cables are guided into the engine com¬ partment without binding or attach¬ ing to anything. • 4WD, 4WD LOW indicator switches and the VSS to the transfer case • Input/turbine speed sensor and CKP sensor. Torque the bolt to 12 ft. lbs. (16 Nm). • Raise the transmission and position it to the engine. Install the upper housing bolts. Torque the bolts in the following sequence: 8. 10mm bolts to 38-60 ft. lbs. (57-81 m).

aligned. Torque the bolts to the dif¬ ferential flanges to 20-22 ft. lbs. (27-30 Nm) and the transfer case flange bolts to 36-43 ft. lbs. (49-59 Nm). • Undercover splash shield. Torque Nm).bolts to 42—62 inch lbs. (5-7 the

• Upper dipstick tube to the lower tube and lower the vehicle 10. Provide automatic transmission con¬ trol cable slack by gently pulling the cable to the left until the cable pin has rotated suf¬ ficiently to line the automatic transmission control cable up with the slot in the rear of the throttle body bellcrank. 11 . Slide the automatic transmission control cable and cable pin into the bellcrank. 12. Tighten the locknut. • Throttle kickdown cable to the mounting bracket • Automatic transmission control cable to the throttle body • Air silencer • Shifter lever assembly to the trans¬ fer case. Torque the bolts to 72-102 inch lbs. (22-28 Nm). • Four wiring connectors under the shift selector lever • Shift selector lever, do not exert any force when installing the shift selector lever • Four shift selector lever nuts. Nm). Tighten to 72-102 inch lbs. (22-28

2. Pull back the carpet to measure the from the firewall to the top of the distance mm). pedal. The standard height is 9.84 in. (250 3. If adjustment is required, loosen the locknut and turn the stopper bolt. 4. After adjustment is made tighten the locknut to 12 ft. lbs. (16 Nm). Clutch Pedal Free-Play

1 . Before servicing the vehicle, refer to s in the beginning of this sec¬ the precaution tion . 2. Depress the clutch pedal gently by hand and measure the amount of free-play (distance the pedal travels before resistance is felt). The proper amount of free-play is 0.5 in. (12.7mm). If the free-play is not within the proper specifications, continue with the procedure. 3. Measure from the floor pan to the middle point of the clutch pedal when the pedal is in the fully released position. The proper clutch pedal height is 7.25 in. (184mm). 4. If the pedal height is incorrect, loosen locknut (A) and turn the pedal adjusting bolt (B) until the proper height is achieved, then retighten the locknut. 5. Remeasure the free-play. If it is still out of specification, loosen the clutch pushrod locknut (C) and turn the pushrod the proper free-play is achieved. (D) until locknut Tighten (C) securely.

• Shift rod and washers to the selec¬ tor lever and install the split pin to the shift selector lever • Power/Economy switch wiring con¬ nector • Rear console • Front console and tie the shift boot draw strings • Negative battery cable 13. Fill the transmission to the proper level. 14. Fill the cooling system. ' 15. Start the vehicle, check for leaks, and repair if necessary.

Clutch ADJUSTMENT Clutch Pedal Height

¬ sec s thi of

in

inn

beg the in

i

t cau p.re n tthieo

9. 12mm bolts to 51-65 ft. lbs. (69-88 m). • Exhaust hanger and bracket. Torque the bolts to 38-60 ft. lbs. (57-81 Nm). • Oil cooler pipe to the lower engine mount. Torque the bolt to 60 ft. lbs. (81 Nm). • Crossmember. Torque the bolts to 23-34 ft. lbs. (31-46 Nm). • Two transfer case mounting bolts located at the right center of the transfer case. Torque the bolts to 23-34 ft. lbs. (31-46 Nm). • Four transfer case nuts to the crossmember. Torque the nuts to 23-34 ft. lbs. (31-46 Nm). • Torque converter-to-drive plate bolts. Torque the bolts to 12-20 ft. lbs. (16-27 Nm). • Torque converter inspection cover. Torque the bolts to 41-62 inch lbs. (5-7 Nm). • Front splash guard. Torque the bolts to 41-62 inch lbs. (5-7 Nm). • Starter. Torque bolts to 27-40 ft. lbs. (37-54 Nm). • Left side lower gusset. Torque the bolts to 38-60 ft. lbs. (57-81 Nm). • Right side lower gusset in 3 steps: a. Install the bottom mounting bolts, but do not tighten. b. Install the top bolt to the intake manifold support bracket and manifold. Tighten to 27-40 ft. lbs. (37-54 Nm). c. Secure the manifold intake bracket by tightening the two attaching bolts to 38-60 ft. lbs. (57-81 Nm). • Oil cooler pipes at the transmis¬ sion. Torque the lines to 42-62 inch lbs. (5-7 Nm). • Two oil cooling tube clamps to the lines

• Driveshafts with the matchmarks

Clutch pedal height and free-play adjust¬ ment points

OQ j.AO • «J ir

kia AGE SPORT

.

0 6. 7. 8 9.

CLUTCH DISC FLYWHEEL PILOT BEARING FLEXIBLE HOSE 7924QG26

Exploded view of the clutch assembly

REMOVAL & INSTALLATION

• Transmission

Hydraulic Clutch System BLEEDING 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. With an assistant in the vehicle, raise and safely support the vehicle. 3. Have your assistant pump the clutch

pedal three times and hold the pedal to the floor. 4. Open the bleeder valve on the clutch slave cylinder until the air is purged from the cylinder. 5. Tighten the bleeder valve. 6. Have your assistant release the clutch pedal. 7. Fill the clutch master cylinder if below minimum. 8. Repeat Steps 2 through 6 until no air exits from the bleeder valve. 9. Lower the vehicle.

oir

erv

res

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. Remove or disconnect the following: • Transmission • Pressure plate bolts and remove the clutch plate and disc To install: 3. Install or connect the following: • Clutch disc and plate using a cen¬ tering tool • Clutch cover. Torque the bolts to 73 ft. lbs. (99 Nm) and remove the centering tool

sary • Check the release bearing condition and lubricate or replace as neces¬

.

Transfer Case Assembly REMOVAL & INSTALLATION

precautions in the beginning of this section .

2. Drain the transfer case. 3. Remove or disconnect the following: • Negative battery cable • Two rear console mounting screws. Slide the console forward to clear the parking brake handle and set aside

• Three mounting screws from the front console. Untie the shift boot draw strings and open the boot • Loosen the transfer case shift lever locknut and remove the lever knob • Pull the console up to access the Power/Economy switch wiring con-

. 1 Before se rvicing the ve hicle, refer to the

FRONT

COVER 9308QG05

Exploded view of the transfer case assembly

nector. Unplug the connector and remove the console

tion.

• Cover plate • Retaining bolts from the transfer case and lift the shifter lever assembly straight out and properly 4. Shift support the transftheer transmission lever to the 4 • Matchmark the driveshaft sL atposi the¬ flanges and remove the driveshafts • Crossmember bolts • 4WD light switch connector • Transfer case mounting bolts located at the right center of the transfer case • Transfer case nuts from the cross¬ member • Separate the transfer case from the transmission by striking the trans¬ fer case with a plastic mallet at the seal area 5. Lower the transfer case from the vehicle. To install:

8. Start the vehicle and check for leaks, repair if necessary.

Halfshaft REMOVAL & INSTALLATION

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. Remove or disconnect the following: • Negative battery cable • Both front wheels • Six free wheel hub bolts and remove the hub • Snapring and spacer from the hub • assembly Carefully remove the fixed cam • Caliper from the brake rotor • Upper control arm link lockbolt, spring washer and nut • Tie rod end from the steering knuckle • Loosen the drop link lower locknut • Loosen the four upper drop link locknuts • Spread open the drop link fork with a rubber mallet • Matchmark the halfshaft and differ¬ ential.

6. Install or connect the following: • Transfer case in position with a new gasket. Torque the bolts to 32 ft. lbs. (44 Nm). • Carefully pry the halfshaft from the • Crossmember. Torque bolts to 32 differential • Halfshaft ft. lbs. (44 Nm). • Transfer case mounting bolts To install: located at the right center of the transfer case. Torque the bolts to • Halfshaft with the matchmarks 38 ft. lbs. (52 Nm). aligned with the differential • Four transfer case nuts to the crossmember. Torque the nuts to 15 ft. lbs. (20 Nm). • Align the matchmarks on the driveshafts to the flanges. Torque the Ins and bolts to 27 ft. lbs. (36 Nm) tal lor remove the transmission support con nec ¬ • 4WD light switch electrical connec t he tor fol low • VSS electrical connector ing : • Shifter lever assembly. Torque retaining bolts to 20 ft. lbs. (27 Nm).

• Cover plate. Torque the bolts to 15 ft. lbs. (20 Nm). • Power/Economy switch wiring con¬ nector • Front console • Lever knobs • Front console and tie the shift boot draw strings • Slide the console over the parking brake handle • Rear console • Negative battery cable

• Torque the upper and lower drop link nuts to 36 ft. lbs. (49 Nm). • Tie rod end to the steering knuckle. Torque the locknut to 27 ft. lbs. pin (36 Nm) and install a new cotter • Upper control arm link lockbolt, spring washer and nut. Torque the bolt to 36 ft. lbs. (49 Nm). • Fixed cam assembly • Snapring and spacer in the hub • Wheel hub and the six free wheel hub bolts. Torque the bolts in two passes, 14 ft. lbs. (17 Nm), then to 23 ft. lbs. (31 Nm). • Front wheel assemblies • Negative battery cable

Locking Hubs REMOVAL & INSTALLATION

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. ing: 2. Remove or disconnect the follow¬

• Negative battery cable • Wheel asse mbly • Six free wheel hub bolts and remove the hub hub • Snapring and spacer from the • assemb Carefulllyy remove the fixed cam

lev el

SPORTAGE

4WD

ONLY

Exploded view of the 4WD locking hub assembly

i

®*v \

1 BOLT/WASHER 2 FREE WHEEL HUB BODY 3 SNAP RING 4 SPACER 5 FIXED CAM ASSEMBLY 6 LOCKNUT 8 SCREW

I vP w

9 10 11 12 13 14 15

ROTOR WHEEL

HUB INNER BEARING INNER RACE INNER BEARING OUTER RACE OUTER BEARING OUTER RACE OUTER BEARING INNER RACE OIL SEAL

16 17 18 19 20 21 22

20

BOLT & SPRING WASHER DUST COVER KNUCKLE NEEDLE BEARING OIL SEAL SPACER DRIVE SHAFT (LH) 7924Q628

9 1R I U.Q OC

KIA

SPORTAGE

To install:

3. Install or connect the following: • Fixed cam assembly • Snapring and spacer in the hub • Wheel hub and the six free wheel hub bolts. Torque the bolts in two passes, 14 ft. lbs. (17 Nm), then to 23 ft. lbs. (31 Nm). • Wheel assembly • Negative battery cable

•

•

•

• Spindle Bearings

with the upper and lower ball joints in the mounting holes Lower control arm. Torque the lock nut to 110 ft. lbs. (148 Nm) and install a cotter pin Tie rod end to the steering knuckle. bly the nut to 27 ft. lbs. (36 Torque Nm) and install a cotter pin Upper control arm. Torque the lock bolt to 36 ft. lbs. (49 Nm). Free wheel hub and bearing assem¬

• Front wheel • Negative battery cable

REMOVAL & INSTALLATION

Axle Shaft Bearing and Seal REMOVAL & INSTALLATION

1 . Before servicing the vehicle, refer to the precautions in the beginning of this se

tion .

2. Remove or disconnect the following. • Negativ battery cable • Wheel easse mbly • Rear wheel • Brake drum

• wheel speed sensor, if equipped

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion . 2. Remove or disconnect the follow¬ ing: • • • •

Negative battery cable Wheel assembly Free wheel hub and bearing Upper tie rod end from the steering knuckle

• Lower control arm from the steer¬ ing knuckle • Steering knuckle • Inner oil seal • Spindle bearing

To install:

3. Install or connect the following: • Spindle bearing using Bearing Installer tool K95B-5011-A • New oil seal and apply grease to the bearing and seal lip • Halfshaft end • Steering knuckle to the halfshaft

1. 2. 3. 4. 5. 6.

Lock Nut Lock Washer Bearing Oil Seal Oil Seal Retainer Axle Shaft

9308QG07

exploded view of the axle shaft, bearing and seal

• Bearing retaining nuts • Axle shaft and bearing To install:

3. Install or connect the following: • Oil seal retainer, oil seal and wheel Nm). bearing to the axle shaft. Torque the new lock nut to 220 ft. lbs. (300 '■►Turn the right side halfshaft lock nut clockwise and the left side halfshaft lock nut counterclockwise.

• Axle shaft assembly into the axle housing. Torque the nuts to 74 ft. lbs. (100 Nm). •• Wheel speed sensor, if equipped Brake drum

• Rear wheel assembly • Negative battery cable 4. Check necessary . the fluid level and top off if

KiA

SPORTAGE

I

e*Use an inch lb. (Nm) torque wrench , measure and record the amount of torque required to maintain rotation of the pinion.

Pinion Seal REMOVAL & INSTALLATION

tO

1 . Before servicing the vehicle, refer to ons in the beginning of this sec¬ the precauti . tion ng: 2. Drain the gear oil. 3. Remove or disconnect the follow-

ss«

• • • •

• Pinion flange • Pinion seal

To install:

4. Install or connect the following: • New pinion seal lightly coated with clean gear oil • Pinion flange

5. Rotate the pinion flange occasionally while tightening the flange nut and make certain that the pinion bearings are seated properly.

Negative battery cable Wheel assemblies Brake drums driveshaft

15-33

6. Take several bearing preload torque readings. Tighten the flange nut to achieve the preload torque reading. The maximum torque reading should not exceed 14 inch lbs. (1.6 Nm). • Driveshaft after aligning the matchmarks • Brake drums • Wheel assemblies • Negative battery cable 7. Fill the gear oil to the proper level. 8. Start the vehicle and check for leaks, repair if necessary.

STEERING AND SUSPENSION for any reason, to rearm, be sure no one is in the vehicle (as an added safety measure), then connect the negative battery cable.

Air Bag PRECAUTIONS

Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible per¬ sonal injury. 1 . Never carry the inflator module by the wires or connector on the underside of the module. 2. When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed away from you. 3. Place the inflator module on a bench or other surface with the bag and trim cover facing up. 4. With the inflator module on the bench, never place anything on or close to the module which may be thrown in the event of an accidental deployment.

!t?

ADJUSTMENT

1 . Before servicing the vehicle, refer to ns in the beginning of this sec¬ the precautio tion .

2. Place the steering gear in a vise with protective jaws. 3. Place a torque wrench on the Pitman arm end of the shaft. 4. Loosen the locknut on the adjusting bolt. 5. Slowly turn the adjusting bolt to until the breakaway torque is 65 ft. lbs. (88 Nm). 6. Hold the adjusting bolt in position Nm). and tighten the locknut to 25 ft. lbs. (34

¬ sec s thi of

gi be the in in

nn g

s

4. Wait 10 minutes for the back-up power to discharge. '

ARMING 1 Bef

rto

e r,ef cle

i veh tghe cin

i erv

ores

Assuming the system components (air bag control module, sensors, air bag, etc.) are installed correctly and are in good work¬ ing order, the system is armed whenever the battery positive and negative battery cables are connected.

If you have disarmed the air bag system

nut • Separate the Pitman arm from the centerlink with a ball joint puller • Power steering hoses • Coolant recovery tank and the power steering reserve tank • Set bolt from the intermediate shaft • Intermediate shaft from the steering •• Steering gear-to-frame bolts Steering gear To install:

5. Install or connect the following: • Position the steering gear to the gear frame. Torque the bolts to 159 ft. lbs. (215 Nm). • Pitman arm to the centerlink. Torque the bolt to 36 ft. lbs. (49 Nm) and install a new cotter pin . Intermediate shaft to the steering Torque the set bolt o 25 gearlbs.shaft. ft. (34 Nm).

ion

1 . Before servicing the vehicle, refer to ons in the beginning of this sec¬ the precauti . tion 2. Turn the ignition switch to the LOCK position. 3. Disconnect the negative battery cable.

t cau pr. e n thtieo

ill

• Pitman arm-to-centerlink attaching

REMOVAL & INSTALLATION

DISARMING ::

Power Steering Gear

2. Center the steering wheel. 3. Drain the power steering fluid. 4. Remove or disconnect the following: • Negative battery cable • Left front wheel

Exploded view of the steering gear

1 v» 04 1

KIA SPORTAGE

• Power steering hoses/lines. Torque the fasteners to 29 ft. lbs. (34 Nm). • Power steering reserve tank over the bracket and press until full engagement is reached • Coolant recovery tank • Left front wheel • Negative battery cable 6. Fill the power steering fluid to the proper level and bleed the system. 7. Start the vehicle and check for leaks, repair if necessary. 8. Road test the vehicle to check that the steering wheel is straight.

-

\

1

Shock Absorber REMOVAL & INSTALLATION Front

The front shock absorber and coil spring are removed as a single unit. 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion . 2. Remove or disconnect the following: • Negative battery cable • Both front wheels • Upper shock absorber mounting block nuts • Stabilizer bar • Drop link nut and allow the drop link to remain in place • Both halves of the front fork • Drop link • Shock absorber and coil spring as an assembly To install:

3. Install or connect the following: • Coil spring to the shock absorber and position the assembly to the upper mounting block • Upper mounting block nuts and hand tighten them • Both front forks . Torque the bolts to 36 ft. lbs. (48 Nm). • Drop link. Torque the nut to 145 ft. lbs. (197 Nm). • Stabilizer bar to the drop link. Torque the nut to 36 ft. lbs. (48 Nm).

• Front wheels and torque the mounting block nuts to 18 ft. lbs. (25 Nm). • Negative battery cable Rear

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion .

1 Front Shock Absorber & Coil Spring Assembly 2 Front Fork 3 Drop Link 9308QG09

Exploded view of the front shock absorber assembly

Remove or disconnect the following: • Negative battery cable • Rear wheels

• Raise the rear axle with a floor jack to relax the shock absorbers and support the rear axle when the shock absorber is removed. • Rear safety nut, upper nut and washer • • • •

Upper Lower Lower Shock

rubber plate bolt from the shock absorber the rear axle housing absorber

3. Remove the lower mounting bolt and remove the shock absorber. To install:

4. Install or connect the following: • Bottom washer and rubber cushion on the top of the shock absorber. Position the shock absorber on the vehicle • Lower bolt

• Rubber cushion, washer and nut. Tighten to 53 ft. lbs. (72 Nm) • 62 Safety nut. (84 Torque ft. lbs. Nm). the lower bolt to

KIA SPORTAGE

15-35

• Rear wheels • Negative battery cable

Coil Spring REMOVAL & INSTALLATION Front

1 . Before servicing the vehicle, refer to ns in the beginning of this sec¬ the precautio . tion 2. Remove or disconnect the following: • Negative battery cable • Shock absorber and coil spring as an assembly • Place the shock absorber in a vice • Loosen the pivot rod nut several turns • While still secured in a vise com¬ press the coil spring • Piston rod nut and disassemble the coil spring as needed To install: 79240G32

3. Install or connect the following: • Bottom portion of the shock absorber in a vice and compress the coil spring • End of the coil spring to the rubber seat and install the spring • Assemble the dust boot and lower retainer, lower insulator, spring seat, boss, center washer, upper insulator and install the coil spring • Hand tighten the piston rod nut.

Upper shock absorber mounting nut

• Carefully loosen the spring com¬ pressor tool and remove the tool • Torque the piston rod nut to 31 ft. lbs. (42 Nm). springy and shock absorber as Coilassembl • an

SHOCK ABSORBER Rear

JACK

SHOCK ABSORBER LOWER BOLT

1 . Before servicing the vehicle, refer to ons in the beginning of this sec¬ the precauti . tion 2. Remove or disconnect the following: • Both rear wheels • Raise the rear axle with a floor jack to relax the shock absorbers and support the rear axle when the shock absorber is removed. ^For easier installation, complete one side at a time.

7924QG33

Lower shock absorber mounting bolt

• Lower mounting bolt, then the shock absorber • Lower the floor jack until the coil • Coil spring spring is fully expanded

• Inspect the upper and lower rubber

1 5-36 SPORTAGE

sary spring seats and jounce stop for wear or damage, replace if neces¬

worn, replacement of the upper control arm is necessary.

Lower Ball Joint

To install:

3. Install or connect the following: • Position the spring in the upper and lower saddles • Raise the floor jack and connect the lower shock absorber bolt. Torque the bolt to 62 ft. lbs. (84 Nm). • Rear wheels

Upper Ball Joint REMOVAL & INSTALLATION

REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion . 2. Remove or disconnect the following: • Negative battery cable • Front wheel assembly • Cotter pin and lower ball joint nut • Separate the lower ball joint from the spindle with a puller tool by

The upper ball joint is an integral part of the upper control arm. If the ball joint is

pryingit down on the to sep¬ arate from the lowerspindle ball joint

1. Nut 2. Upper retainer 3. Upper insulator 4. Centering washer 5. Spring seat 6. Coil spring 7. Lower insulator 8. Lower retainer 9. Dust boot 10. Rubber seat 11. Shock absorber 12. Front jounce stop 9308QG10

Exploded view ol the front shock absorber and coil spring assembly

3 4 5 6

DROP LINK FRONT FORK DROP LINK BUSHING LOWER CONTROL ARM

BALL JOINT 7924QG34

Exploded view of the lower control arm and ball joint assembly

KIA

SPORTAGE

• Bolt securing the upper ball joint to the steering knuckle

• Lower ball joint attaching bolts • Lower ball joint To install:

3. Install or connect the following: • Position the lower ball joint and install the attaching nuts and bolts. Torque the fasteners to 36 ft. lbs. (48 Nm). • Pry down and guide the spindle onto the lower ball joint. Torque the nut 87 ft. lbs. (118 Nm) and install a new cotter pin • Front wheel assembly. • Negative battery cable

Upper Control Arm REMOVAL & INSTALLATION

»»Note the matchmark setting on the upper control arm mounting bolts before removal.

• Upper control arm mounting bolts • Upper control arm from the vehicle.

To install:

3. Install or connect the following: • Position the upper control arms in the frame mounting. Hand tighten the bolts

• Position the ball joint in the spin¬ dle. Torque the through bolt to 36 ft. lbs. (48 Nm). ^Be sure the slot in the ball joint aligns with the through-bolt during installation.

1 . Before servicing the vehicle, refer to ons in the beginning of this sec¬ the precauti tion . 2. Remove or disconnect the following: • Negative battery cable • Front wheel assembly

• Align the upper control arm bolts to the previous settings. Torque bolts to 62 ft. lbs. (108 Nm). • Front wheel assembly 4. Check and adjust the alignment, if necessary. 2

15-37

UPPER CONTROL ARM BUSHING REPLACEMENT 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion . 2. Remove or disconnect the following: • Upper control arm assembly • Secure the control arm in a vise bushing • Using a standard press, remove the To install:

3. Install or connect the following: • Lubricate the new bushing and press it into the upper control arm • Upper control arm to the vehicle 4. Check the wheel alignment and adjust if necessary.

Lower Control Arm REMOVAL & INSTALLATION

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion . 2. Remove or disconnect the following: • Negative battery cable • Front wheel assembly • Stabilizer bar • Driveshaft from the differential and steering knuckle • Shock absorber and coil spring from the front half of the fork • Cotter pin and castle nut from the lower control arm ball joint • Lower control arm ball joint from the steering knuckle • Lower control arm bushing bolts from the front frame crossmember brackets • Lower control arm

\

\

To install:

3. Install or connect the following: • Lower control arm to the front frame crossmember brackets and hand tighten the bushing bolts • Lower control arm ball joint and bolt to the steering knuckle. Torque the bolt to 87 ft. lbs. (118 Nm). • New cotter pin and castle nut

• Torque the lower control arm bush¬ ing bolts to 206 ft. lbs. (280 Nm). • Front fork halves to the shock

1 UPPER CONTROL ARM 2 UPPER CONTROL ARM BUSHING 3 FRONT SPINDLE 4 REAR SPINDLE

Exploded view ot the upper control arm assembly

7924QG31

absorber and coil spring and posi¬ tion the lower portion over the lower control arm drop link holes . Drop link. Torque the nut to 145 ft. lbs. (197 Nm). . Driveshaft to the front differential and steering knuckle

15 “3 8

SPORTAGE

• Stabilizer bar • Front wheel assembly • Negative battery cable 4. Check and adjust the front wheel alignment if necessary. LOWER CONTROL ARM BUSHING REPLACEMENT 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion . 2. Remove or disconnect the following: • Lower control arm assembly • Secure the control arm in a vise • Using a standard press, remove the bushing To install:

3. Install or connect the following: • Lubricate the new bushing and press it into the lower control arm • lower control arm to the vehicle 4. Check the wheel alignment and adjust if necessary.

Wheel Bearings ADJUSTMENT Front

1 . Remove or disconnect the following: 2. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion . • Negative battery cable • Front wheel • Brake caliper from the rotor and hang it out of the way 3. Attach a dial indicator to the axle hub and measure the bearing play 4. If the play exceeds.004 inch (,10mm), check and adjust locknut torque. The bolts should be tightened to 23 ft. lbs. (31 Nm).

• Brake caliper • Brake rotor • Wheel bearing and using a screw driver, pry out the oil seal • Inner and outer bearings • Using a drift punch, remove the inner and outer bearing race To install:

3. Pack the new bearings with grease. 4. Install or connect the following: • Inner bearing and race and a new oil seal • Outer bearing and race and secure the dust cover with four screws • Apply grease to the new bearings and the lip of the oil seal • Hub assembly in the steering knuckle • Screw the locknut against the hub assembly until there is 10 inch lbs. (1.3 Nm) of preload on the hub • Brake rotor and retaining screws • Attach a run-out gauge to check the rotor run-out. The run-out should not exceed 0.004 inch (0.10mm) • Brake caliper • Free wheel hub fixed cam key with the locknut groove and push the on the fixed cam assembly • Axle retainer snap ring • Apply a light coat of sealant on the free wheel hub body. Install the body on the hub. Torque the bolts in 2 passes. Tighten the bolts on the first pass to 18 ft. lbs. (25 Nm). Tighten the bolts on the second pass to 23 ft. lbs. (31 Nm). • Negative battery cable

Rear

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec2. Remove or disconnect the follow• Negative battery cable • Rear wheels • Brake drum • Oil seal retainer flange '••The axle shafts are different from side-to-side, mark the to ensure they are returned to the proper side.

• Using a slide hammer, remove the axle shaft assembly • Using a hydraulic press, remove the bearing collar and bearing from the axle • oil seal from the differential To install:

3. Install or connect the following: • Using the appropriate seal driver, install the new axle seal into the differential '•The left-hand axle is 25.5 inches (647mm) long, (697mm) and the right-hand axle is 27.4 inches long.

• Using a hydraulic press, install the new wheel bearing and retainer col¬ lar to the axle shaft Nm). • Axle shaft into the carrier. Torque the nuts to 75 ft. lbs. (100 • Brake drum and rear wheels • Negative battery cable

Rear

The rear wheel bearings are not adjustable. REMOVAL & INSTALLATION Front 21 Bearing Bearing Collar

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section . 2. Remove or disconnect the following: • Negative battery cable • Front wheel • Free wheel hub body

3 Shaft 4 Axle Rib Ring 5 Oil Seal 6 Oil Seal Retainer

7924QG35

Rear axle bearing component identification

KIA

1

SPORTAGE

15-39

BRAKES To install:

Brake Caliper

0

0 REMOVAL & INSTALLATION

Disc Brake Pads

5. Seat the caliper piston using a Cclamp.

6. Connect the brake fluid flex line bolt to the caliper. Tighten the bolt to 17 ft. lbs. . Sportage (23.5 Nm). 7. Position the caliper over the disc 1. Raise and safely support the assembly. Install the caliper bolts. Tighten . vehicle. to 72 ft. lbs. (98 Nm). 2. Remove the front wheels. 8. Install the front wheels. Tighten the 3. Remove the 2 caliper bolts and lift lug nuts 77 ft. lbs. (99 Nm). the caliper from the disc. 9. Bleed the hydraulic system if the flex 4. Disconnect the brake fluid flex line hoses were removed. by removing the retaining bolt if the caliper is to be replaced. Low

er

the

veh

icl

e.

REMOVAL & INSTALLATION 1. Raise and safely support the vehicle. 2. Remove the front wheels. 3. Remove the 2 caliper bolts and lift the caliper from the disc. 4. Slide the disc pads off the caliper bracket. To install:

5. Clean the caliper bracket contact surface with a wire brush and lightly coat with assembly lube. 6. Position the disc pads. 7. Position the caliper over the disc assembly. Install the caliper bolts. Tighten to 72 ft. lbs. (98 Nm). 8. Install the front wheels. Tighten the lug nuts 77 ft. lbs. (99 Nm). 9. Bleed the hydraulic system if the flex hoses were removed. Low

er the Drums Brake veh

icl e REMOVAL &. INSTALLATION

1. Raise and safely support the vehicle. 2. Remove the rear wheels. 3. Apply the parking brake. 4. Remove the 4 attaching nuts. 5. Release the parking brake and remove the brake drum. Installation is the reverse of the removal procedure.

Brake Shoes REMOVAL & INSTALLATION 1. Raise and safely support the vehicle. 2. Remove the rear wheels. 3. Apply the parking brake. 4. Remove the 4 attaching nuts. 5. Release the parking brake and remove the brake drum.

Disc Pad 93026G87

Exploded view of the front disc brake assembly— Sportage

6. Remove the spring from the sec¬ ondary shoe to the adjusting lever. 7. Remove the adjusting lever. 8. Remove the return spring above the star adjusting wheel. 9. Turn the starwheel clockwise to relieve tension on the brake shoes.

1 5-40 S PORTAGE Parking Brake Cable

Primary Brake Shoe (Leading)

v

Adjusting Lever ing) Parking Brake Operating Lever

SpringLever Adjusting

Secondary

Brake Shoe

(Trai Brake Drum 93026G88

Exploded view of the rear drum brake assembly — Sportage

10. Remove the starwheel. 11. Remove the hold-down pin clips. 12. Remove the primary shoe. 13. Disconnect the C-clip and pin attaching the parking brake lever to the sec¬ ondary brake shoe. To install:

14. Lubricate the backing plate contact points.

15. Connect the parking brake lever to the secondary brake shoe. 16. Attach the primary and secondary brake shoes to the backing plate. 17. Install the starwheel. 18. Install the return spring above the starwheel. 19. Install the adjusting lever. 20. Install the spring from the secondary

shoe to the adjusting lever. Be sure the lever contacts the starwheel. 21. Install the brake drum and retaining nuts. 22. Adjust the rear brakes through the slot in the rear of the backing plate. 23. Install the wheels. Tighten the wheel lugs to 77 ft. lbs. (99 Nm). 24. Lower the vehicle.

LEXUS ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400 16-106 BRAKES . 16-76 DRIVE TRAIN . 16-13 ENGINE REPAIR . 16-73 FUEL SYSTEM . 16-13 PRECAUTIONS . SPECIFICATION CHARTS . 16-2 STEERING AND

SUSPENSION . A

16-84

Air Bag . Arming . Disarming . Precautions . Alternator . Installation . Removal . Axle Shaft, Bearing and Seal . Removal & InstalBlation .

16-84 16-84 16-84 16-84 16-13 16-13 16-13 16-83 16-83

Brake Caliper . Removal & InstallCation .

16-106 16-106

Camshaft and Valve Lifters . Removal & Installation . CV-Joints . Overhaul . Cylinder Head . Removal & InstallD ation .

16-55 16-55 16-80 16-80 16-44 16-44

Disc Brake Pads . Removal & InstallEation .

16-111 16-111

Engine Assembly . Removal & Installation . Exhaust Manifold . Removal & Installation .

16-14 16-14 16-54 16-54

F

Power Rack and Pinion

Fuel Filter . Removal & Installation . Fuel Injector . Removal & Installation . Fuel Pump . Removal & Installation . Fuel System Pressure . Relieving . Fuel System Service Precautions . H

16-73 16-73 16-74 16-74 16-73 16-73 16-73 16-73

Halfshaft . Removal & Installation . Heater Core . Removal & InstallIation .

16-80 16-80 16-30 16-30

Ignition Timing . Adjustment . Intake Manifold . Removal & InstallLation .

16-14 16-14 16-51 16-51

Lower Control Arm . Control Arm Bushing

16-97

16-73

16-101 Replacement . O ation . 16-97 Removal & Install Oil Pan . Removal & Installation . Oil Pump . Removal & InstallP ation .

16-65 16-65 16-68 16-68

Pinion Seal . Removal & Installation . Piston and Ring . Positioning .

16-83 16-83 16-72 16-72

Steering Gear . Removal & InstallSation .

16-84 16-84

Starter Motor . Removal & Installation . Strut and Coil Spring . Removal & InstallT ation .

16-65 16-65 16-87 16-87

Timing Belt . Removal & Installation . Transaxle Assembly . Removal & Installation . Transmission Assembly . U ation . Removal & Install

16-70 16-70 16-79 16-79 16-76 16-76

Upper Ball Joint . Removal & Installation . . ol Arm Control Bushing ContrArm Upper

16-95 16-95 16-95

Replacement . V ation . Removal & Install

16-97 16-95

Valve Lash . W Adjustment .

16-62 16-62

16-28 Water Pump . 16-28 . ation Install & al Remov 16-101 Wheel Bearings . 16-101 Adjustment . Removal & Installation . 16-101

A a o ID“t

LEXUS ES 300 * IS 300 « GS 300 * GS 400 « GS 430 * LS 400 * LS 430 * SC 300 « SC 400 ■

SPECIFICATION CHARTS ENGINE AND VEHICLE IDENTIFICATION

Code©

Liters (cc)

1MZ-FE

3.0 (2995)

1UZ-FE

4.0 (3969)

Engine Cu. In. 183

2JZ-GE

3.0 (2997)

242 183

3UZ-FE

4.3 (4264)

262

Cyl.

Fuel Sys.

6

SFI

8

SFI

6 8

Engine Type

Eng. Mfg.

DOHC DOHC

Toyota

DOHC DOHC

SFI SFI

Code®

Model Year Year

2000 Y

Toyota Toyota Toyota

1

2001

2

2002 2003

3

SFI: Sequential Multi-port Fuel Injection DOHC: ©

Double Overhead Camshaft

t

Located on the timing belt cover

©10th

digit ot the VIN 42356- LEXC-C01

GENERAL

ENGINE SPECIFICATIONS

All measurements are given in inches. Engine Displacement Engine Year_

2000

2001

2002

2003-04

Model

Liters (cc)

GS 300 GS 400

3.0 (2997) 4.0 (3969)

LS 400

4.0 (3969)

SC 300 SC 400

3.0 (2997) 4.0 (3969)

ES 300

3.0 (2995)

GS 300

3.0 (2997)

GS 430 IS 300

4.3 (4264)

LS 430 ES 300

4.3 (4264)

ES 300

3.0 (2995)

3.0 (2997) 3.0 (2995)

GS 300

3.0 (2997)

GS 430

4.3 (4264)

IS 300

3.0 (2997)

LS 430

4.3 (4264)

ES 300

3.0 (2995)

GS 300

3.0 (2997)

GS 430 IS 300

4.3 (4264)

LS 430

3.0 (2997) 4.3 (4264)

ID/V1N 1MZ-FE 2JZ-GE 1UZ-FE 1UZ-FE 2JZ-GE 1UZ-FE 1MZ-FE 2JZ-GE

Net Net Fuel System Horsepower Torque 0 rpm Type SFI

SFI SFI SFI SFI SFI SFI SFI

3UZ-FE 2JZ-GE

SFI

3UZ-FE 1MZ-FE

SFI

2JZ-GE 3UZ-FE 2JZ-GE 3UZ-FE 1MZ-FE 2JZ-GE 3UZ-FE 2JZ-GE 3UZ-FE

SFI SFI SFI SFI SFI SFI SFI SFI SFI SFI SFI

® rpm

(ft. lbs.)

Bore x Stroke (in.)

Oil Compression Pressure 0 rpm Ratio 43-78 0 3000 10.5

188 @5200

203 0 4400

3.44x3.27

22005800

21004800

3.39x3.39

260 @5300

270 0 4500

3.45x3.25

26005300

270 0 4500

3.45x3.25

10.4 1 10.4 1

220 @5800

210 0 4800 2700 4500

3.39x3.39 3.45x3.25

10.0 1 1

220 0 4400 220 0 3800

3.44x3.27 3.39x3.39

10.4 10.0 1 10.5 1

3.58x3.25

1

215 0 5800

32504500 218 0 3800

3.39x3.39

29005300

320 0 4500

3.58x3.25

10.4 1 10.0 1

210 0 5200

220 0 4400

220 0 5800

220 0 3800

3.44x3.27 3.39x3.39

10.4 1 10.5 10.0 1

300 0 5300

325 0 4500 218 0 3800

3.58x3.25 3.58x3.25

210 0 5200

32004500 220 0 4400

220 0 5800 300 0 5300

220 0 3800 325 0 4500

3.39x3.39

215 0 5800 290 0 5300

290 @5300 210 0 5200 22005800 300 @5300

215 0 5800 290 0 5300

10.0

47-84 0 3000 43-85 0 3000 43-85 0 3000 47-8403000 43-85 0 3000 43-78 0 3000 47-84 0 3000 43-85 0 3000 47-84 0 3000 43-85 0 3000 43-78 0 3000 47-84 0 3000

1 10.4 1 10.0 1 10.5 10.4 1 10.0 1

43-85 0 3000 47-84 0 3000

218 0 3800

10.4 1 10.0 1

43-85 0 3000

3.58x3.25 3.39x3.39

320 0 4500

3.58x3.25

10.4 1

43-85 0 3000

3.39x3.39 3.44x3.27

43-85 0 3000 43-78 0 3000 47-84 0 3000 47-84 0 3000

SFI : Sequential fuel injection 42356- LEXC-C02

Intake 8-12B©

2000

3.0 (2995)

0.043

1MZ-FE

750 8-12B©

3.0 (2997)

0.043

2JZ-GE

0.010

750

0.0060.010

2001

3.0 (2995)

0.043

508006

0.010 0.006-

1MZ-FE

8-1 2B© 8-1 2B@

3.0 (2997)

0.043

2JZ-GE

0.043

3UZ-FE

44-50

750 650-

2002

3.0 (2995)

800 650-

0.043 0.039-

2JZ-GE

4.3 (4264)

0.043 0.0390.043

3UZ-FE

8-1 2B@

8-1 2B®

8-1 2B©

2003-04

3.0 (2995)

750 650-

44-50

750 007

2JZ-GE

4.3 (4264)

3UZ-FE

0.043 0.039-

8-1 2B©

0.043 0.0390.043

8-1 2B®

0.01060.00

0.014 0.010-

650750

0.0060.010

0.014 0.010-

750 007

0.010 0.006-

44-50 0.010 0.006-

800

reflects specification changes made differ from those in this chart. NOTE: The Vehicle Emission Control Information label often during production. The label figures must be used if they 650B: Before top dead center 0.006TE1 and El of check connector must be connected

©Terminals

TC and El of check connector must be connected

0.014 0.010-

800 650-

650-

©Terminals

0.014 0.010-

0.0100.014

44-50 44-50

0.010 0.006-

0.014 0.010-

0.0060.010

44-50

1MZ-FE

3.0 (2997)

0.010 0.006-

44-50

1MZ-FE

3.0 (2997)

0.014 0.010-

0.010 0.006-

44-50

8-1 2B©

0.014 0.010-

0.010 0.006-

44-50 750700-

8-1 2B® 4.3 (4264)

0.014 0.010-

44-50

0.043

1UZ-FE

0.014

44-50

8-12B© 4.0 (3969)

Exhaust

44-50

0.0100.014 0.014 0.010-

0.010-

700-

be connected ® LS 430: Terminals TC and CG of check connector must be connected GS 430/300: Terminals TC and El of check connector must

© ©

42356-LEXC-C03

m

CO

© ©

©

0(7)

L

FRONT 9307C601

4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines Firing order: 1-8-4-3-6-5-7-2 Distributorless ignition system (one coil on each cylinder)

0®

OF CAR 9307CG02

3.0L (1MZ-FE) Engine Firing order: ignition system (one coil per cylinder) orless1-2-3-4-5-6 Distribut

16-4

LEXUS ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430

SC 300 • SC 400

: ©©EMM)© 9307C604

3.0L (2JZ-GE) Engine Firing order: 1-5-3-6-2-4 Distributorless ignition system (one coil on each cylinder)

ALTERNATOR

P/S PUMP

A/C COMPRESSOR CRANKSHAFT 79234G33

79234G31

Serpentine drive belt routing — 4.0L (1UZ-FE) and 4.3L (3UZ-FE) Accessory drive belt routing— 3. OL (1MZ-FE) engine

engines

Cooling

CAPACITIES Engine Year

Model

2000

ES 300

2001

2002

2003-04

Displacement Liters (cc) 3.0 (2995)

GS 300

3.0 (2997)

GS 400

4.0 (3969)

LS 400

4.0 (3969)

SC 300

3.0 (2997)

SC 400 ES 300

4.0 (3969) 3.0 (2995)

GS 300

3.0 (2997)

GS 430

4.3 (4264)

Engine ID/VIN

2JZ-GE

Transmission

6.0 5.5 4.0

1UZ-FE 1 UZ-FE

6.5

2JZ-GE

5.5

4.0

5.1

4.0

5.0

8.2 4.0

1 UZ-FE 1MZ-FE 2JZ-GE 3UZ-FE 2JZ-GE

IS 300

3.0 (2997) 4.3 (4264)

ES 300

3.0 (2995)

GS 300

3.0 (2997)

GS 430

4.3 (4264)

IS 300

3.0 (2997)

LS 430

4.3 (4264)

ES 300

3.0 (2995)

3UZ-FE 1MZ-FE

GS 300

3.0 (2997)

2JZ-GE

GS 430 IS 300

4.3 (4264)

LS 430

4.3 (4264)

3UZ-FE 1MZ-FE 2JZ-GE 3UZ-FE 2JZ-GE

3UZ-FE 2JZ-GE 3UZ-FE

—

(9al) 19.8 22.5 20.6 20.6

2.8 —

4.0

4.0 8.2

2.8 — 2.8

4.0

2.8

4.0

2.8

5.0

8.2

—

4.0 5.7 5.5

4.0

2.8 2.8 2.8

6.0

4.0

2.8

6.5

8.1

—

lf Wf 9.8 11.6 8.9 12.3

18.5 19.8 19.8 17.5 22.2 18.5 19.8 19.8 17.5 22.2

2.8

6.5

System 9.7

19.8

2.8 2.8 2.8

4.0 5.7 5.5 6.0

18.5

(pts.) 2.8

6.0 6.5 5.0

Fuel Tank

2.8 2.8 2.8

6.0 5.5

Drive Axle

Auto. © (Pts) 4.0 8.2

1MZ-FE

LS 430

3.0 (2997)

Engine Oil with Filter 5.0

18.5 19.8 19.8

9.7 9.5 8.1 7.9 10.4 9.7 9.5 8.1 7.9 10.4 9.7

17.5

7.9 9.5 8.1

22.2

10.4

NOTE: All capacities are approximate. Add fluid gradually and check to be sure a proper fluid level is obtained. ©

Specification is for transmission drain and refill, not overhaul.

42356-LEXC-C04

LEXUS SC 400

16-5

Ste m

—

Spring

Engine Displacement Engine IDA/IN Liters 001

3.0 (2995) 3.0 (2997)

1MZ-FE

2JZ-GE 1 UZ-FE

Seat Angle (deg.) NA

NA NA

Face Angle (deg.) 44.5

41.9-46.3® 44.5

2JZ-GE

NA NA

1.331 41.9-46.3® 1.358 ©

44.5 44.5

1MZ-FE

Springiest Pressure (lbs. ® in.)

41.9-46.3®

44.5

41.9-46.3®

3.0 (2995)

1MZ-FE

2002

3.0 (2997)

2JZ-GE

NA NA

45.9-50.7® 1.3795

44.5

41.9-46.3® 1.331

44.5

41.9-46.3® 1.358

45 4.3 (4264)

44.5 3UZ-FE 44.5

04" 2003-

3.0(2995)

©

2.130

1.791

1MZ-FE

©

2.130

1.791 ©

4.3 (4264)

NA Not Available

2JZ-GE

NA 45

44.5

44.5

0.21540.2356

0.2354 0.2152-

0.0010-

0.00120.0026

0.21540.2159

0.21520.2157

0.00120.0026

0.21540.2356

0.21520.2354

0.00120.0026

0.0024 0.0010-

0.23500.2159

0.23480.2157

0.0012-

0.0024

0.0026

0.21540.2159

0.21520.2157

0.00120.0026

0.21540.2356

0.21520.2354

0.00120.0026

0.23500.2159

0.23480.2157

0.21540.2159

0.21520.2157

0.0010-

0.0024 0.0010-

0.0010-

1.791

~

NA

0.2157

0.23480.2157

41.9-46.3®

2.130

0.2159

0.00120.0026

0.23500.2159

0.0024 0.0010-

©

0.0026

0.0026

0.0010-

1.3795

Exhaust

0.0024

2.130

45.9-50.7®

3UZ-FE

eter Intake

0.0012-

45.9-50.7® 1.3795

41.9-46.3® 1.358

Diam

0.0024 0.0010-

0.0024

1.331 3.0 (2997)

0.0024 0.0010-

0.0024

1.358 44.5

3UZ-FE

Guide nee Cleara Stem-to_ Intake ill Exhaust

1.791

1.331

45 4.3 (4264)

FreeLength (in.)

0.0012-

0.0024 0.0010-

0.0026

0.0024

0.0026

0.21540.2356

0.0010-

0.00120.0026

0.23500.2159

0.23480.2157

0.0012-

0.2154-

0.2152-

0.0024 0.0010-

0.0012-

(in

0.2152-

0.2354

©Pink: 1.7209 Yellow: 1.7362 ©GS400:

45.9-50.761.3795

SC400 & LS400: 45.9-50.76 1 .378 42356-LEXC-C05

S

LEXU ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400

fi If Ui.U 1

TORQUE

SPECIFICATIONS

All readings in ft. lbs.

Year

Engine Displacement Liters (cc)

Engine IDA/IN

2000

3.0 (2995)

1MZ-FE

3.0 (2997)

2JZ-GE

4.0 (3969) 2001

3.0 (2995) 3.0 (2997) 4.3 (4264)

2002

Bearing Rod

Bolts

Bolts

Bolts

© © ©

© © © © © © © © © © © ©

© © © © © © © © © © © ©

1MZ-FE

©

2JZ-GE

© ©

3.0 (2995)

3UZ-FE 1MZ-FE

3.0 (2997)

2JZ-GE

4.3 (4264) 2003-04

1UZ-FE

Bearing Main

Cylinder Head

3.0 (2995)

3UZ-FE 1 MZ-FE

3.0 (2997)

2JZ-GE

4.3 (4264)

3UZ-FE

©Head bolt:

© © © © © © ©Step

Crankshaft Damper Bolts 159

Plugs Flywheel Bolts

243 181 159 243 181 159

61

Manifold Exhaust Intake 11 13 21 11

36

Spark 13

36 30

13 13

32 30

61 61

13

13 21

13

61

®

32

13

61 61

11

36

13

30

13

181

®

11 13

32

13

159 243

61

21

36

181

61 61

21

30

13

32

243

®

1:25 ft. lbs.

©Nuts:

Step 1 : 40 ft. lbs.

Step 2: Tighten an additional 90 degrees

Step 1 : 20 ft. lbs.

Step 2: Plus 90 degrees

Step 3: Tighten an additional 90 degrees

Step 2: Plus 90 degrees

Recessed head bolt: 13 ft. lbs. ©6-point bolts: 20 ft. lbs. 12-point bolts: Step 1:16 ft. lbs. Step 2: Plus an additional 90 degrees

=5)

.J

..

57.9 (590, 43)

Adjusting Washer — *» • 52(530,38)

|

W®Yti5T

Adjusting Nut

-

—

37 (375, 27)

79(805,58)

i*

Heat Insulator

V?

44 (440, 32)

si )~1 (700,In 1 69 Heat sula

tor

79 (805, 58)

6

^

\ ♦ Gasket-^J^

Heated Oxygen Sensor (Bank 2 Sensor 2)

Center Exhaust Pipe Pipe Support Bracket

Front Floor Center Brace

e 1 N-m (kgf cm. tt lbf) : Specified torqu ♦ Non-reusable part 9301 LG04

(cont.)— GS 300 Exploded view of the engine removal and related components

on ESLExu300s • IS 300 if I Ui.CU

• GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400

• • • •

Heater hoses EVAP hose Brake booster hose The air conditioning compressor and tighten the Torx® bolt to 19 ft. lbs. (26 Nm). Tighten the nut and bolts to 38 ft. lbs. (52 Nm). • Power steering pump • Fuel lines with new gaskets and tighten the union bolts to 22 ft. lbs. (29 Nm) • Igniter • Ignition coil • Wiring harness from the wire clamp and coolant tank • Alternator and ground strap from the left engine mount • Starter • Radiator • Drive belt • Air cleaner • Volume air flow meter and intake air connector pipe as an assembly • Air cleaner duct • Accelerator, cruise control and the automatic transmission throttle control cables • Fuel • Engine oil • Coolant • Negative battery cable 16. Start the engine and check for leaks. 17. Check the automatic transmission fluid level.

18. Check and/or adjust the ignition tim¬ ing. 19. If equipped, install the front suspen¬ sion brace and tighten the mounting bolts to 43 ft. lbs. (58 Nm). 20. Install the hood and the hood insula¬ tor pad.

21. Road test the vehicle. 22. Recheck the fluid levels. IS 300

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Drain the engine oil. 5. Remove or disconnect the following: • Negative battery cable • Engine under cover • Air cleaner inlet • Brake booster vacuum hose • Radiator hoses • Mass Air Flow (MAF) sensor con¬ nector • Positive Crankcase Ventilation (PCV) hose

• • • • • • •

Air intake resonator Accelerator cable Accessory drive belt Front subframe brace Floor ground strap Starter motor wiring harness Fuel inlet hose support • Dash panel ground strap • Heater hoses

• Evaporative Emissions (EVAP) can¬ ister hose • Heated Oxygen (HO2S) sensor con¬ nectors clamp • Alternator wiring harness and • Cylinder block ground cable bracket • Igniter connector • clamps Data link connector and harness

• Powertrain Control Module (PCM) harness connectors • Power steering pump • A/C compressor • Drive shaft • • • • • •

Transmission control rod Exhaust front pipe Exhaust center pipe Stabilizer bar Front shock absorbers Lower ball joints from the steering knuckles

• Transmission mount crossmember. Support the powertrain from below. • Steering intermediate shaft • Front subframe 6. Lower the engine, transmission and

subframe away from the vehicle. To install: 7. Installation is the reverse of the removal procedure, while using the follow¬ ing torque values: • Transmission flange bolts: 53 ft. lbs. (72 Nm)

• Transmission flange-to-oil pan bolts: 27 ft. lbs. (37 Nm) • Torque converter bolts:74 ft. lbs. (100 Nm) Nm) • Left and right motor mount nuts: 52 ft. lbs. (70 Nm)

• Front subframe bolts: 52 ft. lbs. (70 • Transmission mount crossmember: 19 ft. lbs. (26 Nm) • Lower ball joint bolts: 181 ft. lbs. (245 Nm) Nm) • Lower shock absorber bolts: 47 ft. lbs. (64 Nm) Nm) • Stabilizer bar bolts: 13 ft. lbs. (18

• Stabilizer bar nuts: 36 ft. lbs. (49

• Steering intermediate shaft pinch bolt: 26 ft. lbs. (35 Nm) • Transmission control rod nuts: 108 inch lbs. (13 Nm) LS 400 and LS 430

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Relieve the fuel system pressure oil 3. Drain the engine coolant and engine 4. Remove or disconnect the following: Batter •• The y y clamp cover batter • Battery cables • Hood

• The oil pan protector • Air cleaner inlet assembly • Air cleaner and intake air connector • Drive belt, fan clutch and fan pulley • Accelerator, cruise control actuator and automatic transmission throttle • cables Radiatorfrom the throttle body • Engine oil level sensor connector • Alternator connector and wire • Engine wire clamp from the bracket on the alternator • 2 igniter connectors • Engine wire clamp from the igniter bracket • Ground strap from the right-hand engine mounting bracket • Ground strap from under the lefthand fender apron

• Engine wire clamp from the cowl

• water Radiator reservoir hose from the bypass pipe • Brake panel booster vacuum hose from the air intake chamber • Heater hose from the heater water valve and water bypass pipe • Fuel inlet hose from the fuel inlet

• Fuel return hose to the return pipe • Power steering air hose from the air intake chamber pipe • 2 power steering hoses from the clamp on the right-hand No. 3 tim¬ ing belt cover • Evapora tive Emission (EVAP) hose canister from the). pipe (from the charcoal • Engine wire from the cabin as fol¬ lows: • Undercover from under the glove compartment • Glove compartment

S -1C I U

LEXU 400 ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 * SC

0-1

fc. I

Transmission Control Rod 13(130,9)1

Fuel Inlet Hose

Rear Engine Mounting Member

PS Vane Pump Assembly

Hole Plug

Suspension Member (w/PS Gear Housing)

PS Pump Rear Stay

35 (360, 26)

O

152(530,38) 74 (750, 54)

A/C Compressor

100(1,020,74)

Adjusting Washer

43 (438, 32)

Center Exhaust Pipe ♦ Gasket

Propeller Shaft

Heat Insulator

Heat Insulator Heated Oxygen Sensor (Bank 1 Sensor 2)

♦ Gasket

♦ Re

Front Exhaust Pipe

N-m (kgf-cm, ft-lbf) : Specified torque ♦ Non-reusable part 9347LG03

Exploded view of the engine mounting— IS 300

9301LG05

Exploded view of the engine removal and related components— LS 400

16-23 Engine

and Transmission

Assembly

PS Pump

Rear Engine Mounting Member

_ \

■r—

A

, Wire Bracket

A-"'

^WireClamp^\r\\ A/C Compressor Stay - *- ® ® \ ft ABS Actuator Ground Cable

25 (250, 19)

A/C Compressor Connector ,

Rear Center Floor Crossmember Brace

Adjusting Washer Propeller Shaft

"r”

Heated Oxygen Sensor (Bank 2 Sensor 2)

czi^

Heat Insulator for Rear Side of Front Exhaust Pipe

Front Center Floor Crossmember Brace RH Heat Insulator for

^

Front Side of Front Exhaust Pipe

♦ Gasket

Gasket

LH Heat Insulator for Front Side of Front Exhaust Pipe Pipe Support Bracket

Heated Oxygen Sensor ♦ Gasket

(Bank 1 Sensor 2)

♦ Gasket

' N-m (kgf-cm. ft-lbf) ] : Specified Torque ♦ Non-reusable part

Center Exhaust Pipe 9301LG06

LS 400 Exploded view of the engine removal and related components (cont.)

1 6-24 ESLE300XUS • IS 300 » GS 300 • GS 400 * GS 430 • LS 400 • LS 430 • SC 300 • SC 400 Transmission Control Rod

Engine and Transmission Assembly PS Oil Pressure Switch Connector

Steering Intermediate Shaft

Engine Rear Mounting Insulator

A/C Compressor

A/C Compressor Connector

Front Suspension Member (w/PS Gear Housing) Adjusting Washer

Heated Oxygen Sensor (Bank 2 Sensor 2) Heat Insulator

Pipe Center Exhaust

♦ Gasket

Center Front Floor Brace

TWC ♦ Gasket

Heated Oxygen Sensor (Bank 1 Sensor 2)

Pipe Suppor Brackett

Heat Insulator

lii? (kgf cm, ft-lbf) |: Specified torque

♦ Non-reusable part

components— LS 430 Exploded view of the engine remov al and related

9347LG04

LEXUS iC.OC ES 300 * IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 * SC 300 • SC 400 ^ • 3 Powertrain Control Module (PCM) connectors • 2 cowl wire connectors from the connector on the bracket • Wire clamp from the bracket • Grommet from the cowl panel, then pull the engine wire out. • Power steering oil cooler pipe from the oil pan • Heated Oxygen (HO2) sensors • Front exhaust pipe • 2 catalytic converters • Center exhaust pipe • Heat insulator from the rear side of the front exhaust pipe • Front center floor and rear center floor crossmember braces • Driveshaft

• Air conditioning compressor with¬ out disconnecting the air condition¬ ing lines • Power steering pump • Heat insulators for the front side of the front exhaust pipe • Heater water valve from the cowl panel by removing the 2 nuts 5. Attach the engine chain hoist to the ingine hangers. 6. Remove or disconnect the following: • Engine mounting insulators from the engine suspension crossmem¬ ber by removing the 2 nuts • Transmission control rod from the shift lever by removing the nut • Rear engine mounting member by removing the 4 nuts and 4 bolts

7923LG05

Engine mounting insulator tastener loca¬ tions— LS 400

7923LG06

Engine mounting member LS 400

bolt locations —

7. Lift the engine and transmission assembly out of the vehicle slowly and carefully. 8. Disconnect the engine from the transmission as follows: 9. Remove or disconnect the following: • Vehicle Speed Sensor (VSS) con¬ nector • Park/Neutral Position (PNP) switch connector • Solenoid connector

• Direct clutch speed sensor connec¬ tor • 4 engine wire clamps from the brackets • Oil dipstick and guide from the transmission

pipes from the transmis¬ Oil cooler • sion and clamps • The flywheel housing undercover by removing the 2 bolts • The 6 torque converter bolts • 10 bolts holding the transmission to the engine • Transmission together with the torque converter clutch

To install:

10. Install the transmission to the engine and install the 10 bolts. Tighten the bolts as follows: • 14mm: 27 ft. lbs. (37 Nm) • 17mm: 53 ft. lbs. (72 Nm) 11. Install or connect the following: • Torque converter clutch bolts. Apply adhesive to 2 or 3 threads of the bolt end. Tighten the bolts to 30 ft. lbs. (41 Nm). • Flywheel housing undercover with the 2 bolts. Tighten bolts to 14 ft. lbs. (19 Nm). • Oil cooler pipe for the transmission • Dipstick guide and dipstick for the transmission • Engine wire to the transmission • VSS connector • PNP switch connector • Solenoid connector

• Direct clutch speed sensor connec¬ tor • 4 wire clamps to the brackets • Engine and transmission assembly to the vehicle • Rear engine mounting member to Nm)vehicle and the 4 bolts and 4 the nuts; bolts tightened to 19 ft. lbs. (25 Nm), nuts to 10 ft. lbs. (14

sion crossmember. Tighten the 2 nuts to 52 ft. lbs. (70 Nm). • Heater water valve to the cowl panel with the 2 nuts 12. Remove the engine hoist. 13. Install or connect the following: • Heat insulators for the front side of the front exhaust pipe • Power steering pump with the nut and 3 bolts-tighten the nut to 32 ft. lbs.ft.(43 29 lbs.Nm); (39 tighten Nm) the bolts to • The air conditioning compressor. Nm). the bolts to 36 ft. lbs. (49 Tighten Nm) and the nut to 22 ft. lbs. (29 • Driveshaft to the vehicle • Front center floor crossmember brace and tighten the bolts to 108 inch lbs. (13 Nm) • Rear center floor crossmember brace and tighten the bolts to 108 inch lbs. (13 Nm) • Heat insulator for the rear side of the front exhaust pipe • Center exhaust pipe • 2 front catalytic converters with 3 new nuts each. Tighten the nuts to 46 ft. lbs. (62 Nm). • Front exhaust pipe. 4 bolts holding bracket to the the pipe support transmission: 32 ft. lbs. (44 Nm). • HO2 sensors. Tighten the sensors to 33 ft. lbs. (44 Nm). • Power steering oil cooler pipe

• Engine wire harness to the passen¬ ger’s compartment • 3 PCM connectors • 2 engine wire connectors to the connector on the bracket • Engine wire clamp to bracket • Glove compartment and the dash undercover • All of the engine assembly connec¬ tors, wires, straps, clamps and hoses • Radiator • Accelerator and cruise control cables to the throttle body • Throttle control cable to the throttle

with automatic if equipped body,pulley • transmiss Fan ion • Fan clutch and the drive belt. Tighten the 4 nuts for the fan to 16 ft. lbs. (21 Nm). Air cleaner and intake air connector • assembly

• The transmission control rod to the shift lever with the nut. Tighten the nut to 108 inch lbs. (13 Nm).

•• Air cleaner inlet Battery • Coolant

• 2 nuts holding the engine mount¬ ing brackets to the front suspen¬

• Engine oil

16-26

LEXUS

• • • • •

cables cover undercover protector

Battery Battery Engine Oil pan Hood

ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300

SC 300 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Release the fuel system pressure. 3. Drain the fuel from the fuel tank. 4. Remove or disconnect the following: • Negative battery cable. Wait at least 90 seconds before performing any other work. • Battery and tray • Hood • Engine undercover, then drain the engine coolant and oil. • Accelerator cable • Cruise control cable • Throttle control cable (automatic transmission only) from the throttle body • Air cleaner assembly, resonator and the air intake hose. • Drive belt, fan (with fluid coupling attached) and the water pump pulley • Radiator • Evaporative Emissions (EVAP) hoses (vacuum hose and air hose) from the charcoal canister • Charcoal canister • Power steering pump • Air conditioning compressor • All wires, electrical leads and vac¬ uum hoses from the block • Wiring clips or brackets • Undercover beneath the glove box • Lower instrument panel, the trim panel and the glove box door • Right door sill trim (scuff plate). Lift the front edge of the carpet and remove the protective cover from the Powertrain Control Module (PCM).

• PCM connectors, the cowl wire connectors and the control unit connectors behind the glove box • 2 nuts holding the harness to the firewall and carefully pull the engine harness into the engine compartment • Power steering pipe and 2 clamp bolts from the engine block • Union bolt and 2 gaskets • Fuel inlet hose • Starter wiring and unhook the starter wiring from the clip • Front exhaust pipe and heat shield • Transmission control rod at the shift lever • Intermediate shaft

^Some vehicles are not equipped with adjusting washers. 5. Attach an engine lift to the lift hooks 6. Remove or disconnect the following: • The 2 nuts holding the engine to the front suspension crossmember • The 4 bolts and 4 nuts holding the engine to the rear crossmember • The rear engine mount • Engine/transaxle assembly out of the engine compartment 7. Place the engine and transmission assembly onto a stand. 8. For vehicles with automatic trans¬ ing: mission, remove or disconnect the follow¬ • Oil dipstick guide and dipstick for the transmission • Oil cooler tubes • Engine wire from the transmission • Starter from the engine by remov¬ ing the bolts 9. Separate the engine and transmis¬ sion.

To install:

• Engine and transmission • Starter to the engine by installing the bolts

ng:

owi oll

f tthe nec

n rco

lo tal Ins

• Engine wire to the transmission • With automatic transmission, the oil cooler tubes • With automatic transmission, the oil dipstick guide and dipstick to the transmission

Accelerator cable (1), throttle control cable (2), cruise control cable (3) loca¬ tions — SC 300

• Engine into the engine compart¬ ment • The rear mount. Tighten the 4 nuts to 10 ft. lbs. (13 Nm). Tighten the 4 bolts to 19 ft. lbs. (25 Nm). • Intermediate shaft to the rear differ¬ ential and tighten the bolts and nuts to 54 ft. lbs. (74 Nm). Install the center support bearing set bolts

SC 400 with the adjusting washers. Tighten the bolts to 36 ft. lbs. (49 Nm). • Transmission control rod to the shift lever (automatic transmission only) by installing the nut. • Exhaust heat insulator by installing the 4 nuts • No. 2 front exhaust pipe, tighten the nuts to 46 ft. lbs. (62 Nm) • The Nm).pipe support bracket to the transmission with the 2 bolts. Tighten the bolts to 32 ft. lbs. (43 • No. 2 front exhaust pipe to the front exhaust pipe with the 2 bolts and nuts. Tighten the bolts to 32 ft. lbs. (43 Nm). • With transmissions, the clutch release cylinder and tighten the bolts to 108 inch lbs. (12 Nm). • Starter and secure the har¬ ness in wiring the clips • Fuel inlet hose with 2 new gaskets and tighten the union bolt to 22 ft. lbs. (29 Nm) • Power steering pipe below the engine • Engine harness • Connectors to the proper PCM, controller, or relay. Make certain each connector is square and secure. • PCM and cover; connect the wiring harnesses. Refit the carpet and install the scuff plate. • Lower instrument panel trim, the glove box door and the under¬ cover. • Engine wiring harness in the clips and retainers • All wires, electrical leads and vac¬ uum hoses • Air conditioning compressor. Tighten the through-bolt to 19 ft. lbs. (26 Nm) and the other bolt and nut to 38 ft. lbs. (52 Nm). • Power steering pump. Tighten the long bottom bolt to 43 ft. lbs. (58 Nm); tighten the others to 29 ft. lbs. (39 Nm). Connect the power steering air hoses. • Charcoal canister and connect the hoses • Radiator, coolant hoses and the transmission lines • Water pump pulley, the fan and the drive belt. Tighten the 4 pulley nuts to 12 ft. lbs. (16 Nm). • Air cleaner assembly, resonator and the air intake hose • Accelerator, throttle control (auto¬ matic transmission only) and the

LEXUS ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 * LS 430 • SC 300 • SC 400 cruise control cables to the throttle body • Battery tray and battery • Battery cables • All fluids, including fuel 1 1 . Check the automatic transmission ; fluid level 12. Check the ignition timing 13. Shut the engine oft and install the engine undercovers. 14. Install the hood

SC 400, GS 400 and GS 430 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Relieve the fuel pressure from the fuel lines. 3. Drain the engine coolant from the cooling system. 4. Remove or disconnect the following:

• Battery cables and remove the bat¬ tery. Wait at least 90 seconds before proceeding with any other work. • Hood • V-bank cover, if equipped • Engine undercover and drain the engine oil. Lower the vehicle. • Drive belt • Throttle body • Accelerator, transmission and cruise control cables from the throttle body. • Air cleaner assembly • Vacuum hose (from the power steering air control valve) from the air intake chamber. • Intake air connector • Coolant reservoir tank • Radiator • Igniter connectors and wire clamp • Engine wires located next to the relay box, which is located next to the left strut tower • Engine ground cable • Power steering solenoid valve con¬ nector • Alternator

• Power steering tubes from the sus¬ pension crossmember • Power steering reservoir tank and bracket from the body by removing the 3 bolts • Power steering pump by removing the pump mounting bolts and nut. Do not disconnect the power steer¬ ing lines and place the pump off to the side. • Air conditioning compressor from the engine. Do not remove the compressor pressure lines.

• Heater water hose from the water hose hose from the heater • bypass Heater water water valve • Brake booster hose from the union on the air intake chamber • Vacuum hose from the Vacuum Switching Valve (VSV) for the heater water valve from the air intake chamber bodystrap from the bracket on • the Ground • Fuel inlet hose from fuel tube • Charcoal canister from the engine

the cabin as fol¬ • Engine lows: wire from • Passenger’s side lower instrument panel undercover • 4 screws to the lower instrument panel finish panel and glove com¬ partment door assembly • Glove compartment and finish • Right scuff plate panel.out the front side of the floor • Take carpet • 2 nuts and the Powertrain Control Module (PCM) protector • Mounting nut and disconnect the PCM from the floor panel. • 2 connectors from the PCM • Connector from the Anti-lock brake system (ABS) and Traction control electronic control unit (TRAC ECU) • 2 connectors from the TRAC ECU • 4 connectors from connector cas¬ sette • Connector from air conditioning control assembly • Bolt holding the engine wire clamp to the heater water valve bracket. • 2 bolts holding the engine wire clamp to the body. • Engine wiring harness (through the cowl panel) from the vehicle cabin the front Oxygen (O2) • exhaust pipe sensors from

16-27

matchmarks on the transmission flange and the flexible coupling. • The transmission control rod from the shift lever by removing the nut 5. Attach the engine chain hoist to the engine hangers. 6. Remove or disconnect the following: • 2 nuts holding the engine mount¬ to the front suspen¬ ing insulators sion crossmember. • 4 bolts, 4 nuts and the rear engine mounting member • Ground strap to the rear mounting member • Engine out of the vehicle • Oil dipstick guide and dipstick for transmission

• Oil cooler pipes for the transmis¬ sionthe engine wiring • All holding the transmis¬ boltsengine Engineto the • sion • Engine from the transmission

To install:

7. Install or connect the following: • Transmission to the engine and install the bolts. Tighten the bolts to 42 ft. lbs. (57 Nm). • Engine wiring

• Oil cooler pipe for the transmis¬ sion. Tighten the unions on the pipes to 25 ft. lbs. (34 Nm). • Engine oil dipstick guide and the dipstick for the transmission • Engine and transmission to the vehicle • Rear engine mounting member with the 4 bolts and 4 nuts. Tighten the bolts to 19 ft. lbs. (25 Nm) and the nuts to 10 ft. lbs. (13 Nm). • 2 nuts holding the engine mount¬ suspen¬ the front toer. ing brackets sion crossmemb Tighten the nuts to 43 ft. lbs. (59 Nm). • Engine chain hoist • Transmission control rod to the lever by installing the nut • shift Driveshaft

• Front exhaust pipe

• Center floor crossmember brace by

• Front catalytic converter by remov¬ ing the 3 nuts and gasket • Tailpipes

installing the 4 bolts. Tighten the bolts to 108 inch lbs. (13 Nm). • Heat insulator for the front exhaust

• Center exhaust pipe by disconnect¬ 2 hooks ing the • Heat insulator by removing the 4 nuts • Center floor crossmember brace by removing the 4 bolts • Driveshaft from the vehicle using

bolts installingpipetheby4 installing pipe byexhaust • Center the 2 hooks • Tailpipe Nm) the 2 bolts to 14 ft. lbs.and(19tighten

the proper tools (2 of tool SST 09922-10010), loosen the adjust¬ ing nut on the driveshaft. Place

• Front catalytic converter and tighten the nuts to 46 ft. lbs. (62 Nm) • Front exhaust. Tighten the 4 bolts

catalytic con¬ holding and nuts exhaust pipe to front the to the verter

no LEXUS "LO

ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400

32 ft. lbs. (43 Nm). Tighten the 2 bolts and nuts holding the front exhaust pipe to the center exhaust pipe. Tighten the bolts to 32 ft. lbs. (43 Nm). Tighten the 4 bolts hold¬ ing the pipe support bracket to the transmission. Tighten the bolt to 32 ft. lbs. (43 Nm). • O2 sensors to the front exhaust and Nm) the sensors to 33 ft. lbs. (44 tighten • Engine wiring harness in through the cowl panel • Engine wire retainer with the 3 bolts • Reattach the connectors under the dash panel • PCM with the nut • PCM protector with the 2 nuts • Floor carpet • Scuff plate • Lower instrument panel finish panel and glove compartment door assembly with the 4 screws • Instrument panel undercover with the 2 screws • Charcoal canister • All hoses and grounds • Air conditioning compressor with the nut and 3 bolts. Tighten the bolts to 36 ft. lbs. (49 Nm) and the nut to 22 ft. lbs. (29 Nm). • Power steering pump with the nut and 3 bolts. Tighten the bolts to 29 ft. lbs. (39 Nm) and the nut to 32 ft. lbs. (43 Nm). • Power steering reservoir tank and bracket with the 3 bolts • Power steering tubes with the clamp and bolt • Alternator, tighten the nut and bolt to 27 ft. lbs. (37 Nm) • Power steering solenoid valve con¬ nector • Engine wire connectors • Theft deterrent horn connector • Ground cable to the body from the engine • Igniter connectors • Yellow taped connector to the igniter on the rear side • Radiator assembly • The reservoir tank and the inlet pipe to the fan shroud and tighten the 4 bolts to 43 inch lbs. (5 Nm) • The 2 hydraulic lines for the fan motor and tighten the bolts to 47 ft. lbs. (64 Nm) • Upper and lower radiator hoses to the radiator • 2 oil cooler hoses for the transmis¬ sion to the radiator

• Coolant tank • Intake air connector • Vacuum hose (from the power steering air control valve) to the air intake chamber • Air cleaner • Accelerator, transmission throttle control and the cruise control actu¬ ator cables to the engine • Throttle cover and hose clamp with the cap nut and 2 bolts • Evaporative emission control (EVAP) hose to the hose clamp • Drive belt to the engine • Battery to the engine compartment and attach the electrical connectors • Engine coolant • V-bank cover if it was removed •• Engine Hood. undercover 8. Fill the engine oil and check the transmission oil. 9. Start the engine, bleed the cooling system, and check for leaks.

Water Pump REMOVAL & INSTALLATION

3.0L (1MZ-FE) Engine 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery terminal • Engine coolant • Timing belt • Right and left camshaft pulleys • No. 2 idler pulley by removing the bolt • 3 clamps and engine wire from the rear timing belt cover • 6 bolts holding the rear timing belt cover to the engine block • 4 bolts and 2 nuts to the water pump • Wat er pump • All the old packing (sealant) and

gasket material from the water pump and clean the mounting sur¬ faces. • All gasket material from the upper inner timing belt cover

To install:

3. Check that the water pump turns smoothly. Also, check the air hole for coolant leakage. 4. Using a new gasket, apply liquid sealer to the gasket, water pump and engine block. 5. Install or connect the following: • Gasket and pump to the engine and install the 4 bolts and 2 nuts. Tighten the nuts and bolts to 53 inch lbs. (6 Nm). • Rear timing belt cover and tighten the 6 bolts to 74 inch lbs. (9 Nm) • Engine wire with the 3 clamps to the rear timing belt cover • No. 2 idler pulley with the bolt. Tighten the bolt to 32 ft. lbs. (43 Nm). After tightening the bolt, be sure the idler pulley moves smoothly. • Right-hand camshaft pulley, with the flange side outward. Be sure to align the knock pinhole on the camshaft pulley with the knock pin on the camshaft. Camshaft bolt to 65 ft. lbs. (88 Nm). • Left-hand camshaft pulley with the flange side inward. Be sure to align the knock pin hole on the camshaft pulley with the knock pin on the camshaft. Camshaft bolt to 94 ft. lbs. (125 Nm). • Timing belt • Engine coolant • Negative battery cable to the battery and start the engine.

3.0L (2JZ-GE) Engine 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable. Wait at least 90 seconds before performing Drain the engine coolant. any 3.work. 4. Remove or disconnect the following: • Radiator assembly • Air cleaner • • •

Mass Air Flow (MAF) meter Intake airbeltconnector pipe assembly Timing Idler pulley

• Water inlet and the thermostat Water pump mounting bolts — 3.0L (1MZFE) engine

• 2 bolts, the water bypass outlet and the No. 1 water bypass pipe

• Water inlet housing and discard the

• New 0-ring and the water bypass outlet with the 2 bolts and tighten them to 78 inch lbs. (9 Nm) • Thermostat and the water inlet • Idler pulley • Timing belt

3.0L (2JZ-GE) engine

Mounting • to pumpstuds and the nut the waterbolts, gasketpump by carefully prying • Water between the pump and the cylinder block • The old gasket and clean all mounting surfaces

• Air cleaner, the MAF meter and the intake air connector pipe assembly • Radiator assembly • Negative battery cable • Coolant. Start the engine, check for leaks and bleed the cooling system.

To install:

5. Install new seal packing to the water pump groove and a new O-ring to the water pipe end. bypass 6. Install or connect the following: • Water pump to the water bypass

4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines

Be sure to use new 0-rings when installing the water bypass pipe— 3.0L (2JZ-GE) engine

• 3 0-rings from the water bypass outlet and the No. 1 water bypass pipe Generator Bolt and engine wire bracket Bolt and clamp bracket for the Crankshaft Sensor (CKP) connector . Nuts and the No. 2 water bypass pipe from the water pump • 6 bolts and the water pump and

• • •

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable. 3. Drain the cooling system. 4. Remove or disconnect the following: • Timing belt • No. 2 idler pulley • Throttle body

pipe end

Bypassg hose(s) from the water inlet • housin • 2 bolts holding the water inlet housing to water pump

Apply silicone sealant to the water pump as shown — 4.0L engine

Throttle Body

Accelerator Pedal Position Sensor Connector

Throttle Position Sensor Connector

gasket • Drain hose and the 0-ring from the cylinder block

Water Bypass Hose

To install:

5. Install or connect the following: • New O-ring to the cylinder block • Drain hose • New gasket to the water pump • Water pump to the water bypass pipe. Do not install the nut yet. • Water pump with the 2 bolts (A) and the 4 bolts (B)

Throttle Control Motor Connector

Water Inlet Housing Assembly

^Hand-tighten the bolts (A) first. Tighten all 6 bolts to 15 ft. lbs. (21 Nm).

• 2 nuts holding the No. 2 water bypass pipe to the water pump. Tighten the nuts to 15 ft. lbs. (21 Nm). . Clamp bracket for the CKP sensor connector • Engine wire bracket • Generator • O-rings to the No. 1 water bypass

pipe.

Water Pump 9301 LG07

components— 4. 0L engine shown Exploded view ot the water pump mounting and related

S • IS 300 on ESLEXU B I I U OU 300 7

• GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400

.

0-rings • Heater core hoses and discard the • Pull out heater core from the heater housing To install:

New

5. Install or connect the following: • Heater core to the heater housing • rings Heater core hoses using new 0-

O-Ring 7923LG12

Apply sealant to the water inlet housing as shown — 4.0L engine

• Water pump and tighten the mount¬ Nm) bolts and nut to13 ft. lbs. (18 ing • Sealant to the groove of the water inlet housing • A new 0-ring to the water inlet housing • Water inlet housing end into the water pump hole • Water inlet and housing assembly with the 2 bolts. Alternately tighten the bolts to 13 ft. lbs. (18 Nm). • Bypass hose(s) to the water inlet housing • Throttle body. Tighten the mounting bolts to 13 ft. lbs. (18 Nm). • No. 2 idler pulley • Timing belt • Coolant • Negative battery cable 7. Fill the cooling system. 8. Start the engine and check for leaks.

Heater Core REMOVAL & INSTALLATION IS 300 and ES 300

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable. Wait 90 seconds before doing any further work while the airbag system de-energizes. 3. Drain the cooling system into a clean container for reuse. 4. Remove or disconnect the following: • 2 hood release lever screws and the lever • No. 1 lower panel-to-instrument panel bolt/screw, disconnect the electrical connectors and remove the No. 1 lower panel • Lower left hand panel • 3 heater protector clips and remove the heater protector • 2 screws and the 2 clamps holding the heater core in place

• 2 clamps and the 2 screws holding the heater core in place • Heater protector and connect the 3 heater protector clips • Lower left hand panel • No. 1 lower panel, connect the electrical connectors and install the No. 1 lower panel-to-instrument panel bolt/screw • Hood release lever and the 2 lever screws 6. Refill the cooling system. 7. Connect the negative battery cable. 8. Operate the engine to normal oper¬ ating temperatures; then, check the cli¬ mate control operation and check for leaks. GS 300, GS 400 and GS 430

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable. Wait 90 seconds before doing any further work while the airbag system de¬ energizes. 3. Drain the cooling system into a clean container for reuse. 4. Discharge and recover the air condi¬ tioning system refrigerant. 5. Remove or disconnect the following: • Refrigerant lines-to-evaporator bolt, slide the plate clockwise, discon¬ nect both lines and discard the 0rings. Plug the openings to prevent contamination • Heater hoses from the heater core • No. 1 grommet, the heater pipe grommet and the drain hose grom¬ met 6. Remove the steering wheel by removing or disconnecting the following: • Place the front wheels in the straight-ahead position. • Torx® bolt covers at both sides of the steering wheel • Loosen the Torx® bolts (using a Torx® wrench), until the circumfer¬ ence ring on the bolt catches on the screw case • Lift the air bag, disconnect the electrical connector and remove it

• Steering wheel nut and press the steering wheel from the steering column or disconnec the following : ti R•emFront ove ntgpillar he insgarnishes trument and the front door scuff plates by remov ing • Steering column cover screws and the covers • Electrical End pad connectors and remove the combination switch

• 2 No. 1 undercover-to-instrument panel screws and the undercover • 2 hood lock release screws and the release • 4 No. 1 safety pad-to-instrument panel bolts, screw and the safety • Parking brake handle and the No. 1 switch hole base • 4 steering column-to-instrument panel nuts, disconnect the spring from the brake pedal and remove the steering column • Instrument cluster finish panel using pad a suitable prytool • 4 instrument cluster-to-instrument panel connectors screws, disconnect the elec¬ trical and remove the instrument cluster • No. 2 undercover using a suitable • Plate and disconnect the air bag electrical connector inside the prytool • Glove box-to-instrument panel 2 glove box bolts, 3 screws, and the glove box • 3 CD changer-to-instrument panel nuts, disconnect the electrical con¬ • nectors Ashtray and remove the CD changer • No. 2 register using a suitable pry¬ tool and disconnect the connector • Audio unit-to-instrument panel 2 bolts, 2 screws and the audio unit • Cluster finish panel using a suit¬ • • • • •

able prytool, disconnect the con¬ nectors and remove the panel. Console box carpet Lower rear console box Rear console armrest No. 3 console box mounting bracket Console box

• No. 1 console box duct • No. 7 heater-to-register • 5 instrument panel-to-chassis bolts, the nut, the screw and the instrument panel • No. 1 and No. 2 brace

LEXUS • SC 400 ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300

Instrument Panel Reinforcement 1*0 Front Passenger

16-31

Front Pillar Garnish

Airbag Assembly

0 No.l Mounting Bracket

Front Door Opening Trim Cover

No.l Floor Q) Brace Front Pillar Garnish

RH Floor Carpet Bracket

Front Door Scuff Inside Plate

No.2 Under Cover

Cowl Side Trim

Front Door Scuff Inside Plate

Box Bottom No.2 Mat Rear Ash Receptacle Rear Cup Steering Holder Steering Wheel Wheel Pad ©

No.l Lower Panel

N-m (kgf-cm, ft-lbf) | : Specified torque 93112GS3

Exploded view of the instrument assembly

ES 300

16-32

LEXUS ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400

5.4 (55, 48)

Water

Evaporator

Valve Control

Cable Air Outlet Servomotor

Side Air Duct RH

Evaporator Temperature Sensor

Side Air Duct LH A/C Unit Case

Blower Resistor

Blower Motor

Evaporator Cover

Linear Controller Air Mix Servomotor

Heater Radiator

♦Expansion O-Ring

Heater

Clamp

Valve

Radiator

Drain Hose Liquid and Suction Tube Foot Air Duct Heater Protector

Foot Air Duct LH

N-m (kgf-cm, in.-lbf) : Specified torque ♦ Non-reusable part 93112GS4

Exploded view of the heater core, heater/air conditioning housing and related components— ES 300

Front Passenger Airbag Assembly

Reinforcement

Lower Defroster Nozzle.

No.2 Brace Safety Pa< No.1 Side Defroster Nozzle \ CD Glove Compartment Panel Assembly Combination Meter CD Changer

No.1 Switch Hole Base

No.2 Under Cover

No.7 Heater to Register Duct No.1 Safety Pad No.1 Undercover Front Pillar Garnish

Steering Column Upper Cover

Rear Console Armrest Console Box

Front Door Plate

Steering Wheel Steering Column Lower Cover

No.1 Console Box Duct Steering Wheel Pad

N-m (kgf-cm, tt-lbf) : Specified torque 93112GT4

components-GS Exploded view of the instrument panel and related

300, GS 400 and GS 430

300S • IS 300 fi-'M ESLEXU I■U

• GS 300 * GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400

'Instrument Panel Wire Harness

No.1 Defroster Nozzle Garnish

Safety Pad No. 2 Side Defroster Nozzle No.1 Meter Hood Retainer No. 3 Register

No.4 Finish Panel

.Glove Compartment Lock Striker Plate

Mounting Bracket

No.1 Side Defroster Nozzle Duct

Door

No.2 Side Defroster Nozzle Duct

No.1 Heater to Register Duct

No.4 Heater to Register Duct

No.2 Radio Mounting Bracket

No.1 Radio Mounting Bracket 93112GT5

Exploded view ol the instrument panel, ventilation ducts and related components— GS 300, GS 400 and GS 430

LEXUS ifi.OE SC 300 « SC 400 FS ann * IS 300 » GS 300 * GS 400 * GS 430 * LS 400 * LS 430 *

UU

Instrument Panel

Reinforcement

Blower Unit Defroster Nozzle

Air Duct RH

Heater to Register Center Duct

Center Air Duct

Air Duct LH

N-m (kgf-cm, ft-lbf) |: Specified torque ♦ Non-reusable part 93112GT6

and related components-GS Exploded view of the heater/air conditioning housing

300, GS 400 and GS 430

XUS • IS 300 • GS 300 • GS 400 » GS 430 • LS 400 • LS 430 • SC 300 • SC 400 1 6-36 ESLE300

♦ Packing

Wire Harness Tube Connector

♦ Packing Evaporator Temperature Sensor Gv Evaporator G*

Air Mix Servomotor (Driver Side) Cb>.

Plate

Insulator

Air Duct

Drain Pipe

Blower Motor Control Relay Heater Radiator

N-m (kgf-cm, in.-lbf) : Specified torque ♦ Non-reusable part 93112GT7

Exploded view of the heater core, heater housing and related components— GS 300, GS 400 and GS 430

LEXUS 1R.Q7 ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400 I • Reinforcement-to-chassis 5 nuts, 4 bolts and the reinforcement • Ventilation nozzles from the heater/air conditioning housing 8. Remove the blower unit by removing or disconnecting the following:

• Connector clamp • 3 air duct-to-blower housing screws and the air duct • Electrical connector bracket, the wiring harness clamps and the wiring harness • Blower housing connectors • 2 blower housing-to-bracket bolts and the bracket • Blower housing-to-chassis bolt, screw, nut and the blower housing 9. Remove or disconnect the following: • 2 center air duct-to-heater/air con¬ ditioning housing screws and the air duct • Move the floor carpet rearward • Wiring harness clamps • 2 air duct bolts and the ducts at both sides 10. Remove the heater/air conditioning housing by removing or disconnecting the following: • Electrical connector • Wiring harness set nut • Wiring harness clamp • Heater/air conditioning housing 2 nuts and bolt • Heater/air conditioning housing 1 1 . Remove the heater core-to-heater/air conditioning housing clamp screw and the clamp. 12. Pull the heater core from the heater/air conditioning housing.

To install:

13. Install the heater core to the heater/air conditioning housing. 14. Install the heater core clamp and the clamp-to-heater/air conditioning housing screw. 15. Install the heater/air conditioning housing by installing or connecting the fol¬ lowing: • Heater/air conditioning housing • Heater/air conditioning housing 2 nuts and bolt • Wiring harness clamp • Wiring harness set nut • Electrical connector 16. Install or connect the following: • Air duct and the 2 duct bolts on both sides • Wiring harness clamps • Move the floor carpet forward • Center air duct and the 2 air ductto-heater/air conditioning housing screws

17. Install the blower unit by installing or connecting the following: • Blower housing and the blower nut housing-to-chassis bolt, screw and

and the 2 bracketBlower housing • to-bracket bolts • Blower housing connectors • Electrical connector bracket, the wiring harness clamps and the wiring harness • Air duct and the 3 air duct-toblower housing screws • Connector clamp 18. Install the instrument by installing or connecting the following: • Ventilation nozzles to the heater/air conditioning housing • Reinforcement and the reinforcement-to-chassis 5 nuts and 4 bolts • No. 1 and No. 2 brace

• Instrument panel and the 5 instru¬ ment panel-to-chassis bolts, the nut and the screw 19. Install or connect the following: • No. 7 heater-to-register • No. 1 console box duct • Console box • No. 3 console box mounting bracket • Rear console armrest • Lower rear console box • Console box carpet • Connectors and install the cluster finish panel • Audio unit and the audio unit-toinstrument panel 2 bolts and 2 screws • Connector and install the No. 2 • Ashtray register • CD changer, connect the electrical connectors and install the 3 CD changer-to-instrument panel nuts • Glove box and the glove box-toinstrument panel 2 bolts and 3 screws • Air bag electrical connector and install the plate inside the glove box • No. 2 undercover • Instrument cluster, connect the electrical connectors and install the 4 instrument cluster-to-instrument . Instrument panel screwscluster finish panel • Steering column, connect the spring to the brake pedal and install the 4 steering column-toinstrument panel nuts • Parking brake handle and the No. 1 switch hole base

I

• No. 1 safety pad and the 4 safety pad-to-instrument panel bolts and • screw Hood lock release, and the 2 release screws •• No. undercover and the 2 underEnd 1pad cover-to-instrument panel screws • Combination switch and connect the electrical connectors • Steering column covers and the cover screws Nm)pillar garnishes and the front • Front door scuff plates 20. Install the steering wheel by installing or connecting the following: • Steering wheel and torque the steering wheel nut to 26 ft. lbs. (35 air bag • Electrical connector and install the • Tighten the Torx® bolts to 80 inch wrench Torx®sides usingat aboth lbs. (9.0 • Torx® boltNm) covers of the steering wheel • No. 1 grommet, the heater pipe met grommet and the drain hose grom¬ • Heater hoses to the heater core • Refrigerant lines (using new 0refrigerant lines-torings) and the evaporator bolt 21. Refill the cooling system. 22. Connect the negative battery cable. 23. Evacuate, charge and leak test the air conditioning system refrigerant. 24. Operate the engine to normal operat¬ ing temperatures; then, check the climate control operation and check for leaks.

LS 400 and LS 430 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable. Wait 90 seconds before doing any further work while the airbag system de-energizes. 3. Disconnect the negative battery cable. 4. Drain the cooling system into a clean container for reuse. 5. Remove or disconnect the following: ing and the No. 1 safety • Undercover pad-to-instrument panel screws panel at the driver’s • and No. 2theheater-to-register duct side • Heater core-to-heater housing screw and clamp • Heater hoses from the heater core

• Heater core from the heater hous¬ • Discard the O-rings

HC IU

QP JO

LEXUS

ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400 Instrument Panel Reinforcement

0

Instrument Panel

Glove Compartment /I 21 (210, 15) 1

Glove Compartment

0

Door

Coin Box — 0Combination

Meter No.2 Under Cover

Combination

, . . . \ Radio with A/C Instrument Cluster \ . Control Assembly ’ Finish Panel Glove Compartment

Switch

Door Finish Plate ~~

Column

^

Cover-^

^

Q

Instrument Panel

er Box Assembly Lower Center trov Cluster Finish Panel

Q ©

Rear Console Armrest Steering Wheel teering [ 35 (360, 26) Steering Wheel End Panel — ^

Box Duct 0 solye No. 3 ConTra ^sh d Pa

Finish Plate

No.2 Heater to Register Duct

Rear Console CD. Cover

No.1 Safety Pad

Console Box

No.1 Undercover

Lower Console Cover Lower Rear Console Box

N-m (kgf-cm, ft-lbf) : Specified torque 93112GS1

Exploded view of the instrument panel — LS 400

16-39

Wire Harness

Pressure Valve

Evaporator Cover

Regulator

Evaporator Air Outlet Servomotor (Driver Side) Cool Air Bypass Damper Control ^ Servomotor (Driver Side£ Air Mix Servomotor

^

(Driver Side) Water Valve Control Servomotor Clamp

Heater Radiator Pip'

Clamp Air Vent Duct

Lower Unit Case

Aspirator

N-m (kqf-cm, in.-lbf)l: Specified torque ♦ Non-reusable

part

ioning housing and related components-LS Exploded view of the heater core, heater/air condit

400

93112GS2

300S • IS 300 Ifi-Afl LEXU

IU4U ES 9

• GS 300

1

To install: . 6. Install or connect the following: • New O-rings to the heater core • Heater core to the heater housing • Heater hoses to the heater core • Heater core clamp and the heater core-to-heater housing screw • No. 2 heater-to-register duct • Undercover and the No. 1 safety pad-to-instrument panel and the panelthescrews the driver's side 7. Refill coolingat system. 8. Connect the negative battery cable. 0 9. Operate the engine to normal operat¬ ing temperatures; then, check the climate control operation and check for leaks. . SC 300 and SC 400 ^Removal of the heater core requires removal of the entire heater air condi¬ tioning assembly.

:

ing

low fol tchte nne

o isc ord ove

Rem

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable. Wait 90 seconds before doing any further work while the airbag system de¬ energizes. 3. Drain the cooling system into a clean container for reuse. 4. Discharge and recover the air condi¬ tioning system refrigerant. 5. Remove or disconnect the following: • Refrigerant lines from the evapora¬ tor. Discard the 0-rings. Plug the lines to prevent contamination • Heater hoses from the heater core • Brake tubes mounting bolts • Heater water valve and the ABS actuator • Equalizer tube from the EPR, dis¬ card the O-ring and plug the open¬ ings to prevent contamination • 2 insulator retainer bolts and the retainer at the heater core 6. Remove the steering wheel by removing or disconnecting the following: • Place the front wheels in the straight-ahead position • Torx® bolt covers at both sides of the steering wheel • Loosen the Torx® bolts (using a Torx® wrench) until the circumfer¬ ence ring on the bolt catches on the screw case • Lift the air bag, disconnect the electrical connector and remove it • Steering wheel nut and press the steering wheel from the steering column 7. Remove the instrument panel and

GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400 reinforcement by removing or disconnecting the following: • Tilt the steering column down and pull out the steering wheel • Front assist grips • Front pillar garnishes and the front scuff plates • Steering column cover • Shift lever knob • Upper console panel rear • Upper console panel • Radio with the air conditioning control assembly • No. 2 undercover • Finish plate and disconnect the air bag electrical connector located inside the glove box • Glove compartment assembly • 4 lower right side finish panel bolts and the panel • No. 4 heater-to-register duct screw and the duct • Passenger’s side air bag moduleto-instrument panel 3 bolts and 2 nuts; then, remove the air bag • No. 4 undercover-to-instrument panel cover screws and the cover • Console box

• clamps 2 heater core clamp screws and the • Heater core To install: • Heater core I•nstHeater all or ccore and the 2 onnectclamps t h e f o l lowing: clamp screws • Heater core plate and the 2 plateto-heater housing screws • Electrical connector; then, install the heater/air conditioning housing and the 6 housing-to-chassis bolts • Connector bracket and the 2 bracket screw at the under side of the blower motor • Heater-to-No. 3 duct register and the duct screw Floor ECU carpet forward • ABS

•• Cooling PPS ECUfan ECU the or conn by inst ffoorc alli ecti lloewmen ng ingt: ng • Instrument panel reinforcement and the reinforcement fasteners

• Instrument panel and the instru¬ Insta • End pad at the left side of the ment panel-to-chassis fasteners ll th instrument panel e i•n Steering column assembly •strCombination meter umen • Key center plate and the center pad t p • Cluster finish panel a • 2 hood release lever screws and the nel lever • Combinationand switch rein¬ • No. 2 heater-to-register duct • 3 No. 1 lower finish panel screws, disconnect the electrical connectors • Lower left side finish panel and the and remove the panel boltsfinish panel, connect • 4No.panel 1 lower • 4 lower left side finish panel bolts and the panel the electrical connectors and install • No. 2 heater-to-register duct the 3 panel screws • Combination switch • Hood release lever and the 2 lever • Cluster finish panel screws • Combination meter • key center plate and the center pad • Steering column assembly • End pad at the left side of the instrument panel • Instrument panel-to-chassis fasten¬ • Console box ers and the instrument panel • No. 4 undercover-to-instrument • Instrument panel reinforcement fas¬ teners and the reinforcement panel cover and the cover screws • PPS ECU • Passenger’s side air bag module and torque the air bag-to-instru•• ABS Cooling mentlbs.panel 3 bolts and 2 nuts to 15 ECUfan ECU ft. (21 Nm) • Move the floor carpet rearward • Heater-to-No. 3 duct register screw and the duct • 2 connector bracket screws and the bracket at the under side of the blower motor • Electrical connector; then, remove the 6 heater/air conditioning housing-to-chassis bolts and the housing • 2 heater core plate-to-heater hous¬ ing screws and the plate

• No. 4 heater-to-register duct and the duct screw • Lower right side finish panel and the 4 panel bolts • Glove compartment assemble • Air bag electrical connector and install the finish plate inside the • glove No. 2 box undercover • Radio with the air conditioning control assembly

16-41

No. 3 Heater to Register Duct Instrument Panel Reinforcement ^ 0 .Airbag Passenger Mounting Brace _ ^No.4 Heater to Register Duc^

Instrument Panel No.1 Brace

& -

© ^

'

Front Pillar Garnish

Front Assist Grip Instrument Panel

No. 2 Heater to Register Duct

Front Airbag Passenger

Cluster Finish Front Pillar pane| Garnish

Assembly Lower Finish Panel RH

Front Assist Grip End Pad Steering Column Assembly

^

-

Door Finish Plate rtmentCompartment Glove Compa Glove Assembly

Center Pad __ Combination Switch(2K\

No.2 Under Cover

Plat6)e Key Cylinder 35(360,2

Cup Holder Lower Finish Panel LH No.1 Lower Finish Panel

&

Steering Wheel Pad

Radio with A/C Control Panel Steering Wheel Panel Steering Column Upper Console Cover pront ^sh Receptacle%‘^2§||

No.1 Linder Cover Shift Knob Lever ^ Door Console Compartment Front Scuff Plate Console Box

Rear Console Lower Box T

N-m (kgf-cm, ft-lbf)

Upper Console Panel Rear — Cup Holder Box Bottom Mat

: Specified torque

components— SC 300 and SC 400 Exploded view of the instrument panel and related

93112GS5

S 49 ESLEXU 300 • IS 300 l■ fui-He.

♦ Non-reusable

• GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400

part

Exploded view of the heater/air conditioning housing, reinforc ement, ventilation ducts and related components— SC 300 and SC 400

LEXUS SC 400

16-43

A/C Unit Block Joint

Deffroster Nozzle Wire Harness

Blower Motor Control Relay

Air Mix Air Refiner Filter

Servomotor

Plate Evaporator Cover

N-m (kgf-cm, ft-lbf) : Specified torque ♦ Non-reusable part 93112GS7

ioning housing and related components-SC Exploded view of the heater core, heater/air condit

300 and SC 400

•• Water Cylinderinlethead piperear plate

ES^3 16-44 0(f* * IS 300 • GS 300 • GS 400 • GS 430 • LS 400 * LS 430 * SC 300 • SC• Air400assist hose and vacuum

• Upper console panel • Upper console panel rear 8 • Shift lever knob • Steering column cover • Front pillar garnishes and the front scuff plates . • Front assist grips 11. Install the steering wheel by installing or connecting the following: • Steering wheel and torque the steering wheel nut to 26 ft. lbs. (35 Nm) • Electrical connector and install the air bag

• Torx® bolts to 80 inch lbs. (9.0 Nm) using a Torx® wrench • Torx® bolt covers at both sides of the steering wheel 12. Install or connect the following: • Insulator retainer and the 2 retainer bolts at the heater core • Equalizer tube to the EPR using a new O-ring • Heater water valve and the ABS actuator • Brake tubes mounting bolts • Heater hoses to the heater core • Refrigerant lines to the evaporator using new O-rings 13. Refill the cooling system. 14. Connect the negative battery cable. 15. Evacuate, charge and leak test the air conditioning system refrigerant 16. Operate the engine to normal operat¬ ing temperatures; then, check the climate control operation and check for leaks.

Cylinder Head REMOVAL & INSTALLATION 3.0L (1MZ-FE) Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: • Negative battery cable • Accelerator and the throttle cables • Air cleaner cover, air flow meter and the air duct • Cruise control actuator and bracket, if equipped • 2 engine ground straps • Right engine mounting support • Radiator hoses • 2 heater hoses 5. Plug the fuel feed and return lines from the fuel rail assembly.

6. Plug the pressure hose from the hydraulic motor 7. Remove or disconnect the following: • V-bank cover • Fuel pressure control Vacuum Switching Valve (VS V) • Fuel pressure regulator • Cylinder head rear plate • Intake air control valve VSV • Exhaust Gas Recirculation (EGR) vacuum modulator • EGR valve • Intake Air Control (IAC) valve •. Fuel pressure regulator EGR VSV • 2 nuts and the emission control valve set • Brake booster vacuum hose • Positive Crankcase Ventilation hosecontrol valve vacuum • (PCV) Intake air hose • Data link connector from the mounting bracket • 2 ground straps from the intake chamber • Hydraulic motor pressure hose from the intake chamber

• Right Oxygen (O2) sensor connec¬ tor from the power steering pres¬ sure tube • 2 nuts and the power steering pres¬ sure tube from the intake chamber • 2 power steering air hoses • Engine hanger and the intake chamber support • EGR pipe and gaskets • Throttle nector Pressure (TP) sensor con¬

hose

• assembly Intake manifold and fuel rail • Water outlet • EGR pipe from the right exhaust manifold • Exhaust manifolds • Dipstick assembly and the power steering pump bracket • Valve covers and the Camshaft • Position Camshafts(CMP) sensor t 2 (one and remo t ambi ent emperat ve he u r hex bolts on each head 8mme rece the 8ssehdead bolts ev.enl LooBse su and )remo ve en re th y, e in 3 pass einngitnhee rever order of the es, is atCase lift the head sequ tigh or t e to pry the from entihneg engi ncief.it is nreefncueelalry ne; ssar y head loose take great care not to dama , ge Plac the head on the mati surf wood blnogc inacaesc.lea weork area. n ks

i: WARNING

If the cylinder head bolts are loos¬ ened out of sequence, warpage or cracking could result.

9. Remove the cylinder head gasket. With a gasket scraper, carefully remove all the old gasket material from the cylinder head and engine block surfaces. To install;

10. Place the new cylinder head gasket

• Idle Air Control (IAC) valve con¬ nector • EGR gas temperature connector • air conditioning idle up connector • 2 vacuum hoses from the Thermal Vacuum Valve (TVV) • Vacuum hose from the cylinder head rear plate • Vacuum hose from the charcoal canister • Air assist hose and the 2 water bypass • Air intakehoses chamber • Left engine wiring harness and position it out of the way • Wiring harness from the rear of the engine • Right engine wiring harness and position it out of the way • Ignition coils and the spark plugs • Timing belt • Camshaft pulleys and the timing belt rear cover

7923LG13

Cylinder head torque sequence— 3. OL (1MZ-FE) engine

LEXUS LS 430 « SC 300 • SC 400 ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 *

onto the cylinder block. Place the cylinder head onto the gasket. 11. Coat the threads of the 8 cylinder head bolts (12-sided) with clean engine oil and install the bolts into the cylinder head. Uniformly tighten the bolts in sequence in 3 steps to an ultimate tighten of 40 ft. lbs. (54 Nm). If any of the bolts does not meet the torque, replace it. 12. Mark the forward edge of each bolt with paint, then retighten each bolt, in proper sequence, an additional 90 degrees. Check that each painted mark is now at a 90 degrees angle to the front. The paint mark should have been applied to the bolt in the 9 o’clock position and should now be in the 12 o’clock position. 13. Coat the threads of the 2 remaining 8mm bolts with engine oil and install them. Tighten to 13 ft. lbs. (18 Nm). 14. Install or connect the following: • Camshafts and adjust the valves (-Apply sealant to the cylinder heads where the camshaft supports meet the cylinder heads.

• Cylinder head covers. Use new gaskets. • Dipstick and power steering pump bracket . Exhaust manifolds. Tighten the nuts to 36 ft. lbs. (49 Nm).

EGR pipe to the right exhaust mani¬ • fold • Water outlet • Intake manifold and the fuel rail assembly. Tighten the intake mani¬ fold nuts and bolts to 11 ft. lbs. (15 Nm). • Air assist hose and the 2 water bypass hoses • Water inlet pipe and the cylinder head rear plate • Timing belt rear cover and the camshaft pulleys • Timing belt • Spark plugs and the ignition coils • Right engine wiring harness • Wiring harness to the rear of the engine • Left engine wiring harness • Air intake chamber • EGR pipe. Use new gaskets • 2 TVV vacuum hoses • Vacuum hose to the rear cylinder head plate • Charcoal canister vacuum hose • TP sensor connector • IAC valve connector • EGR gas temperature connector • Air conditioning idle up connec¬ tor

16-45

Engine hanger and the intake chamber support

Exhaust manifold cover 2connector(s) Heated Oxygen (HO2) sensor

2 power steering air hoses Power steering pressure tube to the intake chamber

Exhaust manifolds and gaskets by

tor to the pres¬ O2 sensor tube connec sure

2 ground straps to the intake cham¬ ber Data link connector to the bracket Power brake booster vacuum hose PCV hose IAC valve vacuum hose Emission control valve set and related vacuum hoses and connec¬ tors V-bank cover

Pressure hose to the hydraulic motor Fuel lines to the fuel rail assembly Heater and radiator hoses Right engine mounting support 2 engine ground straps Cruise control actuator and bracket Air cleaner, air flow meter and air duct assembly Accelerator and the throttle cables Negative battery cable 15. Fill the cooling system to the proper level with coolant. 16. Start the engine and check for leaks. Bleed the air from the cooling system. 17. Adjust the ignition timing. 18. Road test the vehicle and check for unusual noise, shock, slippage, correct shift points and smooth operation. 19. Recheck the coolant and engine oil levels. 3.0L (2JZ-GE) Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable. Wait at least 90 seconds before per¬ forming any other work. 3. Relieve the fuel pressure from the fuel lines. disconnect the following: 4.• Remove Coolant or • Undercovers

(auto¬ • Acceler body ator, throttle control matic transmission only) and cruise control cables from the throttle • Cleaner duct

cleaner, airflow meter and the . Air intake air pipe

• Drive belt, the fan and fluid cou¬ pling and the water pump pulley • No. 2 front exhaust pipe

removing the 8 bolts outlet and the No. 1 bypass pipe Water bypass water Power steering air hose from the No. 4 timing belt cover Power steering hose from the air intake chamber 2 bolts and the vane pump from the

the pump rear stay. Put bolts,bracket 2pump vane pump and suspend the aside it. Fuel return hose from the fuel return pipe. Plug the hose end. Fuel return hose from the oil dip¬ stick guide Bolt and bracket fold stay Engine wire from the intake mani¬

and intake air con¬ bodybly nectorleassem Thrott Bolt, pullout the oil dipstick guide with the dipstick and remove the 0ring from the dipstick guide ' Transmission dipstick and guide, if equipped with automatic transmis¬ sion > Connector from the No. 2 vacuum ► Exhaust Gas Recirculation (EGR) gas temperature sensor wiring har¬ ness • pipe 2 nuts and the vacuum pipe from the air intake chamber and intake manifold • No. 2 vacuum pipe and Vacuum Switching Valve (VSV) assembly • Nuts and the vacuum tank from the intake manifold • VSV connector and hoses • Vacuum hose (from the air intake

• • •

•

) from port B of the vac¬ chamber tank uum Vacuum hose (from actuator) from the VSV Vacuum control valve set Data Link Connector (DLC1) bracket and VSV assembly Vacuum hose from the brake booster union and the Evaporative pipe hose from the No. vacuum 2Emissi on (EVAP)

. Bolt holding the engine wire pro¬ tector to the air intake chamber • 5 bolts, nut, air intake chamber and • No. 3 (top) timing belt cover by removing the oil filler cap and the 6 gasket

1 6“46 ES 300 * IS 300 * GS 300 * GS 400 * GS 430 * LS 400 * LS 430 * SC 300 *j>(^400 bolts using a 5mm hexagon wrench. • 4 bolts, using a 5mm hexagon wrench, and the rear cylinder head cover • Sparkplugs • Drive belt tensioner by removing the 3 bolts 5. Set the engine to Top Dead Center

(TDC)/compression for cylinder No. 1 pis¬ ton 6. Remove or disconnect the following: • Timing belt tensioner and dust boot. Remove the timing belt from the camshaft pulleys. Support the belt so that it remains in contact with the crankshaft pulley. • Wire clamp from the bracket. • HO2 and the Crankshaft Position (CKP) sensors. • 2 ground straps from the intake manifold. • Engine Coolant Temperature (ECT) sender gauge • Knock Sensor (KS) • Oil pressure switch • Oil level sensor • air conditioning compressor • 6 injector electrical connectors • 3 nuts and the engine wire protec¬ tor from the intake manifold • Water bypass hose from the clamp on the oil filter bracket • Water outlet, 2 nuts, and the bolt with the water bypass hose • 2 bolts and the intake manifold stay • Fuel pressure pulsation damper • Clamp bolt from the intake mani¬ fold • Union bolt and gaskets • Fuel inlet pipe • 6 bolts, 2 nuts, the intake manifold • Delivery pipe assembly and gasket • Cylinder head covers (valve covers) • Camshaft timing pulleys • Rear (No. 4) timing belt cover • Camshafts • Cylinder head bolts in several passes and in the reverse order of the tightening sequence • Head from the engine 7. Clean the head and block of all gas¬ ket material.

10 mm Bi-Hexagon Wrench

Apply sealant to the areas indicated on the cylinder head before installing the cover— 3.0L (2JZ-GE) engine

9301 LG08

Cylinder head torque sequence— 3. OL (2JZ-GE) engine

rect order, tighten each bolt an additional 90 degrees. Again fol¬ lowing the correct order, tighten the bolts another 90 degrees of rota¬ tion.

WARNING

Correct bolt torque must be achieved in 3 steps; do not attempt to shorten the procedure by combining the two 90 degree steps. • Camshafts. Coat the thrust portions of each with engine oil. • No. 3 and No. 7 bearing caps in place. Coat the bolt threads with oil, then uniformly and alternately tighten them temporarily. • New oil seals, coated with multi¬ purpose grease, over the camshafts • Seal packing to the No. 1 bearing cap • Remaining bearing caps in their proper locations. Coat the threads of each bolt with clean oil, then

(20 Nm). • The 2 oil seals in as far as it will go 9. Rotate each camshaft until the forward straight (knock) pin is straight up. Loosen the exhaust Nos. 1, 2 and 6 bearing cap bolts until they can be turned by hand; retighten the bolts, in several passes, to 14 ft. lbs. (20 Nm). Loosen the intake Nos. 1, 2 and 5 bear¬ bolts and retighten the bolts, in sev¬ ing cap eral passes, to 14 ft. lbs. (20 Nm). 10. Turn each camshaft Vo of a revolu¬ tion (120 degrees). Loosen the exhaust Nos. 4 and 7 bearing cap bolts; retighten the bolts, in several passes, to 14 ft. lbs. (20

Nm). Loosen the intake Nos. 4 and 6 bear¬ ing cap bolts; retighten the bolts, in several passes, to 14 ft. lbs. (20 Nm). 11 . Turn each camshaft an additional V6 of a revolution, loosen the exhaust bearing cap bolts Nos. 3 and 5, then retighten the bolts, in several passes, to 14 ft. lbs. (20 Nm). Loosen the intake bearing cap bolts Nos. 3 and 7, then retighten the bolts, in several passes, to 14 ft. lbs. (20 Nm). 12. Check and adjust the valve clearance. 13. Install Nm). or connect the following; • Rear (No. 4) timing belt cover. Tighten the bolts to 78 inch lbs. (9 • Camshaft timing pulleys. Align the shaft pin with the pulley groove and slide the pulley on. Install the bolt temporarily. Hold the hex portion of the camshaft with a wrench and tighten the pulley bolt to 59 ft. lbs. (79 Nm). • Cylinder head covers • Intake manifold and delivery pipe Nm). with a new gasket. Tighten the 6 bolts and 2 nuts to 20 ft. lbs. (27

To install: 8. Install or connect the following: • New gasket and cylinder head on the block • Head bolts, lightly coated with engine oil and plate washers. Uni¬ formly tighten the head bolts in several passes, in sequence to 26 ft. lbs. (35 Nm). Following the cor-

tighten them, in several passes, in the correct sequence, to 14 ft. lbs.

7923LG15

Position the knock pins as shown when installing the camshafts— 3. OL (2JZ-GE) engine

• Fuel inlet pipe to the fuel rail. Tighten the union bolt to 30 ft. lbs. (42 Nm).

LEXUS

3

400 . ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 * LS 430 * SC 300 * SC

4

.

. Compressing the timing belt tensioner— 3.0L (2JZ-GE) engine

• Clamp bolt to the intake manifold • Fuel pressure pulsation damper • Intake manifold stay and tighten the bolts to 29 ft. lbs. (39 Nm) • Water outlet and the bypass hose. Tighten the bolts to 15 ft. lbs. (21 Nm). • Engine wiring harness. Secure the wiring in all clamps and retainers. • Wiring leads to the proper sender, sensor or switch • Injector leads 14. Compress the timing belt tensioner in a vise and retain the pin with a 1 .5mm hex wrench. Install the dust boot onto the tensioner. 15. Install the tensioner. Alternately tighten the bolts to 20 ft. lbs. (26 Nm). Remove the hex wrench with a pair of pliers, allowing the tensioner to be applied to the timing belt. 16. Turn the crankshaft 2 full revolutions clockwise. Check that all timing marks align as before. If the marks (cam and crankshaft) do not align, remove the timing belt and reinstall it. 17. Install the accessory drive belt ten¬ sioner. Take great care not to drop the bolts inside the lower timing cover. Tighten the bolts to 15 ft. lbs. (21 Nm). 18. Double check that the engine is still set to TDC/compression for cylinder No. 1 . Check the alignment of both the crank and camshaft timing marks. Install the timing belt. 19. Install or connect the following: • Spark plugs • Wiring to the spark plugs • No. 3 timing belt cover • Cylinder head rear cover

• Air intake chamber with a new gas¬ ket. Tighten the bolts to 20 ft. lbs. (27 Nm). Install the bolt to hold the engine wire protector to the air intake chamber. • Vacuum hose to the brake booster union and the EVAP hose to the No. 2 vacuum pipe. • DLC connector and bracket and VSV connector • Vacuum control set • No. 2 vacuum pipe assembly and connect the hoses. Tighten the nuts to 20 ft. lbs. (27 Nm). • EGR gas temperature sensor. Tighten it to 14 ft. lbs. (20 Nm). • Vacuum hoses

• Dipstick tubes. Always use a new 0-ring on each tube. • Intake chamber supports and tighten the bolts to 13 ft. lbs. (18 Nm). The supports are marked F and R for the front and rear posi¬ tions.

body and intake air con¬ • Throttle nector assembly • Engine wire bracket • Fuel return hose • Vane pump to the pump bracket • Power steering air hose to the No. 4 timing belt cover and intake chamber. • Water bypass outlet and the bypass

16-47

ve or di cable. Wait at least battery Negative •Remo sconnect the followg inany performin 90 seconds before g: other work. • Oil pan protector • Engine Coolant undercover • Battery clamp cover • Air cleaner inlet • V bank cover by removing the bolt and 2 cap nuts • Air cleaner and intake air connector assembly • Drive belt, fluid coupling and the fan pulley. The drive belt tension may be slackened by turning the tensioner counterclockwise. The the drive belt ten¬ pulley bolt has aforleft-handed thread. • sioner Radiator • Right-hand No. 3 timing belt cover • Left-hand No. 3 timing belt cover • Drive belt idler pulley by removing the pulley bolt and cover plate • Right-hand No. 2 timing belt cover • Left-hand No. 2 timing belt cover • No. 1 ignition coil

• Air conditioning compressor from the engine • Fan bracket by removing the 2 bolts and 2 nuts

No. 1. on cyl (TD ind C) WARNING er pipe. Always use new 0-rings. • Exhaust manifolds with new gas¬ kets. Tighten the bolts to 29 ft. lbs.S et t Since the thrust clearance of the he e camshaft is small, the camshaft must (39 Nm). ngi • O2 sensor leads benetokept level while it is being • Front exhaust pipe. Tighten the Top d. If the camshaft is not kept remove Dea bolts to 46 ft. lbs. (62 Nm). of the cylinder head level, thed Ceportion • Manifold cover nte receiving ther shaft thrust may crack • Water pump pulley or be damaged, causing the camshaft • Fan and coupling and the drive to seize or break. belt. Tighten the 4 nuts to 12 ft. lbs. (16 Nm). • Air cleaner, airflow meter and the an put the clo 50 deg mat d intake air connector pipe c r e k in lin e pul tim ly mar ofesthe cra wis • Air cleaner duct leypu boel of the nkscrae wit ing the cekn lle t h n t h a to • Control and accelerator cables y bol ftksh an the idl ers pul a d t e l f . r the throttle body ey t Tur • Coolant nth WARNING ecr • Negative battery cable. Start the anksh afpt If the timing belt is disengaged, hav¬ ull engine and check for leaks. eing • Engine undercovers yap the crankshaft pulley at the wrong pr angle ox can cause the piston head and i¬ head to come into contact with valve 4.0L (1UZ-FE) and 4.3L (3UZ-FE) each other when you remove the Engines camshaft timing pulley. Always set to 1 . Before servicing the vehicle, refer the crankshaft pulley at the correct angle before removing the timing the precautions in the beginning of this sec¬ tion. belt.

2. Relieve the fuel system pressure.

HC AQ LEXUS 4 3 ID-tfO ES 0 300 • IS 300 ♦ GS 300 6. If the timing belt is to be reused, turn the crank pulley slowly; check that the 3 installation marks are present on the belt. If the marks are not present, make new instal¬ lation marks before removing the belt. The marks should align with the timing marks on each camshaft pulley and the crank pul¬ ley. 7. Remove the timing belt tensioner. Alternately loosen the 2 bolts; remove the bolts, the tensioner and the dust protector. 8. Loosen the tension between the left side and the right side timing pulleys by slightly turning the left side camshaft clock¬ wise. 9. Remove or disconnect the following:

.

0

• Timing belt from the camshaft tim¬ ing pulleys. Using the proper tool, remove the bolt and the camshaft timing pulleys. • Power steering pump from the engine. Do not disconnect the hoses or lines from the power steering pump. Support the power steering pump with a piece of wire. Do not allow the pump to hang. • Front catalytic converter • High tension spark plug wires, wire bly clamps and the wire cover assem¬ • No. 2 ignition coil by removing the connector and the 2 bolts • 2 bolts and the rear timing belt plate. Remove both plates • Intake chamber assembly • Throttle Position Sensor (TPS) connector • With TRAC system, sub TP sensor connector

300 • SC 400

* GS 400 • GS • LS(from 400 the• LS • Vacuum430hose VSV for * SC

fuel pressure control) from the fuel pressure regulator • EVAP hose (from charcoal canister) from the VSV for EVAP • Heater hose from the water bypass

• Fuel inlet hose from the delivery pipe • Fuel return hose from the fuel pipe pipe return • Engine wire from the delivery pipes and rear water bypass joint • Fuel hose from the fuel pressure • • • • • •

• • • •

2regulator bolts and fuel return pipe from the intake manifold 8 injector connectors 6 bolts, 4 nuts, the intake manifold assembly and the 2 gaskets Water inlet and inlet housing Front water bypass joint Rear water bypass joint and No. 1 EGR pipe assembly Oil dipstick and guide for the auto¬ matic transmission Oil dipstick and guide for the engine Engine hangers Right and left cylinder head covers

the 8 bolts, seal wash¬ by removing ers and gaskets • Semi-circular plug, if necessary

Driven Sub-Gear

• sequence. Intake camshaft from the right side cylinder See the camshaft procedurehead'. for tightening sequence. • Exhaust camshaft of the left side cylinder head. See the camshaft procedure for tightening sequence. ^When removing the camshaft, be sure the torsional spring force of the subgear has been eliminated.

• Intake camshaft from the left side • • • • •

cylinder head. See the camshaft procedure for tightening sequence. Main Heated Oxygen (HO2) sensor Bolt and H02the ground cable from the right cylinder head Bolt and the ground strap from the left cylinder head Bolt and the engine wire protector from the left-hand cylinder head 2 bolts, seal washers, bearing cap and the camshaft housing plug

from the right-hand cylinder head • 10 cylinder head bolts and plate washers to each cylinder head. Loosen the bolts in the reverse order of the tightening sequence. Lift the heads from the dowels on the block with the exhaust mani¬ folds attached. Place the heads on blocks of wood on the workbench.

Securing the exhaust camshaft on the right cylinder head — 4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines

If necessary to pry the head loose, take great care not to damage the contact surfaces of the head or block.

• 2 bolts, seal washers, bearing cap and camshaft housing plug from

• EGR gas temperature sensor con¬ nector • Brake booster vacuum hose from the union on the air intake chamber • Positive Crankcase Ventilation (PCV) hose from the PCV valve on the left-hand cylinder head • Water bypass hose (from the EGR valve) from the rear water bypass joint • Water bypass hose (from the throttle body) from the rear water bypass joint

side cylinder head. See the camshaft procedure for tightening

^Do not drop anything in the opening in the front of the right side cylinder head. The opening leads through the block and into the oil pan. If anything falls into the opening the oil pan will have to be removed in order to retrieve it.

• With TRAC system, sub TP con¬ nector • Idle Air Control (IAC) valve con¬ nector • Exhaust Gas Recirculation (EGR) valve connector • Vacuum Switching Valve (VSV) connector for fuel pressure control • VSV connector for Evaporative Emissions (EVAP) system

• Exhaust camshaft from the right

the right-hand cylinder head • Right exhaust manifold from the cylinder head by removing the heat insulator, 8 nuts and the gasket • Left exhaust manifold from the cylinder head by removing the heat insulator, 8 nuts and the gasket

To install: Turning the exhaust camshaft 10 degrees on the right cylinder head — 4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines

• Right exhaust manifold. The new

LEXUS GS 300 • GS 400 • GS 430

LS 400 • LS 430 • SC 300 • SC 400

16-49

white marks facing the manifold side. Tighten the bolts to 33 ft. lbs. (44 Nm). Install the right O2 sensor. • Left exhaust manifold. The new gasket must be installed with the white marks facing the manifold side. Tighten the bolts to 33 ft. lbs. (44 Nm). Install the left (^sensor. • The 2 new cylinder head gaskets in position on the engine block. Each gasket has a painted mark denoting the rear of the gasket. The gasket for the right bank has a white mark and the gasket for the left bank has a yellow mark. Double check the gasket position and placement. 11. For 4.0L engines, install the cylinder heads and tighten the bolts in sequence as follows: a. Step 1:29 ft. lbs. (39 Nm) b. Step 2: Plus 90 degrees 12. For 4.3L engines, install the cylinder heads and tighten the bolts in sequence as follows: • HO2. a. Step 1:44 ft. lbs. (60 Nm) b. Step 2: Plus 90 degrees

Front

• Engine wire to the right-hand cylin¬ der head with the 2 bolt

Cylinder head torque sequence— 4. 0L (1UZ-FE) engine

RH Bank

9

3

1

6

8

Apply a dot of paint at the front of each bolt— 4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines

LH Bank 9

3

16

8

Painted Mark

7923LG21

The paint mark must be 90 degrees from the starting point — 4.0L (1UZ-FE) and 4.3L Cylinder head torque sequence — 4.3L (3UZ-FE) engine

(3UZ-FE) Engines

S cn ESLEXU 1I RO OU 300 • IS 300

• GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400

• Ground cable to the right-hand cylinder head with the bolt • The engine wire protector to the left-hand cylinder head with the bolt • Ground cable to the left-hand cylin¬ der head with the bolt • Old packing and apply new seal packing to the bearing caps • Bearing cap on the right side cylin¬ der head, marked II, in position with the arrow mark facing the rear. Install the bearing cap on the left side cylinder head, marked 16, in position with the arrow mark facing the front. • Bearing cap bolts with new wash¬ ers. Apply a light coat of oil on the threads of the cap bolts. Alternately tighten each bolt to 12 ft. lbs. (16 Nm). (■►Use silver colored bolts 1.50 in. (38mm) in length.

• Camshaft housing plugs on the cylinder heads. Be sure to face the cupped side forward.

and put the timi or cou n pull in line nwgith the mar otfertchelo cran k ckw ksh e pulyl bolt and the o t cis af cent ers f he raenksht ey aft idle pull bolt . r ey

WARNING

Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being installed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break.

14. Install or connect the following: • Right side cylinder head intake camshaft. Tighten the bracket bolt in the reverse order of the loosen¬ ing sequence. • Right side cylinder head exhaust camshaft. Tighten the bracket bolt in the reverse order of the loosen¬ ing sequence. • Left side cylinder head intake ock wis camshaft. Tighten the bracket bolt e in the reverse order of the loosen¬ ing sequence. • Left side cylinder head exhaust camshaft. Tighten the bracket bolt in the reverse order of the loosen¬ ing sequence. 15. Check and adjust the valve clear¬ ance.

16. Install or connect the following: • Camshaft oil seals with the proper tool (SST 09223-46011). Be sure to sealapply lip. MP grease to the new oil • Semi-circular plugs, if removed 17. Clean the cylinder head covers. Apply new sealant in the correct locations and install the gaskets. 18. Install or connect the following: • Right cylinder head cover and bolts. Tighten the bolts to 52 inch lbs. (6 Nm). • Left cylinder head cover and bolts. Nm). the bolts to 52 inch lbs. (6 Tighten • Engine hanger with the 2 bolts. Install both engine hangers. Nm). the bolts to 27 ft. lbs. (37 Tighten • • •

Oil dipstick guide for the engine Oil dipstick for the transmission Rear water bypass joint and No. 1 EGR pipe

• Front water bypass joints. Install 2 gaskets and alternately tighten the nuts to 13 ft. lbs. (18 Nm). • Water inlet and inlet housing, alter¬ nately tighten the bolts to 13 ft. lbs. (18 Nm) • Delivery pipe and intake manifold • Return pipe with 2 new gaskets. Tighten the union bolt to 26 ft. lbs. (35 Nm). • Engine wire to the delivery pipes and rear water bypass joint • Fuel return hose to the fuel return • delivery Fuel inletpipe hose to the left-hand pipe • Fuel hose to the fuel pressure regu¬ lator • Air intake chamber assembly • Brake booster vacuum hose to the union on the air intake chamber • PCV hose to the PCV valve on the left-hand cylinder head • Water bypass hose (from EGR valve) to the rear water bypass joint • Water bypass hose (from throttle body) to the rear water bypass joint • Vacuum hose (from VS V for fuel pressure control) to the fuel pres¬ sure regulator • EVAP hose (from charcoal canister) from the VS V for EVAP • TPS connector • With TRAC system, sub TPS con¬ nector • With TRAC system, sub throttle actuator connector • IAC valve connector

• EGR valve connector • EGR gas temperature sensor con¬ nector • VSV connector for fuel pressure control • VSV connector for EVAP • Accelerator bracket with the 2 bolts • Accelerator, automatic transmission throttle control and the cruise con¬ trol actuator cable • Spark plug wires and clamps to the right and left cylinder head cover • Belt rear plates by installing the bolts. Tighten the bolts to 66 inch lbs. (8 Nm). • No. 2 ignition coil • A new gasket to the exhaust mani¬ fold and install the catalytic con¬ verters. Tighten the 3 nuts to each converter to 46 ft. lbs. (62 Nm). • Front exhaust pipe, tighten the bolts and nuts to 32 ft. lbs. (44 Nm). Tighten the 4 bolts holding the pipe support bracket to the transmission. Tighten the bolts to 32 ft. lbs. (44 Nm). • Power steering pump with the nut and 3 bolts. Tighten the nut to 32 ft. lbs. (43 Nm) and the bolts to 29 ft. lbs. (39 Nm). 19. Align the knock pin on the right side camshaft with the knock pin of the timing pulley. Slide on the timing pulley with the right side mark facing forward. Tighten the bolt to 80 ft. lbs. (108 Nm). 20. Align the knock pin on the left side camshaft with the knock pin of the timing pulley. Slide on the timing pulley with the left side mark facing forward. Tighten the bolt to 80 ft. lbs. (108 Nm). 21 . Install the timing belt to the left side camshaft timing pulley as follows: a. Using the proper tool, slightly turn the left side timing pulley clockwise. Align the installation mark of the timing belt with the timing mark of the camshaft timing pulley and hang the timing belt on the left side camshaft pulley. b. Align the timing marks of the left side camshaft pulley and the timing belt rear plate. c. Check that the timing belt has ten¬ sion between crankshaft timing pulley and the left side camshaft pulley. 22. Install the timing belt to the right side camshaft timing pulley as follows: a. Using the proper tool, slightly turn the right side timing pulley clockwise. Align the installation mark of the timing belt with the timing mark of the camshaft timing pulley and hang the timing belt on the right side camshaft pulley.

LEXUS SC 400

b. Align the timing marks of the right side camshaft pulley and the timing belt rear plate. c. Check that the timing belt has ten¬ sion between crankshaft timing pulley and the right side camshaft pulley. 23. The timing belt tensioner must be set prior to installation. The tensioner can be set by: a. Place a plate washer between the tensioner and a block. Using a press,

.

press in the pushrod using 220-225 lbs. of pressure. b. Align the holes of the pushrod and housing, pass a 0.05 inch (1.27mm) rod through the holes to keep the setting position of the pushrod. c. Release the press and install the dust boot to the tensioner. 24. Loosely install the tensioner. Evenly and alternately tighten the bolts to 20 ft. lbs. (26 Nm). Remove the tool from the tensioner. 25. Turn the crankshaft pulley 2 com¬ plete revolutions from TDC to TDC. Always turn the crankshaft clockwise. Check that all

• Air intake chamber and tighten the 2 bolts and 2 nuts to 32 ft. lbs. (43

• Battery clamp cover • Engine undercover • Oil pan protector 29. Start the engine and check for leaks 30. Bleed the cooling system and recheck the engine coolant level. 31. Make all the necessary engine

Nm); use an 8mm hex wrench • Chamber stays and tighten the mounting bolts to 29 ft. lbs. (39 Nm) • Remaining components. Tighten the emission control valve set to 73 inchhoses lbs. (8 Nm). • All

adjustments.

• Accelerator cable, if equipped with • automatic Coolant transaxle

Intake Manifold REMOVAL & INSTALLATION

• Negative battery cable

3.0L (1MZ-FE) Engine

3.0L (2JZ-GE) Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: •• Negative Coolant battery cable

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: •• Negative Coolant battery cable

• Throttle/accelerator cable from the throttle body

Spark plug wires at the spark plugs • Sparkplugs • Radiator

• Air cleaner hose at the air intake chamber and remove it • All lines and hoses. Tag them for installation. . Idle Speed Control (ISC) valve and the throttle body • Exhaust Gas Recirculation (EGR) valve and vacuum modulator • Cylinder head rear plate • Intake chamber stays, any wires, then, the air intake chamber • Fuel injection delivery pipe and the

• Water pump pulley • Timing belt • No. 2 front exhaust pipe

• 2 Oxygen (O2) sensor leads • 4 nuts, and the manifold heat shield • Exhaust manifolds • Water bypass outlet and the No. 1 rings. pipe. Remove the 3 0bypass outlet • Water • No. 1 bypass hose • Vacuum Control Valve (VC V) set and the No. 2 vacuum pipe

injectors • Water outlet and the bypass outlet . 2 bolts and the No. 2 idler pulley bracket stay . 8 bolts and 4 nuts, then lift out the intake manifold

• Fuel return hose from the oil dip¬ stick guide, remove the mounting bolt and pull the guide and dipstick from the pan. Plug the hole. • Air intake chamber • Fuel delivery pipe, then pull out the

To install:

3. Thoroughly clean the intake manifold and cylinder head surfaces. Using a machinist’s straight edge and a feeler gauge, check the surface of the intake manifold for warpage. If the warpage is greater than 0.0039 in. (0.10mm), replace the intake manifold. 4. Place new gaskets onto the intake manifold and position the intake manifold between the cylinder heads. Tighten the nuts and bolts to 13 ft. lbs. (18 Nm). Tighten the No. 2 pulley bracket bolts to 13 ft. lbs. (18 Nm). 5. Install or connect the following: • Water bypass outlet and tighten the bolts to 74 inch lbs. (8.3 Nm). Tighten the water outlet to 74 inch lbs. (8 Nm). • Injectors and delivery pipe

• No. 1 and 2 fuel pipes injectors

• Engine harness from the intake manifold • Intake manifold stay . Loosen the 6 bolts and 2 nuts, then lift out the intake manifold To install:

• Install the intake manifold, with a the bolts andft.tighten gasket, new nuts and to 15 lbs. (21 Nm) Mounting stay and tighten the bolts • to 29 ft. lbs. (39 Nm)

ng: owi oll

f tthe nec

on olrc tal

Ins

belt and pulley marks align with their refer¬ ence marks. If any mark is out of perfect alignment, the timing belt must be removed and reinstalled. 26. Install or connect the following: • Drive belt tensioner and tighten the bolt and nuts to 12 ft. lbs. (16 Nm). 27. Install the fan bracket by installing . the 2 bolts and 2 nuts. Tighten as follows: a. 12mm: 12 ft. lbs. (16 Nm) b. 14mm: 24 ft. lbs. (32 Nm) 28. Remove or disconnect the following: • Air conditioning compressor. Tighten the bolts to 36 ft. lbs. (49 Nm) and the nut to 22 ft. lbs. (29 Nm). • No. 1 ignition coil • Right side No. 2 timing belt cover • Left side No. 2 timing belt cover • Drive belt idler pulley and cover plate. Tighten the bolt to 27 ft. lbs. (37 Nm). • Secure the ignition wires. Make certain that all clips and retainers are securely engaged and that the wires are properly routed. • Right side No. 3 timing belt • Left-hand No. 3 timing belt cover • Radiator assembly • Fan pulley, fan, fluid coupling and the drive belt • The air cleaner and intake air con¬ nector assembly • V bank cover • Coolant • Negative battery cable to the battery • Air cleaner inlet

16-51

• Engine harness to the manifold tighten the bolts to 2 fuel • 78 (9 Nm) lbs. and inchpipes

9 ESLEXU 1I RD-RJL 300S • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400 21 (210, 15) |

♦ Non-reusable

part 9301 LG09

Exploded view of the intake manifold mounting and related components— 3. 0L (2JZ-GE) engine

Nm)

• Delivery pipe and injectors. Tighten the pipe bolts to 15 ft. lbs. (21 Nmj.

• Water bypass outlet and the pipe, tighten the bolts to 78 inch lbs. (9

• Air intake chamber and tighten it to 15 ft. lbs. (21 Nm) • 2 stays and tighten them to 13 ft. lbs. (18 Nm); The No. 1 stay is marked with an F and the No. 2 stay is marked with an R. • The oil dipstick and guide, using a new O-ring • VCV set and the vacuum pipe. Tighten the set mounting bolts to 15 ft. lbs. (21 Nm).

• Exhaust manifolds. Tighten the bolts to 29 ft. lbs. (39 Nm). • Heat shield and tighten it to 13 ft. lbs. (18 Nm) • No. 2 front pipe • Timing belt • Radiator and water pump pulley • Plug wires to the plugs • Coolant • Negative battery cable

4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Properly relieve the fuel system pres¬ sure. 3. Remove or disconnect the following: Negative battery cable • Coolant • Accelerator cable • Throttle and accelerator pedal posi¬ tion electrical connectors • Throttle motor electrical connector

LEXUS ifi CO ES 300

• IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 * SC 400 Heater Hose EVAP

EVAP

Pipe

Hose

■

1 Gk 1 § a

Engine Wire

Engine Wire

Engine Wire

Accelerator Pedal Position Sensor

Noise Filter Connector Brake Booster Vacuum

Hose

Injector Connector Throttle Control

t and Inle WatterHou sing Inle Assembly

EVAP

Hose

Motor Connector

VSV Connector

for

EVAP Fuel Inlet Tube Throttle Position Sensor Connector

VVT Sensor . ♦ Gasket Connector

»

. V-Bank Cover Bracket

i Heater Hose

Front Water

VVT Sensor

-^ \ Sensor Cover VVT

Bypass Joint eg*

V-Bank'-. Bracket

Connector VVT Sensor ® t'

♦ Gasket

Coil Connector Ignition

; ^ RH No. 2 Timing Belt Rear Plate

Ignition Coil

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RH No.1 Timing Belt Rear Plate gp

♦ Non-reusable

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LH No. 2 Timing Belt Rear Plate \&iy-

LH No.1 Timing Belt Rear P!ate

part 9301LG10

nts— 4. 0L (1UZ-FE) and 4.3L (3UZ-FE) Engines Exploded view of the intake manifold mounting and related compone

• Vacuum Switching Valve (VSV) electrical connectors • Injector electrical connectors • Noise filter electrical connector • Brake booster vacuum hose from the intake manifold • Positive Crankcase Ventilation hose from the left-hand (PCV) cover valve

• Evaporative Emission (EVAP) hoses and label for installation air hose from the • Power body steering intake manifold • Coolant hoses from the throttle

• 2 EVAP-to-intake manifold mount¬ ing bolts cable bracket • Accelerator

•. 3EVAP V-bank cover brackets VSV • Fuel supply and return lines • 6 bolts and 4 nuts, then the intake manifold assembly 4. Clean the gasket mating surfaces of old gasket and sealant. To install:

5. Install or connect the following:

E/! IC I 0 D4

LEXUS

ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400

• 2 intake manifold gaskets on the cylinder heads with the white painted mark facing upward. • Intake manifold assembly and uni¬ formly, tighten the mounting bolts to 13 ft. lbs. (18 Nm). 6. The remaining steps of the installation procedure are the reverse of the removal, while keeping in mind the following items: • Tighten the V-bank cover brackets to 66 inch lbs. (8 Nm) • Tighten the accelerator cable bracket mounting bolts to 13 ft. lbs. (18 Nm) • Tighten the EVAPVSV to 13 ft. lbs. (18 Nm) • All remaining components • Coolant • Negative battery cable

.

Exhaust Manifold REMOVAL & INSTALLATION 3.0L (1MZ-FE) Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Engine undercovers • 2 front exhaust pipe stay bolts • Front pipe from the center pipe • 3 nuts and the front pipe • Oxygen (O2) sensor at the right side manifold • 3 mounting nuts and lift off the out¬ side heat insulator • 6 nuts and lift off the right side manifold and gasket • Left side heat insulator • 6 nuts and lift off the left side man¬ ifold and gaskets To install:

3. Install or connect the following: • Right manifold with a new gasket. Tighten the nuts to 29 ft. lbs. (39 Nm). • Outer insulator • Left manifold. Use a new gasket. Tighten the nuts to 29 ft. lbs. (39 Nm).

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Engine undercovers • No. 2 front exhaust pipe bolts and disconnect it from the front exhaust pipe. Loosen the 4 nuts, then remove the front pipe.

• Fuel pressure • EGR vacuum VSV • Water bypass ISC valve • Water bypass • Vacuum pipe

VSV hoses and the EGR pipe hose from the joint hose hoses

• EGR gas temperature sensor • EGR valve adapter • hose Fuel pressure regulator vacuum

• Both Oxygen (O2) sensors at the manifold • 4 mounting nuts and lift off the out¬ side heat insulator • 4 nuts and disconnect the mani¬ folds from the pipe. Loosen the mounting bolts and remove the 2 manifolds and the gasket. To install:

3. Install or connect the following: • Manifolds with a new gasket. Nm). Tighten the nuts to 30 ft. lbs. (40 • Outer insulator. Tighten the nuts to 13 ft. lbs. (18 Nm). • No. 2 front pipe. Tighten the nuts to 46 ft. lbs. (62 Nm). • Front exhaust pipe. Tighten the bolts/nuts to 32 ft. lbs. (43 Nm).

• O2 sensors

• Undercovers • Battery cable

• Air intake chamber vacuum hose • Vacuum hose from the Evaporative Emission (EVAP) BVSV pipe bolts, hoses and the vac¬ • uum Mounting • ISC valve • Throttle body sensor connectors and the water bypass pipe from the rear water bypass joint • Positive Crankcase Ventilation (PCV) valve • Throttle body hose and gasket • Accelerator cable bracket and the brake booster vacuum union and hose • Cold start injector connector and the cold start injector tube from the right side delivery pipe, if equipped • Check connector from the intake chamber and remove the mounting nuts and bolts • Air intake chamber and the cold start injector, tube and wire assem¬ bly, if equipped

4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: •• Coolant Negative battery cable • Camshaft timing pulleys • Cooling fan hydraulic pump, on the SC 400 • Accelerator, throttle control and cruise control actuator cables • High tension cord cover and the right side ignition coil • Water inlet housing mounting bolts • Water bypass hose from the Idle Speed Control (ISC) valve • Water inlet and inlet housing assemblies • O-ring from the water inlet housing • Exhaust Gas Recirculation (EGR) • Vacuum Switching Valve (VS V) connector pipe • Vacuum pipe hose olrc tal

Ins

• Outer insulator • Front exhaust pipe and tighten the manifold-to-pipe nuts to 46 ft. lbs. (62 Nm). Tighten the pipe-to-converter nuts to 32 ft. lbs. (43 Nm). • O2 sensor • Undercovers • Battery cable

• EGR water bypass pipe 3.0L (2JZ-GE) Engine

• Engine wire from the intake mani¬ fold and from the right side cylin¬ der head • Heater hoses • Delivery pipes and the fuel injectors • Mounting bolts and nuts. Lift up the intake manifold • Front and rear water bypass joint • Front exhaust pipe and the main catalytic converters. Lower the vehicle. • Right side Oxygen (O2) sensor • Mounting bolts and nuts and • • • •

remove ifold. the right side exhaust man¬ Oil dipstick and guide Left side O2 sensor Mounting bolts and nuts Left side exhaust manifold

To install:

• Right side exhaust manifold with a new gasket (the painted marks should face the manifold) and tighten the mounting bolts to 29 ft. lbs. (39 Nm).

lexus 1 R-RR ES 300 • IS 300 • GS 300 • GS 400 • GS 430 * LS 400 • LS 430 • SC 300 • SC 400 • Right side O2 sensor • Left side exhaust manifold with a new gasket (the painted marks should face the manifold) and tighten the mounting bolts to 29 ft. lbs. (39 Nm) • Left side O2 sensor • Oil dipstick and guide. Raise and safely support the vehicle. • Catalytic converters and front exhaust pipe. Lower the vehicle. • Front and rear water bypass joints. Tighten the mounting bolts to 13 ft. lbs. (18 Nm). • Intake manifold, using new gaskets. Tighten the mounting nuts and bolts to 13 ft. lbs. (18 Nm). • Delivery pipes and fuel injectors • Fuel return pipe with new gaskets. Tighten the union bolt to 26 ft. lbs. (35 Nm). • Fuel hoses and the injector con¬ nectors • Engine wire to the delivery pipes • Connectors on the left side delivery pipe sensor • ECT • Cold start injector time switch • Water temperature sender gauge connectors • Heater hoses and engine wire bracket • Engine wire to the bracket. • Cold start injector, tube and wire assembly. Tighten the mounting bolts to 69 inch lbs. (8 Nm), if equipped. • Air intake chamber with new gas¬ kets and tighten the mounting bolts to 13 ft. lbs. (18 Nm). • Cold start injector tube to the right side delivery pipe and tighten the union bolt to 11 ft. lbs. (15 Nm), if equipped. • Cold start injector connector, if necessary • Accelerator cable bracket • Brake booster union and connect the vacuum hose. Tighten the union bolt to 22 ft. lbs. (29 Nm). • Water bypass hose to the throttle body and the PCV hose to the cylinder head cover. • Throttle body, using a new gasket. Tighten the mounting bolts to 13 ft. lbs. (18 Nm). • Water bypass pipe • Sensor connectors • Idle Speed Control (ISC) valve and tighten the mounting bolts to 13 ft. lbs. (18 Nm). • Water bypass hose.

uu

• Vacuum pipe and the assorted hoses • Remaining components. • Adjust the accelerator cable, the automatic transmission throttle cable and the cruise control actua¬ tor cable. • Cooling fan hydraulic pump on the SC 400 • Camshaft timing pulleys • Coolant • Negative battery cable 7923LG40

Camshaft and Valve Lifters REMOVAL & INSTALLATION

Aligning the right side camshaft timing marks— 3. OL (1MZ-FE) engine

Main Gear Sub-Gear

The following procedures have the valve lash adjuster removal and installation incor¬ porated. 3.0L (1MZ-FE) Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Timing belt and idler pulley • Camshaft timing pulleys • Cylinder head covers

i: WARNING The thrust clearance on both the intake and exhaust camshafts is very small, the camshafts must be kept level during removal. If the camshafts are removed without being kept level, the camshaft may be caught in the cylinder head causing the head to break or the camshaft to seize.

3. To remove the exhaust and intake camshafts from the right side cylinder head: a. Turn the camshaft with a wrench until the 2 pointed marks drive and dri-

Service Bolt 7923LG41

Securing the subgear and driven gear, rinht side— 3.0L (IMZ-FEt engine

ven gears are aligned. (The right camshaft gears have 2 marks apiece; the each.) left side camshaft gears have 1 mark

b. Secure the exhaust camshaft sub¬ gear to the main gear using a service bolt. A bolt 0.63-0.79 in. (16-20mm) long with a 6mm thread diameter and a 1mm pitch is recommended. When removing the exhaust camshaft be sure the subgear is not loaded; all the force must be eliminated. c. Uniformly loosen and remove the exhaust camshaft bearing cap bolts in several passes and in the proper sequence. Remove the 8 bearing cap bolts and remove the caps, keeping them in the correct order.

engine Right exhaust camshaft bearing loosening sequence— 3. OL (1MZ-FE)

1 C

CC

I 0“UD

LEXUS ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400

d. Remove the exhaust camshaft from the engine. e. Uniformly loosen and remove the 10 bearing cap bolts in several passes, in the proper sequence. Remove the bearing caps, keeping them in order, remove the oil seal, then lift out the intake camshaft. 4. To remove the exhaust and intake camshafts from the left side cylinder head: a. Turn the camshaft with a wrench until the pointed marks on the drive and driven gears are aligned. (The right camshaft gears have 2 marks apiece; the left side camshaft gears have 1 mark each.) b. Secure the exhaust camshaft sub¬ gear to the main gear using a service bolt. A bolt 0.63-0.79 in. (16-20mm) long with a 6mm thread diameter and a 1mm pitch is recommended. When removing the exhaust camshaft be sure the subgear is not loaded; all the force must be eliminated. c. Uniformly loosen and remove the exhaust camshaft bearing cap bolts in several passes and in the proper sequence. Remove the 8 bearing cap bolts and remove the caps. Keep the caps in the correct order. d. Remove the exhaust camshaft from the engine. e. Uniformly loosen and remove the 10 bearing cap bolts in several passes, in the proper sequence. Remove the bearing caps, keeping them in order, remove the oil seal, then lift out the intake camshaft. 5. Remove the valve lash adjuster shims and hydraulic lash adjusters. Identity each lash adjuster and shim as it is removed so it can be reinstalled in the same position. If the lash adjusters are to be reused, store them upside down in a sealed container. To install:

6. Install or connect the following: • Valve lash adjusters and shims. Check valve clearance and replace the shims as necessary.

Right intake camshaft bearing loosening sequence — 3.0L (1MZ-FE) engine

Aligning the left side camshaft timing

Securing the subgear and driven gear, left

marks — 3.0L (1MZ-FE) engine

side— 3.0L (1MZ-FE) engine

Left intake camshaft bearing cap bolt loosening sequence — 3.0L (1MZ-FE) engine

"•►Before installing the camshafts in either cylinder head, apply multi-pur¬ pose grease to the thrust portions of each camshaft.

7. To install the right camshafts: a. Position the intake camshaft on the head so that the alignment marks are at a 90° angle from vertical. The mark should be at the 3 o’clock position. b. Apply sealant to the No. 1 bearing cap.

Left exhaust camshaft bearing cap bolt loosening sequence— 3. OL (1MZ-FE) engine

ES 300 • IS 300

SC 400 -II U GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 •LEXUS

U I

c. Apply a light coat of clean engine oil to the bolt threads and under the bolt head. Install the bearing caps to their proper position. Tighten the bolts evenly and in several passes in the reverse order of loosening to 12 ft. lbs. (16 Nm) in the proper sequence. d. Position the exhaust camshaft on the head so that the alignment marks are 7923LG52

7923LG48

Exhaust camshaft installation position on

Exhaust camshaft installation position on

the right cylinder head— 3.0L (1MZ-FE) engine

the left cylinder head— 3.0L (1MZ-FE)

e. Apply a light coat of clean engine oil to the bolt threads and under the bolt head. Install the bearing caps to their proper gear. position. Tighten the bolts evenly and in several passes in the reverse order of loosening to 12 ft. lbs. (16 Nm) in the proper sequence. f. Remove the service bolt. 8. To install the left camshafts: a. Position the intake camshaft on the head so that the alignment mark is at a 90 degree angle from vertical. The mark

engine

7923LG53

7923LG49

Exhaust camshaft bearing cap bolt tighten¬

Exhaust camshaft bearing cap bolt tighten¬

ing sequence on the right cylinder head—

ing sequence on the right cylinder head— 3.0L (1MZ-FE) engine

3.0L (1MZ-FE) engine

at a 90° angle from vertical. The mark should be at the 9 o’clock position and must align with the marks on the other

should be at the 9 o’clock position. cap.b. Apply sealant to the No. 1 bearing c. Apply a light coat of clean engine oil to the bolt threads and under the bolt head. Install the bearing caps to their proper position. Tighten the bolts evenly and in several passes to 12 ft. lbs. (16 Nm) in the proper sequence. d. Position the exhaust camshaft on the head so that the alignment marks are at a 90 degree angle from vertical. The

Intake camshaft installation position on

Intake camshaft installation position on

the right cylinder head— 3.0L (1MZ-FE) engine

the left cylinder head — 3.0L (1MZ-FE)

mark should be at the 3 o’clock position and must align with the marks on the other gear. e. Apply a light coat of clean engine oil to the bolt threads and under the bolt head. Install the bearing caps to their proper position. Tighten the bolts evenly and in several passes to 12 ft. lbs. (16

engine

Nm) in the proper sequence.

7923LG50

7923LG54

7923LG51

Intake camshaft bearing cap bolt tighten¬ ing sequence on the right cylinder head — 3.0L (1MZ-FE) engine

Intake camshaft bearing cap bolt tightening sequence on the right cylinder head— 3.0L (1MZFE) engine

16-58

LEXUS ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400

f. Remove the service bolt.

for the exhaust and intake camshafts. Lift off all 12 bearing

camshaft oil seals. Install the seals. 10. Install or connect the following: • No. 3 (rear) timing belt cover • Camshaft timing gears 9. pulley, timing belt and covers Ap•plyIdler multi-purpo se the 11. Check and adjust greavalve se to clear¬ new ance.

12. Install the cylinder head (valve) cov¬ ers.

caps. • Exhaust and intake camshafts • Valve lash adjuster shims and hydraulic lash adjusters. Identify each lash adjuster and shim as it is removed so it can be reinstalled in the same position. If the lash adjusters are to be reused, store them upside down in a sealed con¬ tainer.

7923LG58

To install:

3.0L (2JZ-GE) Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable from the bat¬ tery ■ • Timing belt from the engine • Cylinder head covers • Camshaft sprocket • 4 bolts and lift out the No. 4 (inner) timing belt cover. • No. 1 camshaft bearing cap bolts. These are the bolts directly behind the sprockets. • Bearing caps • Remaining bearing cap bolts. Note that there are separate sequences

Removing the camshaft sprockets— 3. OL (2JZ-GE) engine

3. Install or connect the following: • Valve lash adjusters and shims. Check valve clearance and replace the shims as necessary. • Camshafts. Coat the thrust portions of each with engine oil, then posi¬ tion them in the cylinder head with the cam lobes and the knock pins in the correct position. • No. 3 and No. 7 bearing caps in place, coat the bolt threads with oil, then tighten them temporarily • New oil seals, coated with multi¬ purpose grease, over the camshafts • No. 1 bearing caps, then apply some sealant. Install the bolts. • All remaining bearing caps. Coat the threads of each bolt with clean oil, then tighten them, in several passes, in sequence, to 14 ft. lbs. (20 Nm). Note that there are sepa¬ rate sequences for the intake and exhaust sides. • Oil seal in as far as it will go 4. Rotate each camshaft until the for¬ ward straight (knock) pin is straight up. Loosen exhaust Nos. 1, 2 and 6 bearing cap bolts until they can be turned by hand; retighten them to 14 ft. lbs. (20 Nm). Loosen intake Nos. 1 and 2 and retighten to 14 ft. lbs. (20 Nm). 5. Turn each camshaft Vz of a revolution (120 degrees). Loosen exhaust Nos. 4 and 7

Installing No. 3 and 7 bearing caps — 3.0L (2JZ-GE) engine

Seal Packing

7923LG59

Applying sealant to the No. 1 bearing cap— 3.0L (2JZ-GE) engine

Camshaft bearing cap bolt tightening sequence— 3. OL (2JZ-GE) engine

7923LG57 7923LG61

Camshaft bearing cap bolt removal sequence— 3. OL (2JZ-GE) engine

2 - 3 mm

Tightening the camshafts (Step 1)— 3.0L (2JZ-GE) engine

LEXUS Ifi.RQ

400 ES 300 • IS 300 • GS* 300 • GS 400 ♦ GS 430 • LS

• 4 bolts to the left-hand timing belt cover * LS 430 • SC 300 • SC 400 W • Cord grommet from the timing belt cover and remove the timing belt cover • Drive belt idler pulley by removing the pulley bolt and cover plate • Right-hand and left No. 2 timing belt covers • No. 1 ignition coil • Air conditioning compressor from the engine. Do not disconnect the air conditioning pressure lines. • Fan bracket by removing the 2 bolts and 2 nuts • Alternator from the engine • Drive belt tensioner

Tightening the camshafts (Step 2)— 3.0L (2JZ-GE) engine

4. Set the engine to Top Dead Center

to® M; £;-S : Lm) Ifoocr ooo^oooLJ Sirs ▼

JCVJSV -

X-

-

7923LG63

Tightening the camshafts (Step 3)— 3.0L (2JZ-GE) engine

bearing cap bolts; retighten them to 14 ft. lbs. (20 Nm). Loosen intake Nos. 4 and 6 1 bearing cap bolts; retighten them to 14 ft. lbs. (20 Nm). 6. Turn each camshaft an additional V& of a revolution, loosen exhaust bearing cap bolts Nos. 3 and 5, then retighten them to 14 ft. lbs. (20 Nm). Loosen intake bearing cap bolts Nos. 3 and 7, then retighten them to 14 ft. lbs. (20 Nm). 7. Check and adjust the valve clearance. 8. Install or connect the following: • No. 4 inside timing belt cover and the camshaft pulleys. Align the shaft pin with the pulley groove and slide the pulley on. Install the bolt tem¬ porarily. Hold the hex portion of the camshaft with a wrench; tighten the pulley bolt to 59 ft. lbs. (79 Nm). • Cylinder head covers • Timing belt to the engine • Negative battery cable to the battery 9. Check and/or adjust the ignition tim¬ ing as necessary 4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines

2. Relieve the fuel pressure from the fuel lines. 3. Remove or disconnect the following: • Negative battery cable. Wait at least 90 seconds before performing any other work • Battery Positive battery cable • Air cleaner inlet • V bank cover by removing the bolt and 2 cap nuts • Air cleaner and intake air connector assembly • Drive belt • Fluid coupling and the fan pulley. The drive belt tension may be slackened by turning the tensioner counterclockwise. The pulley bolt for the drive belt tensioner has a left-handed thread. • Radiator

¬ sec s thi of

nn gi be the in

au ec pr n. thteio

• The right-hand No. 3 timing belt cover • Left-hand No. 3 timing belt cover • Evaporative Emissions (EVAP) hose clamp from the timing belt cover. For all other vehicles, dis¬ connect the EVAP hose from the hose clamp on the timing belt cover.

(TDC) on cylinder No. 1. 5. Turn the crankshaft pulley approxi¬ mately 50° clockwise and put the timing mark of the crankshaft pulley in line with the centers of the crankshaft pulley bolt and the idler pulley bolt.

WARNING If the timing belt is disengaged, hav¬ ing the crankshaft pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when you remove the camshaft timing pulley. Always set the crankshaft pulley at the correct angle before removing the timing belt.

6. If the timing belt is to be reused, turn the crank pulley slowly; check that the 3 installation marks are present on the belt. If marks are not present, make new instal¬ the lation marks before removing the belt. The ley. should align with the timing marks marks on each camshaft pulley and the crank pul¬ 7. Remove or disconnect the following: • Timing belt tensioner

• Timing belt from the camshaft tim¬ pulleystiming pulleys • ing Camshaft • No. 2 ignition coil •• Throttle Rear timing bodybelt plates

• Spark plug wires, wire clamps and the wire cover assembly from the right cylinder head • Right cylinder head cover by removing the 8 bolts and 8 washers • Transmission oil dipstick • Evaporative Emission (EVAP) con¬ trol hose from the Vacuum Switch¬ ing Valve (VSV)

16-60

LEXUS ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400

1

• Engine wire clamp from the wire bracket on the delivery pipe • Spark plug wires and clamps from the left-hand cylinder head cover • Left cylinder head cover by remov¬ ing the 8 bolts and 8 seal washers • Semi-circular plugs, if necessary WARNING

0 Since the thrust clearance of the . camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break.

8. To remove the exhaust camshaft from the right side cylinder head: a. Position the service bolt hole of the drive subgear to the upright position. Secure the camshaft subgear to drive gear with a service bolt. b. Set the timing mark (single dot) on the camshaft drive gear at approximately 10 degrees. Turn the camshaft with a wrench on the hexagonal flats. c. Alternately loosen and remove the bearing cap bolts holding the intake camshaft side of the oil feed pipe to the cylinder head. d. Uniformly loosen (in several passes) and remove the bearing cap bolts, in sequence. e. Remove the oil feed pipe and the bearing caps. Remove the camshaft. f. To remove the intake camshaft from the right side cylinder head: g. Set the timing mark (single dot) on the camshaft drive gear at approximately 45 degrees. Turn the camshaft with a wrench on the hexagonal flats. h. Uniformly loosen (in several passes) and remove the bearing cap bolts in the proper sequence. i. Remove the bearing caps, oil seal and the intake camshaft. 9. To remove the exhaust camshaft of the left side cylinder head: a. Position the service bolt hole of the drive subgear to the upright position. Secure the camshaft subgear to drive gear with a service bolt.

c. Alternately loosen and remove the bearing cap bolts holding the intake camshaft side of the oil feed pipe to the

a. Set the timing mark (single dot) of the camshaft drive gear at approximately 60 degrees, by turning the camshaft with

cylinder head. d. Uniformly loosen (in several passes) and remove the bearing cap bolts in the proper sequence. e. Remove the oil feed pipe and the bearing caps. Remove the camshaft.

the proper tool. b. Uniformly loosen (in several passes) and remove the bearing cap bolts, in sequence. c. Remove the bearing caps, oil seal and the intake camshaft. d. Remove the valve lash adjuster

the left side cylinder head:

shims and hydraulic lash adjusters. Iden-

To re move the i ntake camsh aft from

Bolt loosening sequence for the exhaust camshaft on the right cylinder head— 4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines

Loosen the bearing cap bolts for the intake camshaft on the right cylinder head in the sequence shown— 4. OL (1UZ-FE) and 4.3L (3UZ-FE) Engines

^•When removing the camshaft, be sure the torsional spring force of the subgear has been eliminated.

b. Set the timing mark (2 dots) on the camshaft drive gear at approximately 15 degrees, by turning the camshaft with the proper tool.

Turning the exhaust camshaft on the left cylinder head 15 degrees— 4. OL (1UZ-FE) and 4.3L (3UZ-FE) Engines

LEXUS Ifi-fil ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400

I U

v

7923LG75

Right side intake camshaft bracket bolt

and Bolt removal sequence for the intake camshaft on the left cylinder head— 4.0L (1UZ-FE) 4.3L (3UZ-FE) Engines

tightening sequence — 4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines

7923LG80

Right side exhaust camshaft bracket bolt

7923LG71

tightening sequence— 4. OL (1UZ-FE) and 4.3L (3UZ-FE) Engines

and Bolt removal sequence for the exhaust camshaft on the left cylinder head— 4.0L (1UZ-FE) 4.3L (3UZ-FE) Engines

' tify each lash adjuster and shim as j removed so it can be reinstalled in same position. If the lash adjusters be reused, store them upside down sealed container.

it is the are to in a

To install:

! 11. Install or connect the following: • Valve lash adjusters and shims. Check the valve clearance and replace the shims as necessary. • New seal packing to the bearing caps

• Bearing cap on the right side cylin¬ der head, marked II, in position with the arrow mark facing the rear. Install the bearing cap on the left side cylinder head, marked 16, in position with the arrow mark facing the front. • Oil on the threads of the cap bolts. Install the bearing cap bolts with new washers and tighten to 12 ft. lbs. (16 Nm). 12. To install the right side cylinder head intake camshaft: a. Apply grease to the thrust portion of the camshaft. b. Place the intake camshaft at a 45

degree angle of the timing mark (single dot) on the cylinder head. c. Remove any old packing and apply new seal packing to the bearing cap marked 16 and install the front bearing cap, marked 16 with the arrow facing rearward. d. Align the arrows at the front and rear of the cylinder head with the bearing cap.

7923LG81

Left side intake camshaft bracket bolt

e. Install the remaining bearing caps in the proper sequence with the arrow mark facing rearward. Install the oil feed pipe and the mounting bolts. f. Uniformly tighten the bearing cap bolts in the proper sequence to 12 ft. lbs. (16 Nm). 13. To install the right side cylinder head exhaust camshaft: a. Set the timing mark (single dot) on the camshaft drive gear at a 10 degree angle by turning the intake camshaft with the proper tool. b. Apply grease to the thrust portion of the camshaft. c. Align the timing marks (single dots) on the camshaft drive and driven

tightening sequence — 4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines

7923LG82

Left side exhaust camshaft bracket bolt tightening sequence — 4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines

300S • IS 300 i? ESLEXU fi-fOL IIU

• GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400

d. Place the exhaust camshaft in the cylinder head. Install the rear bearing cap with the arrow mark facing rearward. e. Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing cap. Apply a light coat of oil on the threads of the bearing cap bolts. f. Uniformly tighten the bearing cap bolts in the proper sequence to 12 ft. lbs. (16 Nm). g. Bring the service bolt installed upward by turning the camshaft with the proper tool. Remove the service bolt. 14. To install the left side cylinder head intake camshaft: a. Apply grease to the thrust portion of the camshaft. b. Place the intake camshaft with the timing mark (single dot) at a 60 degree angle on the cylinder head. c. Remove any old packing and apply new seal packing to the bearing cap marked 16 and install the front bearing cap, marked II with the arrow facing rearward. d. Align the arrows at the front and rear of the cylinder head with the bearing cap. Apply a light coat of oil on the threads of the bearing cap bolts. e. Install the remaining bearing caps in the proper sequence with the arrow mark facing rearward. Install the oil feed pipe and the mounting bolts. f. Uniformly tighten the bearing cap bolts in the proper sequence to 12 ft. lbs. (16 Nm). 15. Install the left side cylinder head exhaust camshaft by: a. Set the timing mark (2 dots) on the camshaft drive gear at a 15 degree angle by turning the intake camshaft with the proper tool. b. Apply grease to the thrust portion of the camshaft. c. Align the timing marks (2 dots each) on the camshaft drive and driven gears. d. Place the exhaust camshaft on the cylinder head. Install the rear bearing cap with the arrow mark facing rearward. e. Align the arrow marks at the front and rear of the cylinder head with the mark on the bearing cap. Apply a light coat of oil on the threads of the bearing cap bolts. f. Uniformly tighten the bearing cap bolts in the proper sequence to 12 ft. lbs. (16 Nm). 16. Bring the service bolt installed upward by turning the camshaft with the proper tool. Remove the service bolt.

17. Install or connect the following: • Camshaft oil seals. Be sure to apply Multi-Purpose (MP) grease to the new oil seal lip. • Semi-circular plugs to the cylinder heads • Left cylinder head cover and bolts. Nm). the bolts to 52 inch lbs. (6 Tighten • Spark plug wires and clamps to the left cylinder head cover • Engine wire clamp to the wire bracket on the delivery pipe • EVAP hose to the VSV • Transmission oil dipstick • Right cylinder head cover and bolts. Tighten the bolts to 52 inch lbs. (6 Nm).

the installation mark of the timing belt with the timing mark of the camshaft timing pul¬ ley and hang the timing belt on the right side camshaft pulley. 28. Align the timing marks of the right side camshaft pulley and the timing belt rear plate. 29. Check that the timing belt has ten¬ sion between crankshaft timing pulley and the right side camshaft pulley. 30. The timing belt tensioner must be set set priorby:to installation. The tensioner can be a. Place a plate washer between the tensioner and a block. Using a press, press in the pushrod using 220-225 lbs. (100-102 kg.) of pressure. b. Align the holes of the pushrod and housing, pass a 0.05 in. (1.27mm) rod through the holes to keep the setting position of the pushrod. c. Release the press and install the dust boot to the tensioner. d. Loosely install the tensioner. Evenly and alternately tighten the bolts to 20 ft. lbs. (26 Nm). Remove the tool from the tensioner.

• Spark plug wires and clamps to the right cylinder head cover • Throttle body to the air intake chamber. Install the 2 bolts and 2 Nm). nuts and tighten to 13 ft. lbs. (18 • Timing belt rear plates by installing the bolts. Tighten the bolts to 66 inch lbs. (8 Nm). • No. 2 ignition coil 18. Align the knock pin on the right side camshaft with the knock pin of the timing pulley. Slide on the timing pulley with the right side mark facing forward. Tighten the bolt to 80 ft. lbs. (108 Nm). 19. Align the knock pin on the left side camshaft with the knock pin of the timing pulley. Slide on the timing pulley with the left side mark facing forward. Tighten the bolt to 80 ft. lbs. (108 Nm). 20. Turn the crankshaft pulley and align its groove with the 0 timing mark on the timing belt cover. 21. Turn each camshaft timing pulley and align the timing marks of the pulley with the timing belt rear plate. 22. Attach the timing belt to the left side camshaft timing pulley: 23. Using the proper tool, slightly turn the left side timing pulley clockwise. Align the installation mark of the timing belt with the timing mark of the camshaft timing pul¬ ley and hang the timing belt on the left side camshaft pulley. 24. Align the timing marks of the left side camshaft pulley and the timing belt rear plate. 25. Check that the timing belt has ten¬ sion between crankshaft timing pulley and the left side camshaft pulley. 26. Install the timing belt to the right side camshaft timing pulley: 27. Using the proper tool, slightly turn the right side timing pulley clockwise. Align

e. Turn the crankshaft pulley 2 com¬ plete revolutions from TDC to TDC. Always turn the crankshaft clockwise. Check that all belt and pulley marks align with their reference marks. If any mark is out of perfect alignment, the tim¬ ing belt must be removed and rein¬ stalled. 31 . Install or connect the following: • Remaining components • V bank cover • Coolant • Battery and battery tray •• • • •

Battery cables, Air cleaner inletpositive cable first Battery clamp cover Engine undercover Oil pan protector

Valve Lash ADJUSTMENT 3.0L (1MZ-FE) Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. ^Adjust the valve clearance when the engine is cold.

ing:

2. Remove or disconnect the follow¬ • Negative battery cable

LEXUS Ifi.fiQ ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 » SC 400

• Accelerator/throttle cable from the throttle linkage • Air intake chamber • Cylinder head covers 3. Turn the crankshaft pulley and align it's groove with the timing mark 0 of the No. 1 timing cover. 4. Check that the valve lash adjusters on the No. 1 intake are loose and the exhaust are tight. If not, turn the crankshaft on complete revolution (360 degrees). 5. Measure the clearance between the valve lash adjuster and the camshaft. Record the measurements on valves No. 1, 2, 3 and 6.

7923LG28

Adjust these valves FIRST — 3.0L (1MZ-FE) engine

6. The intake valve clearance cold is 0.006-0.010 in. (0.1 5-0.25mm). 7. The exhaust valve clearance cold is 0.010-0.014 in. (0.25-0.35mm). 8. Turn the crankshaft % of a revolution (240 degrees) and check the clearance on valves No. 2, 3, 4 and 5 and record. 9. Turn the crankshaft another % of a revolution and check valves; No. 1, 4, 5 and 6 and record. 10. Remove or disconnect the following:

Adjust these valves SECOND — 3.0L (1MZFE) engine

12. Install the specified valve shim on the valve lash adjuster 13. Recheck the valve clearance. 14. Install the cylinder head covers and intake chamber. 15. Connect the negative battery cable. 3.0L (2JZ-GE) Engine

• Adjusting shim and turn the crank¬ shaft to position the cam lobe of the camshaft on the adjusting valve upward. Press down the valve lash adjuster with the proper tool and place the proper tool between the camshaft and the valve lash adjuster. Remove the tool. • Adjusting shim with the proper tool. 11. Determine the thickness of the replacement shim as follows: a. T: Thickness of the used shim b. A: Measured valve clearance c. N: Thickness of new shim d. Intake: N = T + (A— 0.006-0.010 in. (0.15-0.25mm)) e. Exhaust: N = T + (A— 0.010-0.014 in. (0.25— 0.35mm))

7923LG29

13-^11 —

1 0

^Adjust the valve clearance when the engine is cold.

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Accelerator/throttle cable from the throttle linkage • Cylinder head covers 3. Turn the crankshaft pulley and align it’s groove with the timing mark 0 of the No. 1 timing cover. 4. Check that the timing marks on the camshaft sprockets are in alignment with the marks on the No. 4 timing cover. If not, turn the crankshaft 1 complete revolution (360 degrees). 5. Uniformly tighten the camshaft bear¬ ing cap bolts in several passes, in the sequence, to 14 ft. lbs. (20 Nm). 6. Measure the clearance between the

1 \&rW -

5m/-\o/'9 7923LG31

Camshaft bearing cap bolt tightening sequence— 3. OL (2JZ-GE) engine

5 5

7923LG30 7923LG32

Adjust these valves THIRD— 3. OL (1MZFE) engine

Adjust these valves FIRST— 3.0L (2JZ-GE) engine

16-64

LEXUS ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400

3 3

6 6

e. Exhaust: N = T + (A— 0.010-0.01 in. (0.25-0.35mm)) 12. Install the specified valve shim on the valve lash adjuster. 13. Recheck the valve clearance. 14. Install the cylinder head covers and intake chamber. 15. Connect the negative battery cable. 4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines

5 5

3 3

7923LG33

the precautions in the beginning of this sec¬ tion. ing: 2. Remove or disconnect the follow-

Adjust these valves SECOND— 3. 0L (2JZ-GE) engine

2

2

4

4

6 6 7923LG34

Adjust these valves THIRD— 3. OL (2JZ-GE) engine

.

0

2 2

valve lash adjuster and the camshaft. Record the measurements on valves No. 1, 4 and 5. a. The intake valve clearance cold is 0.006-0.010 in. (0.1 5-0.25mm). b. The exhaust valve clearance cold is 0.010-0.014 in. (0.25-0.35mm). 7. Turn the crankshaft % of a revolution (240 degrees) and check the clearance on valves No. 3, 5 and 6 and record. 8. Turn the crankshaft another % of a revolution and check valves: No. 2, 4 and 6 and record. Press down the valve lash adjuster with a special tool— 3.0L (2JZ-GE) engine

Removing the adjusting shim— 3.0L (2JZGE) engine

1 . Before servicing the vehicle, refer to

9. Remove the adjusting shim and turn the crankshaft to position the cam lobe of the camshaft on the adjusting valve upward. The notches should be perpendicular to the camshaft. Press down the valve lash adjuster with the proper tool and place the proper tool between the camshaft and the valve lash adjuster. Remove the tool. 10. Remove the adjusting shim with the proper tool (a magnetic finger). 11. Determine the thickness of the replacement shim as follows: a. T = Thickness of the used shim b. A = Measured valve clearance c. N = Thickness of new shim

• Negative battery cable • No. 3 timing belt covers • Spark plug wires • Cylinder head covers 3. Turn the crankshaft pulley and align its groove with the timing mark 0 of the No. 1 timing cover. Check that the timing marks of the camshaft timing pulleys and timing belt rear plates are aligned. If not, turn the crankshaft 1 revolution (360 degrees) and align the mark. 4. Measure the clearance between the valve iash adjuster and the camshaft on the valves in the first sequence and record. a. The intake valve clearance cold is 0.006-0.010 in. (0.15-0.25mm). b. The exhaust valve clearance cold is 0.010-0.014 in. (0.25-0.35mm). 5. Turn the crankshaft 1 full revolution (360 degrees) and align the mark. 6. Measure the clearance between the valve lash adjuster and the camshaft on the valves in the second sequence and record. 7. Remove the adjusting shim and turn the crankshaft to position the cam lobe of the camshaft on the adjusting valve upward. Position the hole in the shim toward the outside of the cylinder head. Press down the valve lash adjuster with the proper tool and place the proper tool between the camshaft and the valve lash adjuster. Remove the tool. 8. Remove the adjusting shim with the 9. tool. Determine the thickness of the proper replacement shim as follows: a. T = Thickness of the used shim b. A = Measured valve clearance c. N = Thickness of new shim d. Intake: N = T + (A— 0.006-0.010 in. (0.15— 0.25mm)) e. Exhaust: N = T + (A— 0.010-0.014 in. (0.25-0.35mm))

d. Intake: N = T + (A— 0.006-0.010 in. (0.15-0.25mm))

d

. ers

cov

er

ind

hea

cyl the

LEXUS Ifi-fiR

400 ES 300 • IS 300 • GS * 300 • GS 400 • GS 430 • LS RIGHT SIDE

4.0L (1UZ-FE) and 4.3L (3UZ-FE) * LS Engines 430 • SC 300 • SC 400 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. •Remove disconnect the following: V-bank orcover • Accelerator cable • Intake air connector • Throttle Body

LEFT SIDE

7923LG37

Adjust these valves FIRST— 4. 0L (1UZ-FE) and 4.3L (3UZ-FE) Engines

• • • •

Intake manifold assembly Rear water bypass joint Water bypass pipe 2 bolts

• Water bypass pipe from the water pump • water Wire clamp bypassfrom pipethe bracket on the • 0-ring from the water bypass pipe • water Water bypass pipe bracket from the • Starterbypass pipe • 2 bolts holding the starter to the

RIGHT SIDE

FRONT

LEFT SIDE

7923LG38

Adjust these valves SECOND— 4. 0L (1UZ-FE) and 4.3L (3UZ-FE) Engines

11. Connect the spark plug wires and nstall the No. 3 timing belt covers. 12. Connect the negative battery cable.

Starter Motor REMOVAL & INSTALLATION 3.0L (1MZ-FE) Engine 1 . Before servicing the vehicle, refer to the orecautions in the beginning of this section. 2. Remove or disconnect the following: • Negative cable • Automatic transmission shift con¬ trol cable • Engine wire • Starter connector • Nut, and disconnect the starter wire • 2 bolts, automatic transmission shift control cable clamp and starter

To install: 3. Installation is the reversal of the removal process. 4. Torque the starter bolts to 27 ft. lbs. (37 Nm). 3.0L (2JZ-GE) Engine 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative cable • Starter connector • Nut, and disconnect the starter wire • 2 bolts and starter To install: 3. Installation is the reversal of the removal procedure. 4. Tighten the starter bolts to 27 ft. lbs. (37 Nm).

• • •

cylinder blockthe cylinder block Starter from Starter connector Nut, Starterand disconnect the starter wire

To install: 3. Install or connect the following: • Wire clamp to the wire bracket with the bolt. Tighten to 87 inch lbs. • Starter wire with the nut. Tighten to 87 inch lbs. • Starter connector • Starter with the 2 bolts. Torque the bolts to 29 ft. lbs. (39 Nm). • Water bypass pipe pipe bracket to the water bypass • 0-ring to the water bypass pipe • Water bypass pipe • Wire the bracket on the water clamp bypassto pipe • Water bypass pipe bolts. Torque the bolts to 13 ft. lbs. (18 Nm). • Rear water bypass joint •• Throttle Intake manifold body assembly • Intake air connector • Accelerator cable • V-bank cover Oil Pan REMOVAL & INSTALLATION 3.0L (1MZ-FE) Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

HC

CC

I D“OD

LEXUS

ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 * LS 430 * SC 300 * SC 400 The engine/transmission assembly must be removed. The manufacturer does not provide any on vehicle infor¬ mation for the No. 2 oil pan removal and installation. If only the No. 2 oil pan is being serviced, the engine/transmission assembly can remain in the vehicle. 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: Engine/transmission assembly Timing belt Idler pulley Crankshaft timing pulley

2. Drain the engine oil. 3. Remove or disconnect the following: • Negative battery cable from the bat¬ tery. • • • • •

Right front wheel Fender apron seal Engine undercover Front exhaust pipe Front exhaust pipe bracket from the No. 1 oil pan • Flywheel housing undercover • 10 bolts and 2 nuts to the No. 2 oil

4. Insert pana blade between the No. 1 and No. 2 oil pans. Tap the tool sideways to break the seal and remove the pan. Clean the surfaces of the oil pans. • Oil strainer and gasket from the engine by removing the 3 nuts. • No. 1 oil pan as follows. Make a note of the position of the each bolt. When replacing the bolts into the

bolt in the posi¬ oil pan, tion fromplace whicheach it was removed. • Baffle plate from the No. 1 oil pan To install: 5. Clean all mating surfaces of the oil pans. Using a non-residue solvent, clean both sealing surfaces to the oil pan. 6. Install or connect the following: • Baffle plate to the No. 1 oil pan and tighten to 69 inch lbs. (8 Nm) • No. 1 oil pan. Apply RTV sealant to the oil pan and engine block. Uni¬ formly tighten the bolts and nuts in several passes to: 10mm: 69 inch lbs. (8 Nm); 12mm: 14 ft. lbs. (20 Nm); 14mm: 27 ft. lbs. (37 Nm) • Flywheel housing undercover with the 2 bolts. Tighten the bolts to 69 inch lbs. (8 Nm). • Oil strainer with the 3 nuts. Tighten the nuts to 69 inch lbs. (8 Nm). • No. 2 oil pan. Apply RTV sealant to the oil pan and engine block. Uni¬ formly tighten the bolts and nuts in Nm). passes, to 69 inch lbs. (8 several • Flywheel housing undercover • Front exhaust pipe bracket to the No. 1 oil pan. Tighten the bolts to 15 ft. lbs. (21 Nm). • Front exhaust pipe. 4 pipe-to-pipe nuts: 46 ft. lbs. (62 Nm); front

• • •

Seal Width 4-5 mm

• 7923LG85

Apply sealant as shown to the No. 1 (upper) oil pan— 3.0L (1MZ-FE) engine

Oil dipstick and guide Oil sensor lead 4 attaching bolts and lift off the oil level sensor. Be careful not to drop this sensor. • 14 bolts (16 bolts for GS 300) and 2 nuts and pry off the lower (No. 2) oil pan. Be careful not to damage the No. 1 pan while performing this • procedure. Bolt and 2 nuts and drop down the oil strainer and gasket • 5 bolts and 2 nuts and drop down the baffle plate • 22 bolts and the carefully pry off the upper (No. 1) oil pan • 0-ring from the cylinder block To install: 3. Install or connect the following: • New O-ring in the block and scrape off any old sealant • A Vs inch (3-4mm) bead of RTV sealant to the pan mating surface • Upper pan. 12mm bolts: 15 ft. lbs (21 Nm); 14mm bolts to 29 ft. lbs. (39 Nm) • Baffle plate and oil strainer. Tighten them both to 78 inch lbs. (9 Nm). • Lower pan in the same manner as the tighten the bolts to 78upper inch pan lbs. and (9 Nm)

exhaust pipe-to-the center exhaust pipe bolts and nuts: 41 ft. lbs. (56 Nm); bracket bolts: 14 ft. lbs. (19 Nm); support stay bolts: 22 ft. lbs. (30 Nm). Engine undercover Right fender apron seal The right front wheel and lower the vehicle Engine with oil

3.0L (2JZ-GE) Engine ^The No. 1 oil pan can not be removed with the engine in the vehicle.

Lower oil pan sealant application — 3.0L (2JZ-GE) engine

LEXUS ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400

inch lbs. (8 Nm); 12mm: 21 ft. lbs. (28 Nm) • Oil strainer. Bolts and nuts: 66 inch lbs. (8 Nm) plate. Bolts and nuts: 66 inch • Baffle lbs. (8 Nm)

Upper oil pan sealant application— 3. OL (2JZ-GE) engine

• Oil level sensor and tighten it to 48 inch lbs. (5 Nm) • Oil dipstick and guide • Timing pulleys and belt • Transmission to the engine • Engine and transmission • All fluids

4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines LS 400, LS 430

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Engine/transmission assembly • Remove the timing belt • Idler pulleys • Crankshaft timing pulley • Oil dipstick and guide • Oil level sensor lead • 4 bolts and lift off the oil level sen¬ sor. Be careful not to drop this sen¬ sor. • Oil filter and the bracket assembly by removing the stud bolt and 2 nuts • Engine Crankshaft Position (CKP) sensor connector • Sensor by removing the bolt • 12 bolts and 2 nuts to the No. 2 oil pan. Use a gasket cutting tool to separate the No. 2 (lower) oil pan. Be careful not to damage the No. 1 pan while performing this procedure. • 2 bolts and 3 nuts and drop down the baffle plate • Oil strainer by removing the bolts and nuts

• No. 2 pan in the same manner as the No. 1 oil pan and tighten the bolts to 66 inch lbs. (8 Nm). Be sure the bolts are 14mm in length. • CKP sensor. Tighten the bolt to 56 inch lbs. (6 Nm). • New O-ring in position on the oil filter bracket • Bracket and tighten the bolt and nuts to 13 ft. lbs. (18 Nm) • Wiring to the pressure switch • Oil level sensor and tighten the 4 bolts to 48 inch lbs. (5 Nm). Use a new gasket. • Dipstick and guide

• Timing belt pulleys and the timing belt components • Transaxle to the engine •• All Engine fluidsand transaxle SC 400, GS 400, GS 430

^The No. 1 oil pan cannot be removed with the engine in the vehicle. The

16-67

engine and transmission must be removed as a unit, then separated. It may be possible to remove the No. 2 oil pan from the vehicle while the engine is still in the vehicle. 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Engine/transmission assembly • Oil dipstick and guide • 12 bolts and 2 nuts. Use a gasket¬ cutting tool to separate the No. 2 (lower) oil pan. Be careful not to damage the No. 1 pan while per¬ forming this procedure. • 6 bolts and 2 nuts; remove the baf¬ • fle 16 plate bolts, then carefully pry off the No. 1 oil pan (■•There are slots for inserting the prybar. To install: 3. Install or connect the following: • No. 1 pan. Apply a Vs inch (3-4mm) bead on RTV sealant to the pan mating surface. Bolts: 12mm: 69 inch lbs. (8mm); 14mm: 20 ft. lbs. (28 Nm)

• Bolts, then carefully pry off the No. 1 oil pan. There are slots for insert¬ ing the prybar. To install: • No. 1 pan. Apply a Vs inch (3-4mm) bead sealant to the pan mating surface. Bolts: 10mm: 66

(B) 1.38 in. (35mm), (C) 0.78 SC 400 and GS 400 oil pan bolt locations— (A) 0.78 in (20mm), in (20mm) with 12mm bolt heads

ic

CO

LEXUS

3 • Baffle plate. Bolts and nuts: 69 inch To install: . 4 I 0“00 lbs. (8 Nm). 0 0 ES 300 • IS 300 • GS 300 * • GS 400• Driven • GS 430 • LS * LS 430 rotors, drive, pump body » SC • RTV sealant to the pan mating surface then install the 9 screws Instalcover, l or conn • Relief valve, and the ect spring, Nm) • No. 2 oil pan. Bolts: 69 inch lbs. (8 the follgasket o w i n g : plug to the oil pump body • New 0-ring on the cylinder block • Dipstick and guide • RTV sealant to the oil pump as • Engine/transaxle assembly • All fluids shown • Pump on the engine block. Be sure to engage the spline teeth of the oil Oil Pump pump drive gear with the large teeth of the crankshaft. REMOVAL & INSTALLATION • The 9 bolts to the oil pump and 3.0L (1MZ-FE) Engine 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • tery Negative battery cable from the bat¬ • • • • • • • •

• • • •

• •

Right front wheel Fender apron seal Engine undercover Engine oil Front exhaust pipe Front exhaust pipe bracket from the No. 1 oil pan Alternator drive belt from the engine Air conditioning compressor from the engine, without disconnecting the compressor lines Power steering pump drive belt and adjusting strut Timing belt from the engine Timing belt pulleys Rear timing belt cover from the engine by removing the wire clamps and 6 bolts Air conditioning compressor hous¬ ing bracket by removing the 3 bolts. 10 bolts and 2 nuts to the No. 2 oil

• No. pan2 oil pan from the engine • Oil strainer and gasket from the engine by removing the 3 nuts « No. 1 oil pan • Baffle plate from the No. 1 oil pan • Crankshaft Position (CKP) sensor by removing the connector and bolt • Oil pump. Make a note of the posi¬ tion of the each bolt. When replac¬ ing the bolts into the oil pump body, place each bolt in the posi¬ tion from which it was removed. • O-ring from the cylinder block • Plug, gasket, spring and relief valve from the oil pump body

• • •

• • •

uniformly tighten the bolts in sev¬ eral passes. Tighten the bolts to: 10mm: 69 inch lbs. (8 Nm); 12mm: 14 ft. lbs. (20 Nm). CKP sensor and bolt. Tighten the bolt to 69 inch lbs. (8 Nm). Baffle plate to the No. 1 oil pan and tighten to 69 inch lbs. (8 Nm). No. 1 oil pan Uniformly tighten the bolts and nuts in several passes: 10mm-69 inch lbs. (8 Nm); 12mm-14 ft. lbs. (20 Nm); 14mm-27 ft. lbs. (37 Nm) Flywheel housing undercover with the 2 bolts. Tighten the bolts to 69 inch lbs. (8 Nm). Oil strainer with the 3 nuts. Tighten the nuts to 69 inch lbs. (8 Nm). No. 2 oil pan

• RTV sealant to the oil pan and engine block • No. 2 oil pan. Uniformly tighten the bolts and nuts in several passes to 69 inch lbs. (8 Nm).

300 *

• Remaining components Right front wheel and lower the SC• vehicle 400 • Engine with oil • Negative battery cable to the battery

3.0L (2JZ-GE) Engine 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Timing Engine and belt transmission • Idler pulley • Crankshaft timing pulley • Oil dipstick and tube • Oil level sensor • No. 2 (lower) oil pan • Oil strainer by removing the bolt and 2 nuts • Oil baffle plate by removing the 6 bolts • No. 1 (upper) oil pan by removing the 22 bolts. Take note of bolt size and lation.placement for correct re-instal¬ • 9 mounting bolts to the oil pump body. Carefully drive the pump off the cylinder block using a brass • drift. 2 0-rings To install: 3. Install or connect the following: • 2 new 0-rings in the cylinder block • A Vs inch (3-4mm) bead of RTV sealant around the pump mating surface, taking great care around the oil passages • Pump and tighten the bolts to 15 ft. lbs.Nm) (21 Nm) • A new O-ring on the block • RTV sealant around the No. 1 oil • No. 1 oil pan. Bolts: 12mm— 15 ft. lbs. (21 Nm); 14mm-29 ft. lbs. (39 • Oil baffle plate and tighten the nuts and bolts to 78 inch lbs. (9 Nm) • Oil strainer and tighten the nuts and bolts to 78 inch lbs. (9 Nm) • RTV sealant around the No. 2 oil pan

B Seal Width

2-3

mm

C

• No. 2 oil pan and tighten the bolts to 78 inch lbs. (9 Nm) • Oil lever sensor with a new gasket and tighten the bolts to 48 inch lbs. (6 Nm)

7923LG89

Apply sealant to the mounting surface of the oil pump in the areas shown— 3. OL (1MZ-FE) engine

• Oil dipstick with a new O-ring •. All Remaining fluids components pan • Negative battery cable

LEXUS ES 300 • IS 300 • GS 300 • GS 400 • GS 430 * LS 400

LS 430 • SC 300 • SC 400

16-69

1 . Before servicing the vehicle, refer to

Oil PUI«f Cap

the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: •• Timing Engine/transmission assembly belt • Idler pulleys No. 3 Timing Balt Covar

• Crankshaft timing pulley • Oil dipstick and guide • Oil level sensor lead

♦ Crankshaft Front Oil Seal Oil Pump Idlar Pulley

Oil Laval Sensor Connector

V No.1 Oil Pan

★1 34 I3S0. 3S»1

Crankshaft Timing Pulley _

. .

Gasket No. 2 Timing Belt Cover

„

, 21 1210. IBll

1-

8

14 mm

H«»d

39 1400. 29)

12 mm 21 1210. 191

♦Gasket

1 - -

Oil Lever Sensor Oil Pan Baffle Plate

♦O-Ring g and Quid, / Oil Dipstick

Oust Cover -No. 2 0» Pan Timing Belt T e'naioner Crankshaft Puley

• Oil filter and filter bracket assembly by removing the stud bolt and 2 nuts • Engine Crankshaft Position (CKP) sensor. Remove the sensor by removing the bolt. • 12 bolts and 2 nuts from the No. 2 oil pan

oil pan. Use a gasket¬ No. 2 (lower) • cutting tool • 2 bolts and 3 nuts and drop down the baffle plate • Oil strainer • No. 1 oil pan. There are slots for inserting the prybar. • 8 bolts holding the oil pump to the engine

l

1 H 190. 78 In-HbO I

(■►Make certain to observe bolt position

I 29 [270. 201 ]

during removal. The bolts are different lengths and sizes. Record their position for proper reassembly.

|N-m (kgf-cm, tt-lbfTl : Specified torque ♦ Non-reuaable pert ♦

• 4 bolts and lift off the oil level sen¬ sor. Be careful not to drop this sen¬ sor. • Main Oxygen (O2) sensor bracket, if necessary

Precoated part

7923LG90

engine Exploded view ot the oil pump and related component mountings— 3. 0L (2JZ-GE)

• Oil pump from the engine block • 0-ring from the block No.1 Oil Pan

P Seal Width 2-3 mm

4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines ^The oil pump cannot be removed with the engine in the vehicle. The engine and transmission must be removed as a unit, then separated.

r r

Seal 2-3 Width mm

B

7923LG92

betore installing the oil pumpApply sealant to the oil pump and the No. 1 oil pan, as shown, Engines 4.0L (1UZ-FE) and 4.3L (3UZ-FE)

S 300 • IS 300 iI fOi-7/ nU ESLEXU

• GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400

Center (TDC) of the compression stroke and check that the timing marks on the camshaft timing pulleys are aligned with those on the No. 3 timing cover. It not, turn the engine 1 complete revolution (360 degrees) and check again. 5. Remove or disconnect the following: • Timing belt tensioner and the dust boot

1

0

6. Turn the right camshaft pulley clock¬ wise slightly to release tension, then remove the timing belt from the pulleys. 4.0L engine oil pump mounting bolt loca¬ • Upper (No. 3) and lower (No. 1) . tions, according to bolt lengths— (A) 1.97 timing belt covers in. (50mm), (B) 4.17 in. (106mm), (C) • Timing belt guide 1.18 in. (30mm) and (D) 1.57 in. (40mm) • Timing belt from the engine 7923LG93

To install: ^Prior to installing the oil pump, lubricate the gears with clean engine oil.

• A 2-3mm wide (0.08-0.12 in.) bead of RTV sealant to the oil pump • New 0-ring in position on the block

e fo

• Oil pump on the engine • The 8 bolts in their correct loca¬ tions. Tighten the bolts with 12mm heads to 12 ft. lbs. (16 Nm) and the bolts with 14mm heads to 22 ft. lbs. (30 Nm). • A Vs inch (3-4mm) bead of RTV sealant to the pan mating surface. • No. 1 pan. Bolts— 10mm: 66 inch Nm) (8 Nm); 12mm: 21 ft. lbs. (28 lbs.

llo

win

g:

i*Tf the timing belt is to be reused, draw a directional arrow on the timing belt in the direction of engine rotation (clockwise) and place matchmarks on the timing belt and crankshaft gear to match the drilled mark on the pulley. To install: the old timing belt is being rein¬ stalled, be sure the directional arrow is facing in the original direction and that the belt and crankshaft gear matchmarks are properly aligned.

7. Install the lower (No. 1) timing cover and tighten the bolts. 8. Set the No. 1 cylinder to TDC again. Turn the right camshaft until the knock pin hole is aligned with the timing mark on the No. 3 belt cover. Turn the left pulley until the marks on the pulley are aligned with the mark on the No. 3 timing cover. 9. Check that the mark on the belt matches with the edge of the lower cover. If not, shift it on the crank pulley until it does. Turn the left pulley clockwise a bit and align the mark on the timing belt with the timing mark on the pulley. Slide the belt over the left pulley. Now move the pulley until the marks on it align with the one on the No. 3 cover. There should be tension on the belt between the crankshaft pulley and the left camshaft pulley.

timi belt with the mark on the righ side t ng pull cams Han the belt over the pul¬ Alig the ley whiatfht the felya.n fagci inwa g r n n tAlimi mark on ethe riggh pull d. with the t e i n s y onegn gtohne the No. 3 cove and slid the pull e ey r ins Mov the pul¬ onto the entadllaotfi the cams ley unti the camosn mark khnaofct. pin heole is l t w t hgaft on ti kt p alig ned ith he roove nhe he ulley, hen t b t 5 pin. Tigh the kn ins ten he olt o 5 ft. tlablsl. (75 Nmo)ck .

• Oil strainer and tighten the bolts to 66 inch lbs. (8 Nm) • Baffle plate and tighten the bolts and nuts to 66 inch lbs. (8 Nm) • Remaining components • Engine/transaxle

Timing Belt REMOVAL & INSTALLATION 3.0L (1MZ-FE) Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove all necessary components for access to the upper timing belt cover. Remove the 8 bolts and lift off the upper (No. 2) cover. 3. Paint matchmarks on the timing belt at all points where it meshes with the pul¬ leys and the lower timing cover. 4. Set the No. 1 cylinder to Top Dead

79235G45

Camshaft and crankshaft pulley positioning for timing belt installation— 3. OL (1MZ-FE) engine

LEXUS ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400

1 1 . Position a plate washer between the timing belt tensioner and the block, then press in the pushrod until the holes are aligned between it and the housing. Slide a 0.05 in. Allen wrench through the hole to keep the pushrod set. Install the dust boot, then install the tensioner. Tighten the bolts Nm). Don’t forget to pull lbs. (26 ; to wrench. out20theft.Allen 12. Turn the crankshaft clockwise 2 com¬ plete revolutions and check that all marks

are still in alignment. If they aren't, remove the timing belt and start over again. 13. Install the remaining components. 3.0L (2JZ-GE) Engine

• Timing belt guide • Timing belt ^>lf the timing belt is to be reused, draw a directional arrow on the tim¬ ing belt in the direction of engine rotation (clockwise) and place matchmarks on the timing belt and crank¬ shaft gear to match the drilled mark on the pulley. To install:

7. Install the timing belt on the crank¬ shaft timing pulley and the idler pulleys. iHf the old timing belt is being rein¬ stalled, be sure the directional arrow is facing in the original direction and that the belt and crankshaft gear matchmarks are properly aligned.

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 8. Install the timing belt guide. Install 2. Remove all necessary components the lower (No. 1) timing cover and tighten for access to the upper timing belt covers. the bolts. Using a 5mm Allen wrench, remove the 9 9. Align the crankshaft pulley set key bolts and lift off the two upper (No. 2 and with the key groove on the pulley and slide No. 3) timing belt covers. the pulley on. Tighten the bolt to 239 ft. lbs. 3. Rotate the crankshaft pulley clock¬ (324 Nm). wise so its groove is aligned with the 0 mark in the No. 1 (lower) timing cover. Tur the cam unti the spr tim n ock i sha l Check that the timing marks on the mar are ali ft wit the tim et mar ngon h g i ks ng camshaft timing sprockets are aligned with the ksNo. 4 belt nceodv er. the marks on the No. 4 (inner) cover. If not, rotate the crankshaft 1 complete revolution (360 degrees). 4. Alternately loosen the 2 tensioner mounting bolts and remove them, the ten¬ sioner and the dust boot. Slide the timing 1 Its a belt off of the 2 camshaft sprockets. Set t h e Nopul¬ good idea to matchmark the belt to the .1 leys. cy 5. Ensuring the timing belt is securely linde rto TDC supported, hold the crankshaft pulley with a aga spanner wrench and loosen the mounting in. bolt. Remove the bolt and the pulley. 6. Remove or disconnect the follow¬ ing: • 5 bolts, then lift off the lower No. 1 timing belt cover

1 fi-71 ■

11. Check that the marks on the belt matches with those on the sprockets, then slide it over the sprockets. If not, shift it on the crank pulley until it does. 12. Position a plate washer between the timing belt tensioner and the block, then press in the pushrod until the holes are aligned between it and the housing. Slide a 1.5mm Allen wrench through the hole to keep the pushrod set. Install the dust boot, then install the tensioner. Tighten the bolts to 20 ft. lbs. (26 Nm). Don’t forget to pull out the Allen wrench. 13. Turn the crankshaft clockwise two complete revolutions and check that all in alignment. If they aren’t, marks arethestill remove timing belt and start over again. 14. Position new gaskets, then install the upper (No. 2 and No. 3) timing covers. 4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines

1. Remove all necessary components for access to the right-hand side No. 3 and No. 2, and left-hand side No. 2 timing belt covers, then remove the covers. 2. Turn the crankshaft pulley and align it’s groove with the timing mark 0 of the No. 1 timing cover. Check that the timing marks of the camshaft timing pulleys and

79235G46

Set the engine to TDC by aligning the marks betore removing the lower timing cover— Lexus 3.0L (2JZ-GE) engine

1

79235G47

engine Timing belt sprocket mark alignment for belt installation — Lexus 4.0L (1UZ-FE)

fi-7/L9 ESLEXU300S • IS 300 lIQ

• GS 300

timing belt rear plates are aligned. If not, turn the crankshaft 1 full revolution (360 degrees). 3. Remove or disconnect the follow¬ ing: • Timing belt tensioner. Using the proper tool, loosen the tension between the left side and right side timing pulleys by slightly turning the left side camshaft clockwise. • Timing belt from the camshaft tim¬ ing pulleys • Bolt and timing pulleys, using the proper tool • Bolt and the crankshaft pulley with the proper tool. • Fan bracket • Hydraulic pump, on SC 400 • Mounting bolts and the No. 1 tim¬ ing belt cover • 2 upper and lower timing belt cov¬ ers • Timing belt guide (No. 1 crank position sensor plate) • Timing belt ^►If the timing belt is to be reused, draw a directional arrow on the timing belt in the direction of engine rotation (clockwise) and place matchmarks on the timing belt and crankshaft gear to match the drilled mark on the pulley. To install:

4. Align the installation mark on the timing belt with the drilled mark of the crankshaft timing pulley. Install the timing belt on the crankshaft timing pulley, No. 1 idler pulley and the No. 2 idler pulley. ’Hf the old timing belt is being rein¬ stalled, be sure the directional arrow is facing in the original direction and that the belt and crankshaft gear matchmarks are properly aligned.

5. Install the timing belt guide (No. 1 crank angle sensor plate) with the cup side facing forward. Replace the timing belt cover spacer. 6. Install the No. 1 timing belt cover and tighten the mounting bolts. On the SC400, install the hydraulic pump. Install the fan bracket. 7. Align the pulley set key on the crankshaft with the key groove of the pulley. Install the pulley, using the proper tool to tap in the pulley. Tighten the pulley bolt to 181 ft. lbs. (245 Nm). 8. Align the knock pin on the right side camshaft with the knock pin of the timing pulley. Slide on the timing pulley with the right side mark facing forward. Tighten the bolt to 80 ft. lbs. (108 Nm).

GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400

9. Align the knock pin on the left side camshaft with the knock pin of the timing pulley. Slide on the timing pulley with the left side mark facing forward. Tighten the bolt to 80 ft. lbs. (108 Nm). 10. Turn the crankshaft pulley and align its groove with the 0 timing mark on the No. 1 timing belt cover. Using the proper tool, turn the crankshaft timing pulley and align the timing marks of the camshaft timing pulley and the timing belt rear plate. 1 1 . Install the timing belt to the left side camshaft timing pulley by: a. Using the proper tool, slightly turn the left side timing pulley clockwise. Align the installation mark of the timing belt with the timing mark of the camshaft timing pulley and hang the timing belt on the leftside camshaft pulley. b. Using the proper tool, align the timing marks of the left side camshaft pulley and the timing belt rear plate. c. Check that the timing belt has ten¬ sion between crankshaft timing pulley and the left side camshaft pulley. 12. Install the timing belt to the right side camshaft timing pulley by: a. Using the proper tool, slightly turn the right side timing pulley clockwise. Align the installation mark of the timing belt with the timing mark of the camshaft timing pulley and hang the timing belt on the right side camshaft pulley. b. Using the proper tool, align the timing marks of the right side camshaft pulley and the timing belt rear plate. c. Check that the timing belt has ten¬ sion between the crankshaft timing pulley and the right side camshaft pulley. 13. The timing belt tensioner must be set prior to installation. The tensioner can be set as follows: a. Place a plate washer between the tensioner and a block. Using a suitable press, press in the pushrod using 220-2205 lbs. (100-1 000kg) of pres¬ sure. b. Align the holes of the pushrod and housing, pass the proper tool (0.05 in. Allen wrench) through the holes to keep the setting position of the pushrod. c. Release the press and install the dust boot on the tensioner. 14. Install the tensioner and tighten the bolts to 20 ft. lbs. (26 Nm). Remove the tool from the tensioner. 15. Turn the crankshaft pulley two com¬ plete revolutions from TDC-to-TDC. Always turn the crankshaft clockwise. Check that each pulley aligns with the timing marks. 16. Install all remaining components in the reverse order of removal.

Piston and Ring POSITIONING RH Piston Lower Side Rail Front Mark

No. 2 Compression

Expander No.1 Compression Upper Side Rail

LH Piston

Lower Side Rail Front Mark

No. 2 Compression

Expander No.1 Compression Upper Side Rail

9307LG06

Piston ring positioning— 3. OL (1MZE-FE) engine No.1 Compression

Upper Side l Rai Front Mark (Cavity) ^Expander Lower Side Rail No.2 9307LG07

Piston ring positioning— 3. OL (2JZ-GE) Compression'

engine

Lower \ RH Piston No.2 Side Rail Side

/

Front

^Compression -Expander

Mark No.1 (2 Cavities)' Lower \ Rail LH Piston Upper

Compression No.2 /"Compression

Rail Side

Front

-Expander

Mark (1 Cavity) Side Upper Rail

, Compression \No.1

7923AG45 Piston ring positioning — 4.0L (1UZ-FE) and 4.3L (3UZ-FE) engines

LEXUS

ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400

LS 430 • SC 300 • SC 400

16-73

FUEL SYSTEM Fuel System Service Precautions Safety is the most important factor when performing not only fuel system mainte¬ nance but any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidejlines. • To avoid the possibility of fire and per¬ sonal injury, always disconnect the negative battery cable unless the repair or test proce¬ dure requires that battery voltage be applied. • Always relieve the fuel system pres¬ sure prior to disconnecting any fuel system 'component (injector, fuel rail, pressure reg¬ ulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may pene¬ trate the skin or any part of the body that it contacts. • Always place a shop towel mr cloth around the fitting or connection prior to .loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage .(should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suit¬ able waste container. • Always keep a dry chemical (Class B) fire extinguisher near the work area. • Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. • Always use a back-up wrench when loosening and tightening fuel line connec¬ tion fittings. This will prevent unnecessary stress and torsion to fuel line piping. • Always replace worn fuel fitting 0rings with new. Do not substitute fuel hose or equivalent, where a fuel pipe is installed.

Fuel System Pressure RELIEVING 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove the fuse for the electronic fuel pump. 3. Start the engine until the engine i stalls.

4. Disconnect the negative battery ter¬ minal. 5. Place a catch-pan under the joint to be disconnected. A large quantity of fuel may be released when the joint is opened. 6. Wear eye or full-face protection. 7. Place a shop towel over the area and slowly release the joint using a wrench of the correct size. 8. Allow the any fuel left in the line to bleed off slowly before fully disconnecting the joint. 9. Plug the opened lines immediately to prevent fuel spillage or the entry of dirt. erly.10. Dispose of the released fuel prop¬ 11. After connecting fuel lines, install the fuse for the fuel pump and start the engine. 12. Check for leaks and repair as needed.

Fuel Filter REMOVAL & INSTALLATION The fuel filter on the ES 300 is located under the hood, on the driver’s side, by the fenderwell. The SC 300 fuel filter is located under the vehicle, on the driver’s side, in front of the rear axle. The fuel filter for the LS 400, LS 430 and SC 400 is located under the vehicle on the left side before the rear axle. The fuel filter on the GS 300, GS 400 and GS 430is located under the vehicle, next to the left rear exhaust resonator. 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable. Wait at least 90 seconds before per¬ forming any other work. 3. On the GS 300, remove the rear body protector. 4. Slowly loosen the lower flare nut fit¬ ting until all the pressure is relieved and all the fuel is collected. 5. Loosen the union bolt on the upper portion of the filter and remove the banjo gaskets. Discard the gas¬ fitting kets. and 2 metal 6. Loosen the fuel filter bracket bolt, remove the fuel line with the flared nut from

the filter and pull the filter from the mount¬ ing bracket. To install:

7. Install or connect the following: • A new fuel filter to the vehicle and tighten the bracket bolt

Exploded view of a typical fuel line con¬ nection at the filter

• Banjo fitting with a new metal gas¬ ket on each side • Union bolt. Tighten the union bolt to 22 ft. lbs. (30 Nm). • Flare nut to the lower connection. Tighten the flare nut to 22 ft. lbs. (30 Nm). 8. On the GS 300, install the body pro¬ tector. 9. Lower the vehicle if raised. 10. Remove the drain pan and/or rags and connect the negative battery cable. 1 1 . Start the engine and visually inspect the upper and lower connections for leaks.

Fuel Pump REMOVAL & INSTALLATION ES 300 and IS 300

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Relieve the fuel system pressure. 3. With the ignition switch in the LOCK position, disconnect the negative battery terminal. 4. Remove or disconnect the following: • Rear seat cushion • Fuel pump connector • Floor service hole cover ^Do not lift the fuel pump assembly wiring the filler up using • Fuel cap harness.

• Fuel outlet pipe and the return hose from the pump bracket • 8 screws and lift out the pump/bracket assembly with gasket • Fuel pump lead wire • Lower end of the pump off the bracket • Fuel hose from the pump and remove the pump • Rubber cushion from the pump

wrench. Loosen the V-bank cover fastener counterclockwise. • V-Bank cover • • • •

3

Air cleaner hose with resonator air intake chamber assembly Injector connectors Air assist hoses and pipe

hose 1 clamp • No. fuel pipe and remove the fuel

.

• No. 1 fuel pipe (fuel tube connec¬ tor) from the fuel filter outlet • 5 bolts and delivery pipes together with the 6 injectors and No. 1 fuel

To install: C

*

• 4 spacers from the intake manifold • 6 injectors form he delivery pipes • 2 0-rings and 2 grommets from pipe.injector each • New insulator and grommet to each

Inst

♦ Non -reusable part

all

h

Exploded view of the fuel pump assembly— ES 300

To install:

• 3 nuts and disconnect the fuel

Except ES 300 and IS 300

To install:

• The 4 spacers in position on the intake manifold • A light coat of gasoline on the place where the intake manifold touches an 0-ring • The delivery pipe and fuel pipe

3. Install or connect the following: • A new gasket on the set plate • Fuel hose to the pump and bracket • Pump and bracket assembly with the 3 nuts; tighten the nuts to 48 inch lbs. (5 Nm). Install the set plate and tighten the bolts to 26 inch lbs. (3 Nm). • Panel partition • Rear seat cushion and back electrical connector Fuel pump •• Trim panel

together with the 6 injectors in position on the intake manifold. Position the injector connector out¬ ward. • 4 bolts holding the delivery pipes to the intake manifold, temporarily • Bolt holding the No. 1 fuel pipe to the intake manifold, temporarily

• Spare tire and the trunk floor mat • Negative battery cable

4. Start the engine; check the fuel sys¬ tem for leaks te r¬ ce ta co la ro in Rep t is no e s. do us ng ca O-ri s or e ct th e je of abl in b ro e p th e n If th io at ll s. ta ng e at .ns ri, lyi O-ly ost th th tor oo ooct ec smre tihnej e tth sm

Fuel Injector REMOVAL & INSTALLATION 3.0L (1MZ-FE) Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • 3 cap nuts, using a 5mm hexagon

tha

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable. Wait at least 90 seconds before performing any other work. • Trunk floor mat • Trunk trim cover • Fuel pump electrical connector • Rear seat bottom and seat back • Partition cover • Mounting bolts and remove the fuel pump set plate

^Position the injector connector out¬ ward.

k

• Service cover, and replace the rear seat • Negative battery cable 6. Start the engine and check for leaks.

from the tank bracket pump hose • Fuel from the bracket Pump, bracket and set plate as an • assembly

c

e

5. Install or connect the following: • Filter and rubber cushion on the new pump • Pump on the bracket • Fuel hose and the wire connector on the pump • Pump, using a new gasket and tighten the 8 screws to 35 inch lbs. (4 Nm) • Fuel pipe and return hose to the pump and tighten the bolts to 22 ft. lbs. (29 Nm) • Wire

• injector New 0-rings, coated with gasoline, or c to each injector on ct t coat of gasoline on the • Anelight he f ollo a delivery pipe touches place where wing : injector an O-ring of the while turning Injector, • into the delivery pipe it clockwise,

• 4 bolts holding the delivery pipes to the intake manifold. Torque to 14 ft. lbs. (19.5 Nm)

• No. 1 fuel pipe (fuel tube connec¬ the fuel filter • tor) Fuel tohose clamp to the fuel filter with a “click" sound. After installing the clamp, check that the

LEXUS lfi-71! ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400

• • • •

• The 3 spacers in position on the intake manifold

clamp is fixed by pulling up the clamp. Air assist hoses Injector connectors Air intake chamber assembly Air cleaner hose with resonator

• A light coat of gasoline on the place where an intake manifold touches an 0-ring • Injectors together with the delivery pipe and 3 bolts in position on the intake manifold. Check that the injectors rotate smoothly. Position the injector connector upward.

• V-bank cover, using a 5mm hexa¬ gon wrench with the 3 cap nuts • Press down the V-bank cover. 3.0L (2JZ-GE) Engine

►►If the injectors do not rotate

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Air intake chamber • Fuel pressure pulsation damper • Engine wire from intake manifold • Bolt holding the engine wire pro¬ tector to the body • 6 injector connectors • Camshaft Position (CMP) sensor connector

smoothly, the probable cause is incor¬ rect installation of the O-rings. Replace the O-rings.

• Throttle Position (TP) sensor con¬ nector • Vacuum Switching Valve (VSV) connector for Evaporative Emission (EVAP) control • VSV connector for Acoustic Control Induction System (ACIS) • 3 nuts holding the engine wire pro¬ tector to the intake manifold ’»Be careful not to drop the injectors when removing the delivery N pipe. o. 4, and • 3 bolts and delivery pipe together the with the 6 injectors

4. Tighten the 3 bolts holding the deliv¬ ery pipe to the intake manifold. Tighten the bolts to 15 ft. lbs. (21 Nm). 5. Install or connect the following: • Engine nuts wire protector with the 3 • 6 injector connectors ►►The No. 1, No. 3 and No. 5 injector connectors are dark gray, and the No. nec

tor

s

are bro wn.

6. Install or connect the following: • tor Camshaft position sensor connec¬ • Throttle position sensor connector • VSV connector for EVAP • Bolt holding the engine wire pro¬ tector to the body

4.0L (1UZ-FE) and 4.3L (3UZ-FE) Engines N

o • The injectors from the delivery pipe . 6 in 1 . Before servicing the vehicle, refer to jec • 0-rings, insulator and grommet thetorprecautions in the beginning of this sec¬ tion.s con from each injector ¬ 2. Remove or disconnect the following: • 3 spacers from the intake manifold • V-bank cover To install: • Intake air connector 3. Install or connect the following: • Accelerator cable • A new insulator and grommet to • Fuel pressure pulsation dampers. each injector • VVT sensor connectors • A light coat of gasoline on the • Vacuum Switching Valve (VSV) for place where a delivery pipe touches Evaporative Emissions (EVAP) an 0-ring of the injector • 2 nuts and accelerator cable • Injector, while turning clockwise bracket and counterclockwise, into the • 2 nuts and accelerator cable delivery pipe bracket '►Position the injector connector out¬ • 3 V-bank cover brackets ward. • VSV connector for Acoustic Control

■ \Jl_U

Induction System (ACIS) from the No. 1 V-bank cover bracket • 4 bolts and 3 V-bank cover brack¬ ets • Engine wire from the delivery pipe • 2 wire clamps from the wire clamp bracket on the right-hand deliver • 8 injector connectors • 4 nuts holding the delivery pipe to the intake manifold • 2pipe delivery pipes and 8 injectors assembly and 4 spacers • 2 O-rings, grommet and insulator from each injector To install:

3. Install or connect the following: • A new insulator and grommet to each injector • A light coat of gasoline to new 0rings and install them to each injector • A light coat of gasoline on the place where a delivery pipe touches an O-ring of the injector • Injector, while turning the clockwise and counterclockwise, into the delivery pipe (-►Position the injector connector out¬ ward.

• The 4 spacers in position on the intake manifold • A light coat of gasoline on the place where an intake manifold touches an O-ring • The delivery pipes in position on the intake manifold • Temporarily, the 3 bolts holding the delivery pipe to the intake manifold (■►Check that the injectors rotate smoothly. If the injectors do not rotate smoothly, the probable cause is incor¬ rect installation of the O-rings. Replace the O-rings.

4. Tighten the 3 bolts holding the deliv¬ ery pipe to the intake manifold. Tighten the bolts to 15 ft. lbs. (21 Nm). 5. Install or connect the following: • Engine nuts wire protector with the 3 • Injector connectors • Remaining components

.

16-76

LEXUS ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 * SC 400

Nm)

DRIVE TRAIN Transmission Assembly REMOVAL & INSTALLATION Automatic

GS 300 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Turn the ignition switch to the LOCK position and disconnect the negative battery cable. Wait at least 90 seconds or longer before doing any work on the vehicle. 3. Remove or disconnect the following: • Transmission level gauge • Transmission dipstick and tube • Throttle body cable from the throttle

• Starter and tighten the bolts to 27 ft.Nm) lbs. (37 Nm) • Rear transmission mount and tighten the bolts to 19 ft. lbs. (25 • And tighten the torque converter bolts to 30 ft. lbs. (41 Nm) while rotating the crankshaft • Converter inspection plate • 2 oil cooler pipes • Center and rear oil cooler pipe brackets • Front oil cooler pipe bracket and tighten to 49 inch lbs. (5.5 Nm) • Oil cooler hoses to the oil cooler • 2 oil cooler union nuts and tighten topipes 32 ft. lbs. (44 Nm) • Wiring to the starter • Transmission electrical connectors • Driveshaft

• Oxygen (O2) sensor from the exhaust system. • Remaining components • Left and right tail pipes • Negative battery cable • Transmission level gauge • Front and center exhaust pipe • Exhaust heat insulator • Rear center floor crossmember lev wit Dex or equ el h iva ron brace len ®ll IS 300 t. • Shift control rod from the shift lever • Driveshaft 1 . Before servicing the vehicle, refer to • Overdrive and direct clutch speed the precautions in the beginning of this sec¬ sensor tion. 2. Drain the cooling system. • No. 1 Vehicle Speed Sensor (VSS) • No. 2 VSS Fill • Negative battery cable the • Solenoid wire • Transmission oil dipstick and tube tra • Air cleaner • Park/Neutral Position (PNP) switchnsmis sio • Mass Air Flow (MAF) sensor • Wiring from the starter nto t he • Exhaust manifold • 2 oil cooler union nuts pro p•er Engine under covers • Oil cooler hoses from the oil cooler • Upper radiator hose • Exhaust front pipe pipes oil cooler pipe bracket • Front • Exhaust center pipe • Center and rear oil cooler pipe brackets • Shift control rod • Driveshaft • 2 oil cooler pipes • Oil cooler lines • Torque converter inspection plate • Torque converter bolts • Torque converter • Rear transmission mount cross¬ 4. Support the transmission with a suit¬ able jack. member. Support the transmission with a jack. 5. Support the engine with a jack and a block of wood. • Transmission wiring harness con¬ nectors 6. Remove or disconnect the following: • Starter motor • Rear transmission mount • Wiring harness clamps • Transmission flange bolts • Transmission • Starter • 9 transmission mounting bolts and transmission To install:

7. Install or connect the following: • Transmission and tighten the bolts to 53 ft. lbs. (52 Nm)

To install:

3. Installation is the reverse of the removal procedure, while using the follow¬ ing torque values: • 17mm transmission flange bolts: 53 ft. lbs. (72 Nm)

• 14mm transmission flange bolts: 27 ft. lbs. (37 Nm) • Starter motor bolts: 27 ft. lbs. (37 • Rear transmission mount cross¬ member bolts: 19 ft. lbs. (25 Nm) • Torque converter bolts: 35 ft. lbs. (48 Nm) • Oil cooler lines: 33 ft. lbs. (44 Nm) • Drive shaft center support bolts: 36 ft. lbs. (49 Nm) • Drive shaft U-joint flange bolts: 54 ft. lbs. (74 Nm) • Shift control rod nuts: 108 inch lbs. (13 Nm) • Exhaust manifold nuts: 29 ft. lbs. (39 Nm) LS 400 AND LS 430 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable. Wait at least 90 seconds before performing any other work. • Transmission dipstick and tube • Throttle cable • Driveshaft • Engine undercover • Shift control rod • Exhaust pipe support bracket by removing the 2 bolts • Catalytic converters by removing the 6 nuts • Both side heat insulators • Oil cooler tube clamps and discon¬ nect the tubes • Torque converter inspection plate by removing the 2 bolts • Torque converter bolts

3. Support the transmission with a suit¬ able jack. 4. Remove or disconnect the following: • Rear transmission mount • Overdrive direct clutch speed sen¬ sor connector • Vehicle Speed Sensor (VSS) con¬ nector • Park/Neutral Position (PNP) switch connector • Solenoid connector • 3 wiring harness clamps from the bracket on the transmission. • 10 transmission mounting bolts and the transmission. To install:

5. Install or connect the following: • Transmission and tighten the bolts

Nm) ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 * SC 300 * SC 400

as follows: 14mm-27 ft. lbs. (37 Nm); 17mm-53 ft. lbs. (72 Nm) 3 wiring harness clamp to the bracket on the transmission Solenoid connector

• PNP switch connector • VSS connector

tighten the bolts to 19 ft. lbs. (20 Nm) and the nuts to 10 ft. lbs. (13

• Overdrive direct clutch speed sen¬ sor connector • Rear transmission mount and

Torque converter bolts to 30 ft. lbs. (41 Nm)

V-Bank Cover Propeller Shaft Oil Cooler Pipe

U.

Shift Control Rod Level Gauge

Filler Pipe ♦ O-Ring

Adjusting

Washer

Rear Center Floor Crossmember

•v

Plug for Accumulator v]*> Back Pressure Test w' Plug for Line Pressure Test

Torque Converter. Clutch

Torque Converter Clutch Plate

Heat Insulator

iljTf

Engine Rear Mounting

1

J5^S§1P1j

oor Front Center Fl Crossmember Brace | || pY

urossmemuer

40-

°"

dich-c

Heat Insulator

H iii i ! 'jsssag* p L''1 k Gasket

♦ Gasket Catalytic Converter

♦ Gasket

Engine Under Cover |

r»

m=

Exhaust Pipe Support Bracket

♦

Non-reusable part T

Exploded view of the transmission mounting — LS 400

4 *

7923LG97

S 1C ID 7f (Ot LE ES XU 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400 Converter inspection plate Support from the transmission Oil cooler pipes and tighten the union nuts to 32 ft. lbs. (44 Nm) Side heat insulators

Exhaust pipe support bracket with the 2 bolts and tighten the bolts to 32 ft. lbs. (44 Nm) Shift control rod Engine undercover Driveshaft Throttle control cable Transmission tube and dipstick

Catalytic converters with new gas¬ kets and new nuts. Tighten the nuts to 46 ft. lbs. (62 Nm).

• Negative battery cable 6. Fill the transmission to the proper level with Dexron®ll, or equivalent. SC 300, SC 400, GS 400 AND GS 430 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

Oil Cooler Pipe

Torque Converter Clutch 37 (380, 27) Torque Converter -

Pipe Support Bracket

® A i 4'Gasket ^

RH Main Catalytic Converter ♦ Gasket q

u

/ uxygen

\X

| W (450, 32)

~ -J

♦ Gasket

62 (630 ,46)

Front Exhaust Pipe

Bracket

LH Main Catalytic Converter ♦

Engine Under Cover

| N-m (kgf-cm, ft-lbf) |:Specified torque ♦ Non-reusable part 7923LG98

Exploded view of the transmission mounting — SC 300, SC 400 and GS 400

lexus

1 R-7Q

ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 « SC 300 • SC 400 2. Remove or disconnect the following: • Negative battery cable. • V-bank cover, if equipped • Automatic transmission oil level gauge if equipped • Transmission dipstick and tube • Throttle cable and clamps • Exhaust pipe and converters • Exhaust heat insulator • Rear center floor crossmember brace • Shift control rod • Driveshaft i»The bolts inserted from the driveshaft side should not be removed.

• The electrical harness from the transmission. • Oil cooler tube clamp and discon¬ nect the tubes • Lower engine cover • Torque converter inspection plate • Torque converter bolts 3. Support the transmission with a suit¬ able jack. 4. Remove or disconnect the following: • Starter, if necessary • Rear transmission mount • Transmission mounting bolts and the transmission. To install:

5. Before installing the transmission, use calipers and a straightedge to check the distance between the installed surface of the torque converter and the front edge of the transmission case. Correct distance is 0.673 in. (17.1mm). If this distance is not correct, check the torque converter installa¬ tion. 6. Install or connect the following: • Transmission and tighten the bolts to 14mm: 29 ft. lbs. (39 Nm); 17mm: 42 ft. lbs. (57 Nm) • If removed, the starter. Tighten the bolts to 27 ft. lbs. (37 Nm). • Rear transmission mount and tighten Nm) the bolts to 19 ft. lbs. (20 • And tighten the torque converter bolts to 25 ft. lbs. (33 Nm) while rotating the crankshaft • Converter inspection plate • Lower engine cover • Oil cooler lines and tighten the lines to 25 ft. lbs. (34 Nm) • Oil cooler pipe bracket and tighten the bolt • Transmission electrical connectors • Shift control rod and adjust the shift linkage. Tighten the nut to 12 ft. lbs. (16 Nm). • Rear center floor crossmember

brace. Tighten the bolts to 108 inch lbs. (13 Nm). • Heat insulator • Transmission filler tube and dip¬ stick • Front exhaust pipe and converters with new gaskets • Throttle control cable • Driveshaft. Flange bolts: 58 ft. lbs. (79 Nm). Center bearing support bolts: 36 ft. lbs. (49 Nm). Adjusting nut: 35 ft. lbs. (48 Nm). • Crossmember brace and tighten to 96 inch lbs. (13 Nm) • Automatic transmission oil level • V-bank gauge cover • Negative battery cable 7. Adjust the PNP switch 8. Fill the transmission with Dexron®ll.

Transaxle Assembly REMOVAL & INSTALLATION Automatic

ES300 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Turn the ignition switch to the LOCK position and disconnect the negative battery cable. Wait at least 90 seconds or longer before doing any work on the vehicle. Battery or disconnect the following: 3.• Remove body • Air cleaner assembly • Throttle cable from the throttle • Cruise control actuator cover and detach the connector • Ground wire • Starter • Vehicle Speed Sensor (VSS) con¬ nectors • Direct clutch speed sensor • Park/Neutral Position (PNP) switch connector on the transaxle • Solenoid connector on the transaxle • Shift control cable • Oil cooler hoses • 2 front side transaxle mounting bolts • 2 front engine mounting bolts • Oil cooler line mounting bolts from the front frame

• 3 upper transaxle to engine mount¬ ing bolts 4. Install an engine support fixture. Tie

1 J

steering gear housing to engine support fix¬ ture. 5. Raise and safely support the vehicle. 6. Drain the transaxle/differential fluid. 7. Remove or disconnect the following: • Front wheels • Front exhaust pipe • • • •

Engine side covers and undercov¬ ers Both halfshafts Front side engine mounting nut Rear side engine mounting bolts (remove hole plugs) • 4 left side transaxle mounting bolts • Steering gear housing • Front frame assembly

8. Properly support the transaxle assembly. 9. Remove or disconnect the following: • Rear end plate mounting bolts • Torque converter cover • Torque converter retaining bolts • Remaining transaxle mounting bolts 10. Carefully remove the transaxle assembly from the vehicle. To install:

1 1 . Install or connect the following: • Transaxle aligning the 2 dowel pins on the block with the converter fol¬ bolts thelbs. Tighten ft. housing. lows: 10mm-34 (46 asNm); 12mm-47 ft. lbs. (64 Nm). • Torque converter bolts. Coat the threads of the with sealer. Install the bolts starting with the green bolt followed by the rest and tighten the bolts evenly to 20 ft. lbs. (27 Nm). • 27 Endft.plate lbs. and (37 tighten Nm) the bolts to • Front frame assembly and tighten the fasteners as follows: 12mm-24 ft. lbs. (32 Nm); 19mm-134 ft. lbs. (181 Nm); nut-27 ft. lbs. (36 Nm). • 2 fender liner set screws • Steering gear to the frame and tighten the bolts and nuts to 134 ft. lbs. (181 Nm) • Sway bar brackets and toque the bolts to 14 ft. lbs. (19 Nm) • Left transaxle mounting bolts and tighten them to 38 ft. lbs. (52 Nm) • Rear side mounting bolts and nuts and tighten them to 48 ft. lbs. (66 Nm). Install the plugs. • Front engine mounting nut and it to 59 ft. lbs. (80 Nm) • tighten Halfshafts

• Right and left engine side covers • Lower engine cover • Exhaust pipe to the engine with

US on LEX ic I D OU ES 300 • IS 300

• GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400

new gaskets and tighten the nuts to 46 ft. lbs. (62 Nm). Connect the exhaust pipe to the converter with a new gasket and tighten the nuts 3 and bolts to 32 ft. lbs. (43 Nm). • Wheel . • Engine support • 4 upper transaxle mounting bolts and Nm) tighten them to 47 ft. lbs. (64 • Oil cooler clamping bolts to the front frame • 2 front side engine mounting bolts Nm) tighten them to 59 ft. lbs. (80 and • 2 front side transaxle mounting bolts and tighten them to 59 ft. lbs. (80 Nm) • Remaining components • Battery and connect the battery cables 12. Fill the transaxle/differential to the proper level with Dexron®ll, or equivalent. 13. Check the transaxle/differential fluid level. 14. Check the front wheel alignment.

Halfshaft REMOVAL & INSTALLATION ES 300

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Front wheel(s) • Front fender apron seal • Transaxle fluid • Tie rod end from the steering knuckle by removing the cotter pin and nut. Separate the tie rod from the steering knuckle. • Stabilizer bar link from the lower control arm. Make note of the washers and cushions positions. • Lower ball joint from the steering knuckle by removing the bolt and 2 nuts. Push down on the lower con¬ trol arm and separate the steering knuckle from the ball joint. • Cotter pin, lock cap and locknut holding the halfshaft to the steering knuckle • Left halfshaft from the steering knuckle • Halfshaft from the transaxle • Snapring from the halfshaft • Right halfshaft bearing lockbolt.

The lockbolt is located in the cen¬ ter of the halfshaft, near the damp¬ ener. • Snapring and pull the halfshaft from the transaxle To install:

• Right halfshaft to the transaxle. Coat the side gear shaft and differ¬ ential case sliding surface with gear Install oil. or con nect to the halfshaft • Snapring the fo ll win g: the lock• Bearing lockbolt. oTighten bolt to 24 ft. lbs. (32 Nm). • New snapring to the inner spline of the left halfshaft. Coat the side gear shaft and differential case sliding surface with gear oil. Install the halfshaft to the transaxle with the snapring opening facing down. The halfshaft should click into place when installing. • Halfshaft to the steering knuckle, then install the locknut. Tighten the locknut to 217 ft. lbs. (294 Nm). • Lock cap and a new cotter pin to the halfshaft • Steering knuckle to the lower ball joint. Install the 2 nuts and bolt. Tighten the nuts and bolt to 94 ft. lbs. (127 Nm). • Stabilizer bar link to the lower con¬ trol arm. Tighten the nut to 29 ft. lbs. (39 Nm). • Tie rod to the steering knuckle and tighten the nut to 36 ft. lbs. (49 Nm). Install a new cotter pin to the tie rod end. • Front fender apron seal • Wheel(s) and lower the vehicle. Tighten the lug nuts to 76 ft. lbs. (103 Nm). • Transaxle fluid • Negative battery cable Except ES 300

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Rear tire and wheel assembly • Cotter pin, locknut cap, and locknut • Height control sensor, if equipped • 2necessary exhaust pipe support brackets, if 3. Place matchmarks on the halfshaft and the side gear shaft. Remove the 6 hex bolts and 2 washers. 4. Hold the inboard joint side of the halfshaft so the outboard joint side does not

bend too much. Tap the end of the halfshaft with a rubber mallet to loosen it from the axle hub and remove the halfshaft. To install:

5. Insert the outboard joint side of the halfshaft through the axle hub. Align the matchmarks on the side gear shaft and the halfshaft. 6. Coat the threads with clean oil and install the hex bolts. Tighten the bolts to 61 ft. lbs. (83 Nm). 7. Install or connect the following: • Exhaust pipe support brackets, if removed, and tighten to 14 ft. lbs. (19 Nm) • Bearing locknut, if removed, and have a helper apply the brakes. Tighten the locknut to 213 ft. lbs. (289 Nm). • Lockcap and a new cotter pin • Height control sensor, if removed • Rear tire and wheel assembly • Negative battery cable

CV-Joints OVERHAUL ES 300

1 . Before servicing the vehicle, refer to the tion.precautions in the beginning of this sec¬ 2. Once the driveshaft is removed from the vehicle, place matchmarks on the out¬ board and inboard joints and the shaft. Do not use a punch to make the marks. 3. Remove or disconnect the following: • Boot clamps. Use a side cutter or • snapring Outboard joint shaft expanding the • 2 boots pliers • Dust cover on the left-hand driveshaft, using a hammer and suitable chisel • Dust cover from the inboard joint shaft, using a press • Dust cover •• Snapring. Use a snapring expander. Snapring using • Bearing, the press • No. 2 dust deflector, using a ham¬ mer and suitable chisel ^•Be careful not to damage the Anti¬ lock Brake System (ABS) speed sensor rotor. To install:

4. Install or connect the following: • No. 2 dust deflector

S Ifi-RI ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 * SC 300 * SC 400

I U

U

I

Washer x6 ^ -

83 (850,61)

Drive Shaft

Lock Cap

Suspension Member

♦ Cotter Pin

M

Brace

i

i

_

50(510,37)

-

1

♦ Boot Clam p p ♦ Boot ♦ Boot C lamp ^ 75 (765, 55)

L

Outboard Joint with Driver Shaft ♦ No. 2 Dust Deflector

♦ Inboard Joint End Cover ♦ Gasket ♦ Inboard Joint"

£ ♦ Boot ♦ Snap Ring vC

♦ Inboard Joint Cover ♦ Boot Clamp ♦ Boot Clamp

ue N-m (kgf-cm, ft-lbf) : Specified torq ♦ Non-reusable part 9301 LG1 2

Exploded view of the rear halfshaft and related components except ES 300

OO OL

1 a IO

LEXUS ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400

• New snapring to the inboard joint shaft • New bearing • New dust cover • Dust cover on the left-hand driveshaft • A new dust cover, using a press • Outboard and inboard joint boots and new boot clamps as a tempo¬ rary measure. Before installing the boot, place 3 new clamps to the small boot ends and large end (wheel side) and install it to the driveshaft. • Inboard joint shaft to outboard joint shaft • Using a snapring expander, put in the inboard joint shaft expanding the snapring • Boot to outboard joint, before assembling the boot, pack the out¬ board joint and boot with grease in the boot kit • Boot to inboard joint shaft. Pack the inboard joint, and boot with grease in the boot kit, and install the boot to the inboard joint shaft. • Boot clamps to both boots, make sure that the 2 boots are on the shaft groove. Hold the clamp near the clamp’s free end over the clos¬ ing hooks.

clo ontsingthe o

hoo tog eth books er. t.

Sec

ure

the cl am

p

GS 3C0, GS 400, GS 430 and IS 300

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • End cover. Use nuts and bolts to keep the inboard joint together. Hand tighten only. • 4 Boot clamps, using a side cutter or pliers • Inboard joint, place matchmarks on the inboard joint and driveshaft; do not use punch marks. • Snapring, using a snapring expander • Using a press, the inboard joint from the driveshaft • Inboard and outboard boot • Inboard joint cover from the inboard joint To install:

3. Install or connect the following: • Inboard and outboard joint boots • New No. 2 Dust deflector, using a press

’•-Be careful not to damage the Anti¬ lock Brake System (ABS) speed sensor rotor.

• Inboard joint • Inner race to the cage so that the indented beveled part of the inner race is on the opposite side to the beveled top of the cage • Outer race so that the indented side of the outer race is facing the same side as the beveled surface of the cage 4. Match the narrow projections of the inner race with the wide projections of the outer race. 5. Tilt the cage and inner race to the side and insert the balls one by one. 6. Install or connect the following: • New boots and new boot clamps, temporarily • 4 new boot clamps to the boots • 2 boots to the driveshaft • Inboard joint cover and apply RTV to the inboard joint cover 7. Remove grease from the surface of the inboard joint facing the cover. 8. Align the bolt holes of the cover with those of the inboard joint, then insert the hexagon bolts. 9. Use a plastic hammer to tap the rim of the inboard joint cover into place 10. To install the inboard joint, align the matchmarks placed before removal. 11. Using a brass bar and hammer, tap the inboard joint onto the driveshaft. 12. Install or connect the following: • Newsnapring • Boots to joints, pack with the proper (100—1 grease. 05g) 3.5— 3.7 oz. • New boot clamps to both boots • 6 hexagon bolts and washers from the end cover side, install the 6 nuts to the boot side. SC 300 and SC 400

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Using a suitable prytool, remove the end cover. 3. Use nuts and bolts to keep the inboard joint together. Hand tighten only. 4. Remove or disconnect the following: • 4 Boot clamps, using a side cutter or pliers • Inboard joint, place matchmarks on the inboard joint and driveshaft; do not use punch marks • Snapring, using a snapring expander

• Using a press, the inboard joint from the driveshaft • Inboard joint cover from the inboard joint • Inboard and outboard boot • No. 3 dust deflector

To install: 5. Install or connect the following: • New No. 3 dust deflector, using a 6. If the joint has come apart, reassem¬ ble it in the following order: a. press. Align the matchmarks placed before removal b. Inner race to the cage so that the indented beveled part of the inner race is on the opposite side to the beveled top of the cage. c. Outer race so that the indented side of the outer race is facing the same side as the beveled surface of the cage. 7. Match the narrow projections of the inner race with the wide projections of the outer race. 8. Tilt the cage and inner race to the side and insert the balls one by one. 9. Install or connect the following: • New boots and new boot clamps, temporarily • 4 new boot clamps to the boots • 2 boots to the driveshaft • Inboard joint cover and apply Formed In Place Gasket (FIPG) to the inboard joint cover. Avoid applying an excessive amount to the surface. 10. Remove grease from the surface of the inboard joint facing the cover 1 1 . Align the bolt holes of the cover with those of the inboard joint, then insert the hexagon bolts. 12. Use a plastic hammer to tap the rim of the inboard joint cover into place 13. To install the inboard joint, align the matchmarks placed before removal. 14. Using a brass bar and hammer, tap the inboard joint onto the driveshaft. 15. • Install or connect the following: Newsnapring • Boots to joints, pack with 3.5— 3.7 oz. (100—1 05g) • ance Boot clamps boot. Clear¬ is 0.031 onto inch the (0.8mm) • End cover, and pack with grease. SC 400 uses 1.8-1 .9 oz. (50(42— 47g) 55g); SC 300 uses 1 .5-1 .7 oz. 16. Remove grease from the surface of the inboard joint facing the cover 17. Glue on a new gasket, with the side with adhesive on it facing toward the outer race side of the inboard joint

LEXUS

9 of the the bolt holes0 18. Align . 4 0 ES cove 300 with • IS 300 those of the inboard joint 19. Install or connect the following: • 6 hexagon bolts an washer from the end cover side • 6 nuts to the boot side 20. Check that the claw of the end cover touches the inboard joint

LS 400 and LS 430 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Using a suitable prytool, remove the end cover. 3. Use nuts and bolts to keep the inboard joint together. Hand tighten only. 4. Remove or disconnect the following: • 4 Boot clamps, using a side cutter or pliers • Inboard joint, place matchmarks on the inboard joint and driveshaft; do not use punch marks. • Snapring, using a snapring expander • Using a press, the inboard joint from the driveshaft • Inboard joint cover from the inboard joint • Inboard and outboard boot • No. 2 dust deflector, using a suit¬ able chisel and hammer • New No. 3 dust deflector, using a press To install:

5. If the joint has come apart, reassem¬ ble it in the following order. a. Align the matchmarks placed before removal b. inner race to the cage so that the indented beveled part of the inner race is on the opposite side to the beveled top of the cage. c. Outer race so that the indented side of the outer race is facing the same side as the beveled surface of the cage. 6. Match the narrow projections of the inner race with the wide projections of the outer race. 7. Tilt the cage and inner race to the side and insert the balls one by one. 8. Install or connect the following: • New boots and new boot clamps, temporarily • 4 new boot clamps to the boots • 2 boots to the driveshaft • Inboard joint cover and apply Formed In Place Gasket (FIPG) to the inboard joint cover. Avoid applying an excessive amount to the surface

Ifi.RQ

snapring • Side gear shaft, and install a new • GS* 300 400 * LS 430 » SC 300 * SC 400 »» the inboard •joGS int facing• thGSe co430 ver • LS 10. ReAlign • Side gear shaft to the differential move thegreabolt holes of the cover with from then the suinsert those of the inboardse joint, rface the ^Check that the side gear shaft does of hexagon bolts. not come out by trying to pull it out by 11. Use a plastic hammer to tap the rim hand. of the inboard joint cover into place •• Reconnect 12. To install the inboard joint, align the Gear oil the rear driveshaft matchmarks placed before removal. 13. Using a brass bar and hammer, tap LS 400 and LS 430 the inboard joint onto the driveshaft. 14. Install or connect the following: 1 . •Remove • Newsnapring Gear oilor disconnect the following: • Boots to joints, pack with 3.5— 3.7 oz. (100-1 05g) of grease • A new gasket, with the side with adhesive on it facing toward the outer race side of the inboard • 6 hexagon bolts an washer from the joint end cover side • 6 nuts to the boot side 15. Check that the claw of the end cover touches the inboard joint

Axle Shaft, Bearing and Seal REMOVAL & INSTALLATION GS 300, GS 400, GS 430 and IS 300

1. Drain the gear oil. 2. Remove or disconnect the following: • Rear driveshaft • Side gear • Snapring a suitable • Side gear

shaft from the side gear, using tool shaft oil seal

To install:

• Side gear shaft oil seal • New oil seal 3. Check installation of side gear shaft. There should be 0.08-0.12 inch (2-3mm) of play in the axial direction. Check that the side gear shaft will not come out by pulling on it. SC 300 and SC 400

1 . Remove or disconnect the following: • Gear oil • Rear driveshaft • Side gear • Snapring a suitable lip • Side gear

shaft from the side gear, using tool shaft oil seal

To install:

2. Install or connect the following: • New oil seal until it is flush with the carrier end surface • Multipurpose grease to the oil seal

• Rear driveshaft • Side gear shaft • Snapring from the side gear • Side gear shaft oil seal

To install:

2. Install or connect the following: •• Side gearseal shaft oil seal New oil • Multi-Purpose (MP) grease to the oil seal lip • Side gear • Snapring a suitable • Side Gear gear oil

shaft from the side gear, using tool shaft oil seal

Pinion Seal REMOVAL & INSTALLATION GS 300, GS 400 and GS 430

1. Drain the gear oil. 2. Remove the driveshaft and the com¬ panion flange 3. Remove the oil seal 4. Check oil slinger To install:

5. Installation is the reversal of the removal procedure. SC 300, SC 400, LS 400 and LS 430

1. •Remove or disconnect: Gear oil • Driveshaft • Companion flange • Oil seal and slinger To install:

2. •Install or connect: Oil slinger • New oil seal ^Oil seal drive-in depth: 0.079 inch (2.0mm).

• Multi-Purpose (MP) grease to the oil seal lip • Companion flange on the shaft

jC

04

LEXUS

0* 1 2I U 3 • 4Gear 5#oil ES 300threads on the of a •new '■►The rear brake calipers must be • IS 300 GS 300 • GS a. Used bearings: 4.3— 6.9 inch lbs. 400 GS that 430 there • LS is400no •additional removed • so LS 430 • SC 300 (0.49-0.78 nut. Torque to 80 ft. lbs. (108 Nm). • SC 400 Nm). drag when measuring pinion bearing 3. Adjust the drive pinion preload as b. New bearings: 8.7-13.9 inch lbs.

6

necessary, stake drive the pinion nut, and install the driveshaft. 4. Fill the differential with hypoid gear oil IS 300

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Driveshaft • Rear wheels . • Rear brake calipers • Pinion flange • Pinion seal

(0.98-1 .57 Nm).

preload. To install:

3. Install or connect the following: • Pinion seal and flange • New pinion flange nut 4. Rotate the pinion flange occasion¬ ally while tightening the flange nut to make sure the pinion bearings seat cor¬ Nm). rectly. Do not exceed 249 ft. lbs. (338

Never loosen the pinion nut to reduce bearing preload. If it is necessary to reduce bearing preload, install a new collapsible spacer and pinion nut.

7. •Install or connect the following: Driveshaft • Brake calipers • Rear wheels

5. Take frequent bearing preload torque readings.

8. Fill the differential with gear lubricant and check for leaks.

6. The pinion bearing preload specifica¬ tions are as follows:

STEERING AND SUSPENSION Air Bag _

** CAUTION These vehicles are equipped with an air bag system. The system must be disabled before performing service on or around system components, steer¬ ing column, instrument panel compo¬ nents, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary system repairs.

PRECAUTIONS Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible per¬ sonal injury. • Never carry the inflator module by the wires or connector on the underside of the module. • When carrying a live inflator module, hold securely with both hands and ensure that the bag and trim cover are pointed away. • Place the inflator module on a bench or other surface with the bag and trim cover facing up. • With the inflator module on the bench, never place anything on or close to the module which may be thrown in the event of an accidental deployment. DISARMING To avoid personal injury when working on vehicles equipped with an air bag, the

• Return line and the pressure line from the control valve housing • 4 stabilizer bar bolts and 2 nuts. Position the stabilizer bar out of the way. Do not remove the sway bar from the vehicle. • Heated (HO2) sensor (bank 1 sensorOxygen 1)

negative battery cable must be disconnected and at least 90 seconds must elapse before working on the system. Failure to do so may result in deployment of the air bag. ARMING To rearm the air bag system, simply reconnect the battery cable(s).

• 2 steering gear mounting bolts and nuts. Remove the steering gear

Power Rack and Pinion Steering Gear

through the left side of the vehicle.

To install:

REMOVAL & INSTALLATION ES 300

Ins

• Steering gear on the vehicle and install the 2 mounting bolts and nuts. Tighten the nuts and bolts to 134 ft. lbs. (181 Nm).

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable and wait at least 90 seconds before working on the vehicle to disarm the air bag. • Front wheels • Left and right front fender apron seals • Cotter pin and nut holding the steering knuckle to the tie rod end. Using a tie rod puller, disconnect the tie rod end from the steering knuckle. 3. Place matchmarks on the intermediate shaft and the control valve shaft. 4. Loosen the upper bolt and remove the lower bolt holding the control valve shaft to the intermediate shaft. Disconnect the inter¬ mediate shaft from steering rack housing. 5. •Remove or mp disconnect the following: Tube cla

tal

l or

• HO2 sensor. Tighten the sensor to 33 ft. lbs. (44 Nm). nec tt•h Stabilizer bar bolts and nuts and e fo llo tighten win as follows: Bolts: 14 ft. lbs. g: Nuts: 29 ft. lbs. (39 Nm). (19 Nm); • Pressure and return lines and

con

tighten the connectors to 18 ft. lbs. (25 Nm) • Tube clamp and tighten the nut to 84 inch lbs. (10 Nm) • Intermediate shaft to the steering rack and tighten the retaining bolts to 26 ft. lbs. (35 Nm) • Tie rods to the steering knuckles with the castellated nuts. Tighten the nut to 36 ft. lbs. and install a new cotter pin. The prongs of the cotter pin should be firmly wrapped around the flats of the nut. • Front fender apron seals by installing the 2 bolts • Front wheels and lower the vehicle • Power steering fluid • Negative battery cable

Nm)

LEXUS Ifi-RR

ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 * SC 400

7. Release the steering wheel 8. Bleed the system 9. Check for leaks, adjust the toe-in and check the steering wheel center point GS 300, GS 400 and GS 430

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Front wheels

To install:

6. Center the rack and pinion to the fol¬ lowing dimensions: .

0

3. Matchmark the steering column uni¬ versal joint to the control valve shaft. 4. Loosen the upper bolt and remove the lower bolt to the intermediate shaft uni¬ versal joint. 5. Remove or disconnect the following: • Intermediate shaft from the control valve shaft • Tie rod ends from the steering knuckle • Fluid lines from the rack and pinion and cap the lines • 2 tube clamps by removing the bolt • Mounting bolts and nuts. Remove the rack and pinion.

Matchmarking the intermediate shaft to the control valve shaft — GS 300, GS 400, GS 430

a. Dimension A: 1.14 in. (28.9mm) b. Dimension B: 23.54 in. (589mm) 7. Install or connect the following: • Rack and tighten the bolts to 72 ft. lbs. (98 Nm) • 2 tube clamps and tighten the bolt to 12 ft. lbs. (17 Nm) 8. Align the matchmarks on the inter¬ mediate shaft and control valve shaft. Tighten the intermediate shaft bolts to 26 ft. lbs. (35 Nm). 9. Install or connect the following: • Fluid lines to the rack and pinion with new washers. Tighten the union bolts to 36 ft. lbs. (49 Nm). • Tie rod ends • Wheels • Negative battery cable 10. Lower the vehicle. 1 1 . Check the steering wheel center 12. Check the front wheel alignment. point. IS 300

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Steering wheel • Front wheels • Brake calipers • Outer tie rod ends • Engine undercover • Intermediate shaft • Front subframe brace • Pressure and return lines • Steering gear

m

• Fluid pressure line: 31 ft. lbs. (42 Nm) • Front subframe brace large bolts: 88 ft. lbs. (119 Nm) Nm) subframe brace small bolts: • Front 43 ft. lbs. (58 Nm) • Tie rod end nuts: 40 ft. lbs. (54 • Steering wheel nut: 26 ft. lbs. (35 LS 400 and LS 430

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. • Wheel(s) 2. Remove or disconnect the following: • Engine undercover by removing the 8 bolts and 5 screws • Cotter pin and nut holding each tie rod to the steering knuckle • Tie rod end from the steering knuckle with a tie rod end puller 3. Place matchmarks on the sliding yoke and control valve shaft. 4. Loosen the top bolt holding the slid¬ ing yoke to the intermediate shaft. Remove the bottom bolt holding the sliding yoke to the steering rack. 5. Remove or disconnect the following: • Pressure feed and return lines to the rack and pinion • Power steering connector • 4 mount bolts and nuts to the power steering rack • 2 brackets and grommets • Power steering rack from the vehicle To install:

To install:

3. Installation is the reverse of the removal procedure, while using the follow¬ ing torque values: • Steering gear mounting bracket bolts: 54 ft. lbs. (74 Nm) • Fluid return line: 30 ft. lbs. (40 Nm)

6. Install or connect the following: • Power steering rack to the vehicle. • 2 brackets and grommets to the power steering rack. • 4 bolts and tighten the bolts to 56 ft. lbs. (76 Nm). • Power steering solenoid connector • Pressure feed and return tubes. Tighten the union bolt to 36 ft. lbs. (49 Nm). 7. Align the matchmarks on the sliding yoke and control valve shaft. Nm).8. Tighten the bolt holding the sliding yoke to the steering rack to 26 ft. lbs. (35 9. Tighten the bolt holding the sliding yoke to the intermediate shaft to 26 ft. lbs. (35 Nm). • Tie rod end to the steering knuckle. Tighten the nut to 48 ft. lbs. (65 Nm). Install a new cotter pin.

Ins

OC

ic

I U

OO

LEXUS

ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400 RH Front Brake Caliper LH Front Brake Caliper

4

iding Yoke

Return Tube

58 (590, 43)

119(1,210,88)

4 — I

Front Suspension Member Brace

58 (590, 43)

*

k\ 58 (590, 43)

No. 2 Engine Under Cover

N-m (kgf-cm, ftlbfj] : Specified torque ♦ Non-reusable part * For Use With SST

9347LG02

Exploded view of the steering gear mounting— IS 300

• Engine undercover • Wheel(s) 11. Bleed the power steering system and check the front end alignment. SC 300 and SC 400

pre

cau

tio

in the be gi n

nn

in

g

of thi sec s tio n.

2. Place the front wheels facing straight ahead. ing:3. Remove or disconnect the follow¬ • Negative battery cable. Wait at least 90 seconds before performing any work. • Steering wheel pad

** CAUTION Keep the upper surface of the wheel pad pointed away from you at all times. Store the pad with the upper surface facing upward. • Intermediate shaft • Right and left tie rod ends

lfi-87

Nm). strut retaining nut to 36 ft. lbs. (49 :* CAUTION • Union bolt and gasket and remove 400 ES 300 • IS 300 • GS* 300 • GS 400 • GS 430 « LS * LS 430 * SC 300 * SC 400 I U U * the pressure tube 8. Remove the strut from the vise and Do not remove the center nut to the • Union bolt and 2 gaskets; remove the return tube disassemble the securing nuts and bolt. strut at this time. The spring on the • PPS solenoid connector strut is under high pressure and can 9. Rotate the upper support so the low¬ cause serious injury. • On SC 400 models, the tube est bolt on the support aligns with the pro¬ clamp jection part Nm) of the lower spring. 10. Install or connect the following: • 2 bolts and nuts and remove the nuts 3. Temporarily install the bolt and to the lower bracket of the strut to support it • Strut and tighten the strut to body bracket and grommet bolts to 59 ft. lbs. (80 Nm) and secure the strut in a vise. • 2 bolts and nuts; remove the rack 4. Compress the coil spring • Strut to the steering knuckle and and pinion assembly ing: 5. Remove or disconnect the follow¬ To install: tighten the bolts to 156 ft. lbs. (211 Nm) • Spring seat 11. Run the brake hose through the • Rack and pinion assembly with the brake hose bracket and install the clip. • Upper strut retaining nut 2 set bolts and nuts. Tighten the • Suspension support 12. InstallNm) or connect the following: bolts to 56 ft. lbs. (76 Nm). • Sp ri ng • ABS speed sensor and tighten the • Upper insulator • Bracket and grommet with the 2 mounting bolt to 48 inch lbs. (5 bolts and nuts. Tighten the bolts to • Bumper 56 ft. lbs. (76 Nm). • Insulator • Brake line to the strut housing and • On SC 400 models, the tube To install: clamp tighten the bolt to 22 ft. lbs. (29 • Wheel 6. Install or connect the following: • PPS solenoid • Lower insulator • Return tube with the bolt and new • Negative battery cable • Bumper to the piston rod gaskets. Tighten the union bolt to 13. Check the front alignment. • Coil spring end into the gap of the 36 ft. lbs. (49 Nm). lower seat • Pressure tube with the union bolt GS300, GS 400 AND GS 430 l or c • Upper insulator onnec and a new gasket. Tighten the t tunion 1 . Before servicing the vehicle, refer to • Upper support to the piston rod, he fo bolt to 36 ft. lbs. (49 Nm). llowi aligning it with the groove in the • Right andngleft : tie rod ends the precautions in the beginning of this sec¬ strut rod tion. • Intermediate shaft 7. Install or connect the following: 2. Remove or disconnect the following: • The steering wheel. Tighten the • Negative battery cable. • Spring seat. Tighten the new upper steering wheel set nut to 26 ft. lbs. • Front wheel (35 Nm). • Brake caliper, leaving the line • Steering wheel pad attached • Negative battery cable 3. Loosen the 3 upper strut mounting • Steering fluid and bleed the steer¬ nuts. ing system. 4. Loosen, but do not remove, the

Strut and Coil Spring

upper strut rod nut.

CAUTION

REMOVAL & INSTALLATION

Do not remove the upper strut nut at this time.

Front

ES300 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

ing:

Temporarily install the support nuts and bolt to the strut— ES 300

2. Remove or disconnect the follow¬ • Negative battery cable • Tire and wheel assembly

• If equipped with an Anti-lock Brake speed sen¬ (ABS), System r the ABS sor connecto • Brake line from the strut housing • Strut assembly from the steering knuckle • 3 upper mounting nuts from the strut tower • Strut assembly

Align the out mark ot the upper spring seat with the mark on the upper insulator— ES 300 and LS 400

5. Remove or disconnect the following: • Anti-lock Brake System (ABS) speed sensor and harness • Upper suspension arm from the steering knuckle • Stabilizer bar from the link and remove the bracket • Strut from the lower suspension arm. • 3 upper strut mounting nuts and remove the strut 6. Compress the coil spring. 7. Remove or disconnect the following: • Piston rod locknut • Suspension support, coil spring and bumper

8. If disposing the strut, perform the following procedure:

HC Oft LEXUS 5 I U“00 ES. 300 • IS 300 • GS 300

• GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400 IS 300

To install:

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Front clamp wheel

aloc lati removaInl stpr e veusrsine g the follow¬ edonure,is thwheilre of the ing torque values: • Upper strut mount center nut: 25 ft. lbs.Nm) (34 Nm)

• Upper strut mounting nuts: 26 ft. lbs. (35 Nm) • Lower strut mount bolt: 47 ft. lbs. (64 Nm) • Upper ball joint nut: 50 ft. lbs. (65

• Wheel speed sensor and harness

a. Fully extend the strut rod. b. Drill a hole near the bottom ot the shock to remove the gas inside.

•;* CAUTION The gas is harmless, but be careful of chips that may fly up when the gas is released.

• Upper ball joint • Level control sensor link • Stabilizer bar link • Lower strut bolt • Upper strut mount cap • Upper strut mount nuts • Strut assembly 3. Install a suitable spring compressor and remove the center nut. 4. Remove the upper strut mount and the coil spring.

• Stabilizer bar link nut: 36 ft. lbs. (49 Nm) LS 400 AND LS 430— WITHOUT AIR SUSPENSION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

a-

To install:

9. Install or connect the following: • Spring bumper • Coil spring • Suspension support to the rod and temporarily install a new nut 10. Turn the suspension support so one ot the bolts on the support faces the same direction as shown in the illustration.

♦ Suspension

Spring _

Support

Bumper

Insulator

^Align the bolt so a line drawn between the rod and bolt would be at Spring Coil

90° to the direction of the lower bush¬ ing. Shock Absorber and Coil Spring

1 1 . Install or connect the following: • Spring compressor • Strut and tighten the upper retain¬ ing nuts to 41 ft. lbs. (56 Nm) • New upper strut rod nut to 20 ft. lbs. (27 Nm) • Strut to the lower arm and tem¬ porarily tighten the nut and bolt • Stabilizer bar bracket and tighten the bolts to 21 ft. lbs. (28 Nm) • The stabilizer bar to the link and Nm) the bolts to 29 ft. lbs. (39 tighten • Upper suspension arm to the steer¬ ing knuckle. Tighten the nut to 64 ft. lbs. (87 Nm) and install a new cotter pin. • ABS speed sensor and tighten the bolt to 69 inch lbs. (8 Nm) • Caliper • Wheel 12. Bounce the vehicle several times to stabilize the suspension. 13. Tighten the lower strut bolt and nut to 116 ft. lbs. (157 Nm). 14. Check the front wheel alignment.

Shock Absorber

Suspension Arm Upper

♦ Clip

♦ Non-reusable part 7923LGA8

Exploded view of the strut and spring mounting— LS 400 without air suspension shown

LEXUS

1 fi-PQ IU

ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 * SC 300 * SC 400

♦

U J

34 (350, 25)

Suspension Support

Upper Insulator

Coil Spring

Spring Bumper

ABS Speed Sensor

Height Control Sensor Link

5.4 (55, 48 in.-lbf)

N-m (kgf-cm, ft-lbf) |: Specified torque ♦ Non-reusable pari 9347LG05

Exploded view of the front strut assembly mounting — IS 300

16-90

LEXUS

ly. emb ass

5ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400 . 7. Turn the suspension support so one of the bolts on the support faces the same • Tire and wheel assembly lowing Ifprdiocspedosurine:g the strut perf direction as shown in the illustration. a. Using a screwdriver, remove orm thethefol¬air • Steering knuckle from the upper from inside the cylinder. ball joint ^Align the bolt so a line drawn 2. b. Fully extend the cylinder. • Strut from the lower strut between the rod and bolt would be at Remove assembly or di sc onnect the foll bracket c. Drill a hole in the cylinder at a owing: ing. to the direction of the lower bush¬ 90° point above 1 .57 in. (40mm) from the • Strut cover from the upper strut mount bottom of the strut assembly. This will 8. Tighten the strut rod nut to 20 ft. lbs. release the gas charge in the strut. Do • 3 mounting nuts and remove the (27 Nm) and install the cap. strut assembly with the coil spring not puncture the pneumatic cylinder. from the vehicle. 9. Remove the spring compressor 10. Install or connect the following: CAUTION • Strut and tighten the upper retain¬ The gas coming out is harmless, but ing nuts to 43 ft. lbs. (58 Nm) be careful of chips that may fly up Do not remove the center nut to the while drilling. • Strut to the lower bracket and tem¬ strut at this time. porarily install the nut and bolt To install: • Upper control arm to the steering 3. Compress the coil spring. knuckle. Tighten the nut to 48 ft. 6. Install or connect the following: 4. Remove or disconnect the following: • Piston rod locknut lbs. (65 Nm) and install a new cot¬ • Strut and tighten the upper mount¬ ter pin. • Wheel ing nuts to 43 ft. lbs. (58 Nm) • Suspension support, coil spring and the bumper • Suspension control actuator and 11. Lower the vehicle. tighten the bolts. Tighten the 2 nuts 5. If disposing the strut, perform the 12. Bounce the vehicle several times to to 13 ft. lbs. (17 Nm). following procedure: stabilize the suspension. a. Fully extend the strut rod. • Suspension control actuator cover 13. Tighten the lower strut bolt and nut b. Drill a hole within the shaded area and tighten the nuts to 43 ft. lbs. to 116 ft. lbs. (157 Nm). shown in the illustration to remove the (58 Nm) 14. Check the front wheel alignment. • 2 new 0-rings to the air tube. gas inside. Install the tube and tighten it to 13 LS 400 AND LS 430— WITH AIR CAUTION SUSPENSION ft. lbs. (17 Nm). Install the grom¬ met. The gas is harmless, but be careful 1. Before servicing the vehicle, refer to • The strut to the lower strut bracket of chips that may fly up when the precautions in the beginning of this sec¬ and temporarily install the nut and drilling. tion. bolt 2. Move the height control switch to • Steering Nm) knuckle to the upper ball OFF joint. Tighten the nut to 48 ft. lbs. 3. Bleed the air from the suspension. To install: (65 Nm) and install a new cotter 4.• Remove Wheel or disconnect the following: • Height control sensor link and • Spring bumper • Height control sensor link from the • Coil spring. Match the end of the • tighten Wheel a new nut to 48 inch lbs. (5 lower strut bracket coil into the recess of the strut • Cotter pin and nut holding the spring seat. upper control arm to the steering 7. Turn the height control switch ON. • Suspension support to the rod and knuckle 8. Start the temporarily install a new nut pin.engine to fill the strut with air. • Upper ball joint from the steering knuckle 9. Bounce the vehicle several times to • Pneumatic cylinder from the lower normalize the suspension. bracket by removing the through10. Support the lower control arm with a bolt • Air tube from the strut 1 1 . Install or connect the following: • Front wheel • The actuator cover

i: CAUTION Do not remove the center nut from the pneumatic cylinder.

Be sure to align the suspension support with one of the upper mounting bolts as shown — LS 400 without air suspension

• Actuator electrical connector • 2 bolts to the suspension control actuator and position the actuator aside • 3 upper mounting nuts and the strut from the vehicle

Lower strut mounting nut and bolt jack. •• to Wheel 76 ft. lbs. (106 Nm) 12. Check the front end alignment. SC 300 AND

SC 400

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Tire and wheel assembly

LEXUS 1 R-Q1

400 1 •• Upper Coil spring bolt 400 so a line drawn 300 • IS 300 • Brake caliper support ES bracket insulator * •^Align GS 300the• GS 6 • GS 430 * LS 400 7 * LS 430 between the rod and bolt would be at • SC 300 • SC 0 • Fender apron 8 U J • Spring bumper • Engine undercover . 90° to the direction of the lower bush¬ ing. • Lower insulator • Front fender wheel opening molding 1 • If removing the left side strut, the following 8. Remove the spring compressor. : windshield washer tank 9. Install or connect the following: Ia. f diFully • Anti-lock Brake System (ABS) scard extend the strut rod. • Strut and tighten the 3 upper strut the instrthe 1 b. Drill ianghole the strut ut, side speed sensor at the steering perfoof mount nuts to 26 ft. lbs. (35 Nm). rm the to release the gas. knuckle Tighten the middle nut to 22 ft. lbs. • Wiring harness clamp in order to WARNING (29 Nm) and install the plug. . prevent the harness from being • Lower end of the strut to the lower damaged when removing the control arm. Do not tighten the bolt The gas coming out is harmless, but be careful of chips which may fly up at this time. through-bolt. while drilling. • Plug from the upper strut mount. • Upper control arm and install the Do not remove the center bolt. through-bolt and nut. Do not To install: tighten the bolt at this time. •: CAUTION • VSS, wiring harness and the • Lower insulator to the strut washer tank Do not remove the center bolt to the • Spring bumper to the strut piston strut at this time. The spring on the • Fender apron and the engine rod undercover can and strut is under high pressure Insta • Compressed coil spring ll or • Caliper support bracket and tighten cause serious injury or vehicle damonne spring with the end butted • cCoil the bolts to 87 ft. lbs. (118 Nm) ct t age. _ he f • Tire and wheel assembly olgap against the lowi in the lower seat ng: 10. Lower the vehicle. • Upper control arm through-bolt support match¬ insulator and Upper • from the subframe ing the bolt of the support with the 11. Bounce the vehicle a few times to • Upper control arm and turn the cut-off part of the insulator stabilize the suspension, then tighten the • Upper suspension support control arm completely around. It is strut to lower arm bolt to 106 ft. lbs. (143 • New strut piston rod nut to 36 ft. not necessary to remove the upper Nm). Tighten the upper arm to 121 ft. lbs. lbs. (49 Nm) ball joint. (164 Nm). • Strut at the lower control arm by • Spring compressor 12. Check the front end alignment. • Strut Nm)rod piston nut cap removing the nut and bolt Rear • Strut and tighten the 3 nuts to 29 ft. • 3 upper mounting nuts and remove lbs. (39 Nm) the strut assembly with the coil ES300 • Strut to the axle carrier. Coat the spring from the vehicle Nm)with engine oil and tighten the nuts 1. Before servicing the vehicle, refer to 3. Compress the coil spring. nuts and bolts to 188 ft. lbs. (255 4. Remove or disconnect the following: in the beginning of this sec¬ precautions the Nm) tion. • Piston rod locknut • ABS harness to the strut and 2. Remove or disconnect the following: • Suspension support • Tire and wheel assembly tighten the bolt to 48 inch lbs. (6 • Coil spring • Load sensing proportioning valve • Bumper • Brake line to the strut and tighten 5. If disposing the strut, perform the spring assembly from the lower arm the retaining nut to 22 ft. lbs. (29 • Anti-lock Brake System (ABS) following procedure: a. Fully extend the strut rod. speed sensor harness and brake b. Drill a hole within the shaded area line from the strut assembly • Spring to the lower arm and tighten the nut to 10 ft. lbs. (13 Nm) • Stabilizer bar link from the strut shown in the illustration to remove the • LSPV to the lower arm and tighten 3. Loosen the 2 nuts attaching the strut gas inside and dispose the old strut. the nut to 108 inch lbs. (12 Nm) to the axle carrier. • Rear wheel ■: CAUTION 4. Support the axle carrier. • Rear seat and package tray 5. Remove or disconnect the following: The gas is harmless, but be careful • Rear seat back and package tray trim of chips which may fly up when • Upper mounting nuts drilling. • 2 lower mounting bolts and remove the strut assembly To install: 6. Install or connect the following: 6. Compress the coil spring. Outside • Spring bumper 7. Temporarily install a bolt and 2 nuts on the bracket at the lower end of the strut • Coil spring and secure it in a vise. • Suspension support to the rod and 8. Secure the upper support and temporarily install a new nut remove the strut rod retaining nut. 7. Turn the suspension support so one 7923LGB1 9. Remove or disconnect the following: of the bolts on the support faces the same Position the upper suspension support as • Upper suspension support direction as shown in the illustration. shown when assembling the strut— ES 300

lexu U-QZJ9L ES 300s • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400 1I R High Mount Stop Light

* For use with SST 7923LGA0

Exploded view of the rear strut and coil spring mounting— ES 300

• Wheel(s)

GS300, GS 400 AND GS 430 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Front trunk compartment trim cover

• Brake caliper support bracket from the rear axle carrier by removing the 2 bolts. Leave the brake line way. connected and position it out of the

• Nut and disconnect the sway bar link from the lower control arm • Nut and bolt on the lower end of the strut • 3 upper nuts and lift out the strut. Do not remove the center nut

LEXUS Ifi.QQ

• Strut assembly to the vehicle and 3. Compress the coil spring. • Stabilizer bar link from the stabi¬ 430 bar 400 • GS 300 • IS 300* • GS 300lizer• GS * LS 400 • LS 430 • SC tighten 300 the 4. Secure the upper supportES and • SC3 nuts 400to 47^ft. lbs. (64 • Anti-lock Brake System (ABS) Nm). Tighten the strut rod retaining remove the strut rod retaining nut. nut to 20 ft. lbs. (27 Nm). 5. Remove or disconnect the following: speed sensor and wiring harness • Strut assembly cap and install the 3 • Brake caliper bracket from the axle • Upper suspension support nuts Nm) • Upper insulator con¬ line brake the carrier, leaving • Strut to the rear axle carrier. Install • Coil spring nected. Suspend the brake caliper the bolt from the rear of the vehicle aside with a piece of wire. • Spring bumper • Nut on the lower side of the strut. • Lower insulator and temporarily tighten the nut. • Brake caliper and tighten the Do not remove the bolt. 6. If discarding the strut, perform the • Rear axle assembly with a lifting mounting Nm) bolts to 77 ft. lbs. (104 following: device a. Fully extend the strut rod. b. Drill a hole in the side of the strut • Strut cap by removing the 3 nuts • ABS ness speed sensor and wiring har¬ to drain the gas inside • 3 mounting nuts holding the strut • Stabilizer link to the stabilizer bar assembly to the strut tower. Do not :: CAUTION remove the center bolt. and tighten the nut to 48 ft. lbs. (65

The gas coming out is harmless, but be careful of chips that may fly up while drilling. To install: 7. Install or connect the following: • Lower insulator to the strut • Spring bumper to the strut piston rod • Compressed coil spring. Position the coil spring with the end butted against the gap in the lower seat. • Upper insulator and suspension support • Upper suspension support and tighten a new strut piston rod nut to 20 ft. lbs. (27 Nm) 8. Remove the spring compressor. 9. Install or connect the following: • Strut to the vehicle and tighten the 3 upper mounting nuts to 14 ft. lbs. (20 Nm). Install the cap. • And tighten the lower strut bolt and nut to 101 ft. lbs. (137 Nm) • Sway bar link to the lower control arm. Tighten the nut to 33 ft. lbs. (44 Nm). • Brake caliper to the rear axle carrier by installing the 2 bolts. Tighten the bolts to 77 ft. lbs. (104 Nm). . Wheel(s) • Trunk compartment cover trim 10. Check and adjust the vehicle align¬ ment as necessary. LS 400 AND LS 430— WITHOUT AIR SUSPENSION 1. Before servicing the vehicle, refer to in the beginning of this sec¬ the tion.precautions 2. Remove or disconnect the following: • Rear seat cushion and seat back. • Tray trim • Tire and wheel assembly • Rear halfshaft

Do not remove the center nut to the strut at this time. • Bolt on the lower side of the strut assembly • Strut assembly with the coil spring 3. Compress the coil spring. 4. Secure the strut housing in a vise. 5. Remove or disconnect the following: • Strut rod retaining nut • Upper suspension support •• Upper insulator Coil spring • Spring bumper • Lower insulator 6. If discarding the strut, perform the following: a. Fully extend the strut rod. b. Drill a hole in the strut (about 1 in. above the strut lower mount) and drain the gas inside ic* CAUTION

The gas coming out is harmless, but be careful of chips which may fly up while drilling. To install: 7. Install or connect the following: • Lower insulator to the strut. • Spring bumper to the strut piston rod • Coil spring • Upper insulator and support • Upper suspension support 8. Temporarily install the upper strut rod retaining nut. 9. Rotate the suspension support so that the rod and one of the bolts on the sus¬ pension support are aligned with the lower bushing. 10. Remove the spring compressor. 11. Install or connect the following:

• Rear halfshaft • Tire and wheel assembly 12. Bounce the vehicle up and down to stabilize the suspension. 13. Support the rear axle assembly with a lifting device. Tighten the lower strut bolt to 101 ft. lbs. (137 Nm). 14. Install or connect the following: • Rear seat cushion and rear seat back. • Package tray trim 15. Check the wheel alignment. LS 400 AND LS 430— WITH AIR SUSPENSION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Bleed the air system from the sus¬ 3. Remove or disconnect the following: pension. • Rear seat cushion and seat back • Package tray trim • Trunk trim panel. Move the height control switch, located in the trunk area, to the OFF position. • Tire and wheel assembly • Rear halfshaft • Stabilizer links from the stabilizer bar • Anti-lock Brake System (ABS) speed sensor and wiring harness • Brake caliper bracket from the rear axle carrier. Do not disconnect the brake line. 4. Place matchmarks on the height control sensor link and bracket. Disconnect the height control sensor link from the No. 1 lower control arm. 5. Support the rear axle assembly with a lifting device. 6. Remove or disconnect the following: • Nut on the lower side of the shock absorber. Do not remove the bolt. • Grommet and disconnect the air tube from the shock absorber

16-94

LEXUS ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400 matic cylinder (strut) and tighten the nuts to 27 ft. lbs. (36 Nm) • Strut assembly to the vehicle and tighten the upper mounting nuts to 47 ft. lbs. (64 Nm) 11. Match the holes in the pneumatic cylinder with the holes in the suspension control actuator. 12. Install or connect the following: • Actuator and tighten the mounting nuts to 69 inch lbs. (8 Nm) • Actuator cover and tighten the 3 nuts to 18 ft. lbs. (25 Nm)

9

.

• New O-rings and connect the air line to the shock absorber. Tighten the fitting to 13 ft. lbs. (18 Nm). • Strut to the rear axle carrier. Insert the bolt from the vehicle’s rear and temporarily tighten the nut. • Height control sensor link to the No. 1 lower control arm. Mounting nut: 48 inch lbs. (5 Nm). • Rear brake caliper to the rear axle carrier and tighten the mounting bolts to 77 ft. lbs. (104 Nm) • ABS ness speed sensor and wiring har¬

Pneumatic cylinder (strut) component overview (air suspension)

• Actuator cover from the strut tower by removing the 3 nuts • Actuator electrical connector from the top of the strut • Actuator by removing the 2 nuts • 3 upper mounting nuts holding the strut to the strut tower 7. Lower the rear axle assembly 8. Remove or disconnect the following: • Bolt on the lower side of the shock absorber • Pneumatic cylinder strut assembly from the vehicle • Suspension support from the strut assembly by removing the 3 nuts 9. If discarding the pneumatic cylinder, perform the following: a. Using a screwdriver, depressurize the air from inside the cylinder. b. Drill a hole in the shaded area shown in the illustration and remove the gas inside.

U CAUTION The gas coming out is harmless, but be careful of chips which may fly up when drilling. To install: • Suspension support to the pneu¬

• Stabilizer bar link and tighten the nut to 48 ft. lbs. (65 Nm) • Halfshaft • Actuator electrical connector to the • Tire top of the strut 13. Move the height control switch to the ON position. Start the engine and fill the pneumatic cylinder with air. 14. Bounce the vehicle up and down several times to stabilize the suspension. 15. Turn the suspension height control to the OFF position. bly.16. Remove the tire and wheel assem¬

brake line connected and position it aside. • Nut and bolt on the lower end of the strut • Cap nut on the upper end of the strut. Remove the 3 upper nuts and lift out the strut. Do not remove the center nut from the strut.

: CAUTION Do not remove the center nut on the strut at this time. The spring on the strut is under high pressure and can cause serious injury. 4. Compress the coil spring. 5. Secure the strut housing with 2 nuts and a bolt as shown in the illustration and secure it in a vise. 6. Secure the upper support and remove the strut rod retaining nut. 7. Remove the upper suspension sup¬ port, upper insulator, coil spring, spring bumper and the lower insulator. 8. If discarding the strut, perform the following: a. Fully extend the strut rod. b. Drill a hole in the strut in the shaded area shown in the illustration and drain the gas inside

** CAUTION The gas coming out is harmless, but be careful of chips which may fly up while drilling. To install: • Lower insulator to the strut

• Spring bumper to the strut piston rod • The (compressed) coil spring 10. Position the coil spring with the end Ins 17. Support the rear axle carrier with a tall butted against the gap in the lower seat. lifting device. Tighten the lower strut bolt to or con nec • Upper insulator and support match¬ 101 ft. lbs. (137 Nm). tth ing the bolt of the support with the e fo 18. Install or connect the following: llcut owi off part of the insulator • Package tray trim ng: suspension support • Upper • Rear seat cushion and seat back 11. Secure the upper suspension sup¬ 19. Turn the suspension control switch port and tighten the new strut piston rod nut to the ON position. to 20 ft. lbs. (27 Nm). 20. Check the wheel alignment. 12. Remove the spring compressor. • Strut rod piston nut cap SC 300 AND SC 400 • Strut and the 3 nuts. Tighten the 1 . Before servicing the vehicle, refer to nuts cap. to 19 ft. lbs. (25 Nm). Install the the precautions in the beginning of this sec¬ tion. • Lower bolt to hold the strut to the 2. Raise the rear of the vehicle and lower control arm. Do not tighten support it with safety stands. the bolt at this time. Wheel(s)or disconnect the following: 3. • Remove Wheel(s)support bracket and tighten •• Caliper the bolts to 77 ft. lbs. (104 Nm) • Brake caliper support bracket by removing the 2 bolts. Leave the

LEXUS Ifi.Qi; Nm)

To install: 13. Lower the vehicle. To install: 400 Nm) ES 300 • GS or connect the following: toIS 300 • GS6. 300 * LS 400 * LS 4304. »Install times •* Install or connect* GS the 430 following: SC 300 14. Bounce the vehicle several » SC 400 ■ normalize the suspension. • Upper control arm and tighten the 2 • Upper suspension arm and tighten the mounting bolts to 39 ft. lbs. (53 mounting bolts to 83 ft. lbs. (113 15. Support the lower arm. 16. Tighten the lower strut mounting bolt • ABS speed sensor wire harness to to 106 ft. lbs. (143 Nm). • Strut and tighten the upper retain¬ 17. Check the alignment and adjust as ing nuts to 41 ft. lbs. (56 Nm). the upper control arm with the attaching bolt necessary. Tighten the new upper strut rod nut to 20 ft. lbs. (27 Nm). • Strut, or if equipped with air sus¬ pension, install the pneumatic • Strut to the lower arm and tem¬ Upper Ball Joint • Wheel porarily tighten the nut and bolt • Stabilizer bar bracket and tighten cylinder REMOVAL & INSTALLATION 5. Lower the vehicle. the bolts to 21 ft. lbs. (28 Nm) • Stabilizer bar to the link and tighten 6. Check and adjust the wheel alignment The upper ball joint is an integral part of as necessary. the bolts to 29 ft. lbs. (39 Nm) the upper arm and is not replaced sepa¬ • Upper suspension arm to the steer¬ rately. The upper ball joint replacement is SC 300 and SC 400 ing knuckle. Tighten the nut to 64 arm. upper the accomplished by replacing ft. lbs. (87 Nm) and install a new 1 . Raise the front of the vehicle and sup¬ cotter pin. port it on Wheel safety stands. Arm Upper Control • ABS speed sensor and tighten the 2. •Remove or disconnect the following: bolt to 69 inch lbs. (8 Nm) • Caliper REMOVAL & INSTALLATION

. GS 300

• Front wheel 7. Lower the vehicle. 8. Bounce the vehicle several times to stabilize the suspension. 9. Tighten the lower strut bolt and nut to 116 ft. lbs. (157 Nm).

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the follow¬ ing: IS 300 • Negative battery cable • Wheel 1 . Before servicing the vehicle, refer to the 3. Loosen the 3 upper strut mounting precautions in the beginning of this section. nuts. 2. Remove or disconnect the following: 4. Loosen, but do not remove, the • Front wheel upper strut rod nut. • Strut and spring assembly Che •' CAUTION • Inner bolts and the control arm ck the To install: fro ntw DO NOT completely remove the upper 3. Install or connect the following: hee l al strut nut at this time. • Control arm and tighten the inner ign men bolts to 44 ft. lbs. (59 Nm) t. • Strut and spring assembly • Brake caliper, leaving the line • Front wheel attached and secure it out of the way • Anti-lock Brake System (ABS) speed sensor and harness • Cotter pin and nut from the upper control arm

• Upper control arm from the steer¬ ing knuckle • Stabilizer bar from the link and remove the bracket • Cotter pin and nut from the lower control arm • Strut from the lower suspension arm • 3 upper strut mounting nuts and remove the strut • Mounting bolts holding the upper control arm to the frame • Upper control arm from the vehicle

LS 400 and LS 430 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Raise and safely support the vehicle. 3. •Remove Wheel or disconnect the following:

• Strut or if equipped with air sus¬ pension, remove the pneumatic • cylinder Anti-lock Brake System (ABS) speed sensor wire harness from the upper control arm by removing the bolt. . Mounting bolts holding the upper control arm to the vehicle • Upper control arm

• Caliper support bracket by remov¬ • Rotor ing the 2 bolts. Leave the brake line connected and suspend it aside. • Front fender splash shield, fender liner and wheel opening molding • On the leftside, the washer tank • Bolt and disconnect the Anti-lock Brake System (ABS) speed sensor from the steering knuckle. Remove the 3 bolts and disconnect the wire harness clamp. • Cotter pin and the nut from the upper ball joint; press the upper ball joint from the knuckle • Through-bolt, nut and the upper control arm To install: 3. Install or connect the following: • Upper control arm. Connect the upper control arm to the subframe and install the through-bolt. Do not tighten the bolt at this time. f»The upper control arm mounting bolts are not tightened until the sus¬ pension has been assembled and vehicle is on the ground.

• Ball joint to the knuckle and tighten the nut to 76 ft. lbs. (103 Nm). Install a new cotter pin.

. Wire harness and ABS speed sen¬ sor. Tighten the speed sensor to knuckle bolt to 69 inch lbs. (8 Nm). • Washer tank, the fender liner, • Rotor splash shield and molding Caliper support bracket and tighten •• Wheel the bolts to 87 ft. lbs. (118 Nm)

16-96 ES 30(f* IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400 ♦ Bushing

♦ Bushing

Washer Tank

0-— - — Adjusting Cam Plate »

Lower Suspension Arm Bracket Stay 43 (440, 32)

m ^w

®sRear

SO (600,43)

Front Adjusting Cam-

226(2,300,166)

1 Adjusting Cam

92) ■Lower Suspension Arm

♦ Clip Adjusting Cam Plate 125 (1,270,

W

226 (2,300, 186)

Front Fender Splash Shield

4

i

Engine Under Cover N m (kgf cm, ft Ibf) : Specified torque ♦ Non -reusable part 7923LGC7

Exploded view of the front suspension

control arms

and related components — SC 300 and SC 400 models

16-97 4. Lower the vehicle. 5. Bounce the suspension several times to set the suspension. 6. Support the lower arm and tighten the upper control arm through-bolt and nut to 121 ft. lbs. (164 Nm). 7. Check the front wheel alignment and adjust as necessary.

CONTROL ARM BUSHING REPLACEMENT The control arm bushings are serviced with the control arm as an assembly.

N m (kgf cm, ft lbf)

Lower Control Arm REMOVAL & INSTALLATION

ES 300 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Front wheel(s)

• Side fender apron seal • Steering knuckle with the axle hub, from the vehicle • Dust deflector from the knuckle • Cotter pin and the nut from the ball

the lower ball joint from the 3. Remove joint stud steering knuckle. To install: 4. Install the lower ball joint onto the steering knuckle and tighten nut to 90 ft. lbs. (123 Nm). Install new cotter pin. 5. Align the hole in the dust deflector

: Specified torque

♦ Non-reusable part 7923LGB3

Exploded view of the lower suspension — ES 300

QR ESLEXU300S • IS 300 IIUfi-30

• GS 300

with the ABS speed sensor. Using the appro¬ priate driver, install a new dust deflector.

• Steering knuckle and hub onto the vehicle • Fender apron seal • Front wheel(s) 6. • Negative battery cable Install or c nect the fGS GS 300, GS on400 and ollow430 ing: 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Wheel(s) • Caliper, leaving the brake line con¬ nected and suspend it out of the way

i: WARNING Never allow the brake caliper to hang freely from the brake hose. • Rotor

• Anti-iock Brake System (ABS) speed sensor and harness • Tie rod end from the arm on the lower ball joint • Cotter pin and nut. Disconnect the upper control arm from the steering knuckle. • Cotter pin and nut. Disconnect the steering knuckle from the lower control arm. • Steering knuckle and ball joint assembly from the vehicle • 2 ball joint mounting bolts, then remove the ball joint from the steering knuckle To install: 3. Install or connect the following: • Ball joint and tighten the bolts to 83 ft. lbs. (113 Nm) • Steering knuckle to the lower and upper suspension arms. Tighten the lower control arm nut to 95 ft. lbs. (127 Nm) and install a new cotter pin. Tighten the upper con¬ trol arm to 64 ft. lbs. (87 Nm) and install a new cotter pin. • Tie rod end to the ball joint arm. Tighten the nut to 64 ft. lbs. (87 Nm) and install a new cotter pin. • Rotor • Caliper • ABS speed sensor and harness. Tighten the sensor retaining bolt to 69 inch lbs. (8 Nm). • Wheel(s) • Negative battery cable 4. Check the front wheel alignment.

GS 400 • GS 430 • LS 400 • LS 430 •

300 • SC 400

IS 300 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Front wheel • Engine under covers • Level control sensor link • Front subframe brace • No. 2 lower control arm • Brake caliper and rotor • Outer tie rod end • Stabilizer bar link • Lower strut bolt • Lower ball joint • Steering gear • No. 1 lower control arm To install: 3. Installation is the reverse of the removal procedure, while using the follow¬ ing torque Nm) values: • No. 1 lower control arm bolt: 136 ft. lbs. (184 Nm) Nm) • Lower ball joint nut: 91 ft. lbs. (123 Nm) • Outer tie rod end nut: 40 ft. lbs. (54 • Brake caliper bolts: 87 ft. lbs. (118 • No. 2 control arm-to-No. 1 control arm bolts: 181 ft. lbs. (245 Nm) • Front subframe brace small bolts: 43 ft. lbs. (58 Nm) • Front subframe large bolts: 88 ft. lbs. (119 Nm) LS 400 and LS 430 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. If equipped with air suspension, move the height control switch (located in the trunk) to the OFF position. 3. Remove or disconnect the following: • Tire and wheel assembly • Anti-lock Brake System (ABS) speed sensor and wiring harness from the steering knuckle • Brake caliper support bracket by removing the 2 bolts. Leave the brake line connected. Support the caliper aside by using a piece of wire. 4. Loosen the 2 lower ball joint mount¬ ing bolts. (■►Do not remove the bolts. 5. Remove or disconnect the following: • Clip and nut from the tie rod end • Tie rod end from the steering arm with the proper tool

Disconnecting the ball joint from the lower suspension arm— LS 400, LS 430

• Lower ball joint mounting bolts from the steering knuckle • Cotter pin and nut from the lower ball joint • Lower ball joint from the lower control arm To install: 6. Install or connect the following: • Ball joint to the lower control arm. Tighten the nut to 112 ft. lbs. (152 Nm) and install a new cotter pin. • Mounting bolts, temporarily, hold¬ ing the ball joint to the steering knuckle • Tie rod end to the steering knuckle. Tighten the nut to 48 ft. lbs. (65 Nm) and install a new cotter pin. • Lower ball joint bolts to 83 ft. lbs. (113 Nm) • Brake caliper support bracket and tighten the 2 bolts to 87 ft. lbs. (118 Nm) • ABS Wheelspeed sensor and wiring har¬ ness to the steering knuckle 7. Lower the vehicle. 8. Turn the height control switch ON. SC 300 and SC 400 The lower ball joint is not replaceable. If the lower ball joint is defective, replace the lower arm and ball joint as an assembly, as follows: 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Raise the front of the vehicle and support it on safety stands. 3. Remove or disconnect the following: • Wheel and the engine undercover • Caliper support bracket from the vehicle by removing the 2 bolts. Support the caliper and bracket with a wire. Do not let the assembly hang from the brake line. • Nut and disconnect the stabilizer bar from the lower control arm • Cotter pin and nut from the lower

LEXUS ifi.QQ FS 300 * IS 300 * GS 300 » GS 400 « GS 430 * LS 400 « LS 430 « SC 300 « SC 400

ZfZT

Housing Bracket

Steering Gear Assembly

Front Suspension Member

Height Control * Sensor Link Shock Absorber • Lower Bracket No. 1 Lower Suspension Arm

1 1

95 (970, 70)

123(1,250, 91)

Stabilizer Bar Link

§

®w

\

♦

J

(

Cotter Pin

r'

119(1,210,88)

RH Rear Engine Under Cover

Engine Under Cover

58 (590, 43)

LH Rear Engine Under Cover

Engine Under Cover No. 2

N-m (kgf-cm, ft-lbf) : Specified torque ♦ Non-reusable part

Exploded view of the front suspension — IS 300

9347LG06

16-100

LEXUS ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400

Exploded view of the lower ball joint mounting — LS 400, LS 430

LEXUS -Ifi-IQI • SC 400

.

ball joint. Press the lower ball joint out of the steering knuckle. . Lower end of the strut by removing the nut and bolt . Nut, 2 bolts and the front lower arm bracket stay 4 4. Matchmark the front and rear adjust¬ ment cams to the body and then remove the nuts and adjusting cams. 5. Lift out the lower control arm. To install: 6. Install or connect the following: • Bracket to the lower control arm by . installing the 2 bolts. Tighten the bolts to 38 ft. lbs. (52 Nm). • Lower control arm to the body and temporarily install the adjusting cams and nuts. Do not tighten the nuts at this time. • Lower control arm to the knuckle and tighten the ball joint nut to 92 ft. lbs. (125 Nm). Install a new cot¬ ter pin. • Strut to the arm and tighten the bolt and nut to 106 ft. lbs. (143 Nm) • Stabilizer bar link and tighten the nut to 54 ft. lbs. (74 Nm) • Brake caliper support bracket to the vehicle and tighten the bolts to 87 ft. lbs. (118 Nm) • Wheel 7. Lower the vehicle. 8. Bounce it several times to set the suspension. 9. Support the lower arm, align the matchmarks on the adjusting cams and tighten the nuts to 166 ft. lbs. (226 Nm). 10. Check the wheel alignment.

REMOVAL & INSTALLATION Front

knuckle — ES 300

ES300

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Front wheels • Fender apron seal • Cotter pin and lock cap from the end of the halfshaft • Halfshaft locknut. • Brake caliper and use a wire to support it out of the way

WARNING Never allow the caliper to hang freely from the brake hose. • Rotor

• Snapring • Bearing from the steering knuckle To install: • Snapring • Bearing into the knuckle

• Anti-lock Brake System (ABS) • Dust cover. Tighten the 4 bolts to speed sensor from the steering 74 inch lbs. (8.3 Nm). I nst knuckle all • Hub into the steering knuckle or c • Nuts on the lower end of the strut onn • Lower ball joint to the steering ect • Tie rod end from the steering the Tighten the nut to 90 ft. knuckle fknuckle. oll owi • Lower control arm from the ball ng:pin.Nm) and install a new lbs. (123 cotter • Dust deflector • Driveshaft from the axle hub • Knuckle on the lower strut • 2 joint nuts on the lower end of the strut • Lower Nm). ball joint to the lower arm. • Steering knuckle Tighten the bolts to 94 ft. lbs. (127

t

e.

ckl

knu the

Dust deflector from the hub Ball joint from the steering knuckle Hub from the knuckle Inner race from the hub Dust cover

sof

h wit

• • • • •

tec pro to s jaw t

Wheel Bearings

te hes mpt

a Cl eri uc nkgn e

vis na klie Checking wheel bearings for excessive play

I

are non-adjustable. If the wheel bear¬ ing is out of specifications, replace the wheel bearing.

The control arm bushings are serviced with the control arm as an assembly.

Check the backlash in bearing shaft direction and the axle hub deviation. Maxi¬

l U

mum for backlash should be 0.0020 in. (0.05mm) and for axle hub deviation 0.020 in. (0.05mm). ^The front and rear wheel bearings

CONTROL ARM BUSHING REPLACEMENT

ADJUSTMENT

IU

. Tie Nm).rod end to the steering knuckle. Tighten the nut to 36 ft. lbs. (49

• Nuts on the lower strut to 156 ft. lbs. (211 Nm) Nm). speed sensor. Tighten the • ABS bolt to 69 inch lbs. (8 • mounting Rotor

• Caliper. Tighten the mounting bolts to 79 ft. lbs. (107 Nm). • Axle locknut. Tighten the nut to 217 ft. lbs. (294 Nm). Install the lock cap and a new cotter pin. •• Wheel Front fender apron seal

.

LEXU ES 300S • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400 Nm) • Outside inner race from the axle • Brake dust cover to the knuckle and wheel turns without noise and without bind¬ • Oil seal from the steering knuckle ing. tighten the bolts to 74 inch lbs. (8 • Snapring and bearing from the steering knuckle • Hub into the steering knuckle GS300, GS 400 AND GS 430 To install: • ABS speed sensor rotor 4. •Install or connect the following: 1 . Before servicing the vehicle, refer to • Axle hub locknut. Tighten the nut to Snapri ng Lowe • Bearing in the steering knuckle 147 ft. lbs. (199 Nm) and stake it. r th the precautions in the beginning of this sec¬ tion. e vehic • Grease cap to the steering knuckle le. • Inner race (outside) 2. Remove or disconnect the following: by tapping lightly around the cir¬ • New oil seal until it is flush with • Negative battery cable cumference of the cap with a ham¬ the end surface of the steering mer • Front wheel knuckle • Ball joint to the steering knuckle. • Caliper, leaving the brake line con¬ way • Brake dust cover to the steering nected and suspend it out of the Tighten the 2 bolts to 83 ft. lbs. knuckle and tighten the bolts to 74 (113 Nm). inch lbs. (8.4 Nm) • Steering knuckle to the upper and K WARNING • Axle hub to the steering knuckle lower suspension arms. Tighten the • ABS speed sensor upper nut to 64 ft. lbs. (87 Nm) and Never allow the brake caliper to hang the lower nut to 95 ft. lbs. (127 • New nut on the axle shaft. Tighten freely from the brake hose. the nut to 147 ft. lbs. (199 Nm) Nm). Install a new cotter pin on the cap. Stake the nut and install the grease • Rotor lower nut. Install the clip on the upper suspension arm nut. • Anti-lock Brake System (ABS) • Tie rod end to the steering knuckle. • Steering knuckle to the lower ball speed sensor and harness Tighten the nut to 64 ft. lbs. (87 joint and tighten the bolts to 83 ft. • Tie rod from the arm on the lower lbs. (113 Nm) Nm) and install a new cotter pin. ball joint • Steering knuckle to the upper ball • Rotor, disc brake pads and the • Upper suspension arm from the brake caliper joint and tighten the nut to 48 ft. steering knuckle lbs. (65 Nm) • ABS speed sensor and harness. • Steering knuckle from the lower • Brake rotor Tighten the sensor retaining bolt to control arm 69 inch lbs. (8 Nm). • Brake caliper and tighten the 2 • Wheel • Ball joint from the steering knuckle bolts to 87 ft. lbs. (118 Nm) • Front hub grease cap 7. Lower the vehicle and connect the • Speed sensor to the steering 3. Clamp the hub in a soft jaw vise. knuckle negative battery cable. 4. Using a hammer and chisel, loosen • Front tire and wheel assembly 8. Check the front wheel alignment. the staked part of the locknut. 5. If equipped with air suspension, turn 5. Remove or disconnect the following: LS 400 AND LS 430 • Locknut the height control switch to the ON posi¬ tion. 1 . Before servicing the vehicle, refer to • ABS speed sensor rotor the precautions in the beginning of this sec¬ ^Do not scratch the serrations of the tion. sensor rotor. 2. If equipped with air suspension, move the height control switch in the trunk area to • Brake dust cover bolts and shift the cover toward the outside. the OFF position. 3. Remove or disconnect the following: • Hub from the steering knuckle • Front tire and wheel assembly • Inner bearing race from the hub shaft • Brake caliper bracket from the steering knuckle, leaving the brake • Oil seal from the knuckle line connected. Support the caliper • Bearing snapring from the steering knuckle with a piece of wire. • Brake rotor • Bearing from the steering knuckle To install: • Anti-lock Brake System (ABS) Axle hub nut is located on the inboard side speed sensor from the steering 6. Install or connect the following: of the knuckle assembly— LS 400, LS 430, knuckle • New bearing into the steering SC 300 and SC 400 knuckle • Steering knuckle from the lower ball joint by removing the 2 bolts ^lf the inner race and balls come • Steering knuckle from the upper SC 300 AND SC 400 loose from the bearing outer race, be ball joint sure to install them on the same side 1 . Before servicing the vehicle, refer to • Steering knuckle with the axle hub as before. from the vehicle the precautions in the beginning of this sec¬ tion. • Snapring • Grease cap from the hub 2. Remove or disconnect the following: • New outside inner race and tap in • Nut and the speed sensor rotor • 4 bolts and shift the brake dust the new seal. Tap the seal until it is • Front tire and wheel assembly flush with the end surface of the cover towards the hub side • Brake caliper support bracket, leav¬ steering knuckle. • Axle hub from the steering knuckle ing the brake line connected L 1I fUi-1IfUl9

LEXUS

1 uu ES 300 • IS 300 • GS 300 • GS 400 • GS 430 * LS 400 • LS 430 • SC 300 • SC 400 ■ 4 (•►If it is necessary to replace the hub • Caliper support bracket and tighten • Rotor by removing the 2 screws . the bolt to 87 ft. lbs. (118 Nm) or bearing, replace the components as • Anti-lock Brake System (ABS) an assembly. • Speed sensor to the knuckle and speed sensor tighten the bolt to 69 inch lbs. (8 Nm) • Cotter pin and nut and disconnect To install: • Front wheel and tighten the lug the tie rod from the steering knuckle nuts to 76 ft. lbs. (103 Nm) • Cotter pin and nut • Hub on the carrier and tighten the 5. Lower the vehicle. Instalbolts • Steering knuckle from the upper l or to 59 ft. lbs. (80 Nm) control arm ct the • Rotor coornnedrum 6. Check the front end alignment and followin g: ABS speed sensor signal. knuckle • Clip and nut and press the • Caliper, f equipped with rear disc off the lower control arm IS 300 brakes and tighten the bolts to 34 ft. lbs. (64 Nm) • Wheel • Steering knuckle from the vehicle 1 . Before servicing the vehicle, refer to • Hub bearing cap from the steering knuckle the precautions in the beginning of this sec¬ • Hub nut tion. GS 300, GS 400 AND GS 430 • ABS sensor rotor 2. Remove or disconnect the following: 1 . Before servicing the vehicle, refer to • Front wheel • 4 bolts and shift the brake dust the precautions in the beginning of this sec¬ shield toward the hub (outside) • Brake caliper and rotor tion. • Axle hub from the knuckle • Wheel speed sensor 2. Remove or disconnect the following: • Inner bearing race from the axle hub • Upper and lower ball joints • Negative battery cable. • Oil seal •• Steering knuckle from the vehicle • Rear tire and wheel assembly Grease cap • Snapring and bearing • Brake caliper support from the rear • Hub locknut To install: axle carrier and support it with a • Brake dust cover 3. Press the bearing into the knuckle. If • Wheel speed sensor pulse ring the inner race and balls come loose from piecematchmarks of wire 3. Place on the disc brake 3. Press the hub out of the wheel bearing. the outer race, be sure to install them on the rotor and the axle hub. same side as before. 4. Remove the grease seal and the 4. Remove or disconnect the following: • Brake rotor 4. Install or connect the following: snapring, then press the wheel bearing out of the steering knuckle. • Snapring and inner race, then tap • Speed sensor • Rear halfshaft To install: in a new oil seal until it is flush with the end surface of the knuckle • Parking brake shoes •-►Use a new hub locknut for assembly. • Brake dust cover and tighten the •• Parking Strut rodbrake cable 5. Installation is the reverse of the bolts to 74 inch lbs. (8.3 Nm) • Hub into the knuckle 5. Place matchmarks on the adjusting removal procedure, while using the follow¬ • Speed sensor ing torque values: cam and rear control crossmember. • Hub locknut: 108 ft. lbs. (147 Nm) • New locknut and tighten it to 147 ft. • Nut, adjusting cam and the washer • Brake dust cover bolts: 74 inch lbs. lbs. (199 Nm). Stake the nut with a to the No. 1 control arm (8.3 Nm) chisel. Tap the bearing cap into • No. 1 lower control arm from the Nm) ball joint bolts: 83 ft. lbs. • Lower place. crossmember • Knuckle to the upper control arm (113 Nm) • Loosen the nut holding the lower • Upper ball joint nut: 50 ft. lbs. (65 and tighten the nut to 76 ft. lbs. control arm to the axle carrier (103 Nm). Install a new cotter pin • No. 2 lower control arm from the • Knuckle to the lower control arm • Brake caliper support bolts: 87 ft. axle carrier lbs. (118 Nm) and tighten the nut to 92 ft. lbs. • Nut, then remove the No. 2 lower • Wheel lug nuts: 76 ft. lbs. (103 Nm) (125 Nm). Install a new clip. control arm from the axle carrier • Tie rod end to the steering knuckle • Nut holding the upper control arm Rear with the nut. Tighten the nut to 36 to the axle carrier • Axle carrier ft. lbs. (49 Nm). Install a new cotter ES300 pin. by installing the 2 screws • Rotor

7923LGB0

Pressing the hub into the knuckle — SC 300 and SC 400

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Raise and safely support the vehicle. 3. Remove or disconnect the following: • Rear tire and wheel assembly • If equipped with rear disc brakes, the caliper mounting bolts. Leave the brake line connected and sus¬ pend the assembly out of the way. • Brake rotor or drum • 4 bolts and pull off the rear axle • hub 0-ring

• Nut holding the No. 1 control arm to the axle carrier • No. 1 lower control arm from the axle carrier • Dust deflector •• Axle hub plate from the carrier Backing • • • •

Inner race (outside) Oil seal Snapring Bearing

To install: 6. Install or connect the following: • Bearing to the axle carrier

16-104

LEXUS

ES 300 • IS 300 • GS 300 • GS 400 • GS 430 • LS 400 • LS 430 • SC 300 • SC 400 Nm)

2. Properly relieve the fuel system 3. Drain the engine oil. pressure. 4. Drain the transaxle fluid. 5. Drain the cooling system. 6. Remove or disconnect the following: •• Negative Radiator battery cable

2.5L (KL) ENGINE F*The procedure for pulling the engine requires removing the transaxle along with it. As a result, when the halfshafts are pulled from the transaxle, a special

• • • •

plug/side gear holding tool is recom¬ mended. Accelerator cable adjustment compo¬ nents— 626 models equipped with the 2.0L (FS) engine

1 . Before servicing the vehicle, refer to

Air cleaner assembly Accelerator cable Fuel hoses Front exhaust pipe

• Any rods, pipes or cables related to the transaxle that would hinder removal

the precautions in the beginning of this sec¬ tion.

67—83 {6.8—8.5,50—68}

75—104 {7.6—10.7,55—77}

83—123 {8.4—12.6,68.0—81.1} 88 — 116 {8.7—11.8,63.0—86.0}

58-80 {6.0— 8.2, 44-68}

75—1 04 {7.6—1 0.7, 55.0—77.3}

67—83 {6.8—85, 50—68} 67—83 {6.8 — 8.5, 50—68}

44 — 60 {4.4 — 6.2, 32—44} Nm

{kgfm, fl-lbt}

75—1 04 {7.6—1 0.7, 55.0—77.3}

1

No.5 engine mount rubber

6

No.4 engine mount rubber

2

Engine mount member

7

No.4 engine mount bracket

3

No.1 engine mount stay bracket

8

Engine, transaxle

4

No.3 engine mount rubber

5

No.1 engine mount bolt and nut

No.4 Engine Mount Bracket Installation Note • Tighten the bolt in the order shown.

i

42356-MAZC-G05

Location of the engine mounting components and their torque specifications— 626 models equipped with the 2.5L (KL) engine

MAZDA

17_91

626 • MIATA • MILLENIA • PROTEGE

• Battery • Power steering pump with the lines still attached and set aside • A/C compressor with the lines still attached and position aside • Cruise actuator connector, actuator retainers and the actuator • Halfshafts • Number 5 engine mount retainers. Refer to the accompanying illustra¬ tion for location.

.

• Engine mount member (2) retain¬ ers. Refer to the accompanying illustration for location. • Number 1 engine mount stay bracket retainers. Refer to the accompanying illustration for location. • Number 3 engine mount rubber retainers. Refer to the accompany¬ ing illustration for location. • Number 1 engine mount nut and bolt. Refer to the accompanying illustration for location. • Number 4 engine mount rubber retainers. Refer to the accompany¬ ing illustration for location. • Number 4 engine bracket retainers. Refer to the accompanying illustra¬ tion for location. • Engine and transaxle assembly from the vehicle. To install:

7. Installation is the reverse of removal. Tighten the fasteners to the specifications shown in the accompanying illustration. 8. When possible, leave the engine mounting nuts/bolts loose (hand tight) until all mounts are aligned and bolted. This may help in aligning the engine and transmis¬ sion assembly in the vehicle. 9. Install or connect the following: • Number 4 engine bracket retainers. Tighten the fasteners to the specifi¬ cations shown in the accompanying illustration. • Number 4 engine mount rubber

Free play 1.5— 4.0 mm {0.06—0.15 in}

retainers. Tighten the fasteners to the specifications shown in the accompanying illustration. • Number 1 engine mount nut and bolt. Tighten the fasteners to the specifications shown in the accom¬ panying illustration. • Number 3 engine mount rubber retainers. Tighten the fasteners to the specifications shown in the accompanying illustration. • Number 1 engine mount stay bracket retainers. Tighten the fas¬ teners to the specifications shown in the accompanying illustration. • Engine mount member (2) retain¬ ers. Tighten the fasteners to the specifications shown in the accom¬ panying illustration. • Number 5 engine mount retainers. Tighten the fasteners to the specifi¬ cations shown in the accompanying illustration. 10. When connecting the accelerator cable, perform the following adjustment: a. Move the white locking tab to the unlock position. b. Turn stopper B to the to the unlock position.

i»Mf stopper B will not unlock, it may be necessary to carefully bend back tab C out a little using a suitable pry tool.

c. Push or pull the cable housing directly behind the spring. d. Turn the stopper B to the lock posi¬ tion. e. Measure the free play which should be 0.06-0.15 inch (1.5-4mm) and make sure the cable free play is within specification. f. Move the white locking tab to the lock position and check for proper accel¬ erator operation. 1 1 . Fill the engine and the transaxle with the proper type and amount of fluids. Fill the cooling system. 12. Connect the negative battery cable, start the engine and check for leaks. 13. Check the ignition timing and the idle speed. 14. Check all fluid levels. Millenia

2.5L (KL) ENGINE

nents— 626 models equipped with the 2.5L (KL) engine

plug/side gear holding tool is recom¬ mended.

■

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Properly relieve the fuel system 3. Drain the engine oil. pressure. 4. Drain the transaxle fluid. ing: 5. Drain the cooling system. Hood or disconnect the follow¬ 6. •Remove • Front wheels • Splash shield • Battery clamp, cover, battery, bat¬ tery carrier and battery air duct • Air cleaner assembly • Upper seal board • Radiator reservoir hose and the reservoir • Condenser fan motor connector and the fan • Cooling fan connector and fan • Oil cooler hose • Radiator hose, bracket and the radi¬ • Accelerator cable • ator Drive belt • A/C compressor with the lines still attached and position aside • Power steering pump with the lines still attached and position aside • Selector cable • Front exhaust pipe • Tie rod end ball joint •• Upper and lower ball joints Halfshafts • Joint shaft 7. Support the engine using a suitable support• device. Number 1 engine mount stay. Refer to the accompanying illustration for location. • Number 1 engine mount bracket. Refer to the accompanying illustra¬ tion for location. • Engine mount member retainers. Remove the bolts A first and then the mem¬ the ber. bolts Refer Btoand the remove accompanying illustration for location.

Engine load can damage the number 4 mount bolts holes when removing the bolts so make sure all weight is off the mount.

il up unt t and Lif ly ght st sl,i hoi ice dev the ly t emb h wit uppoarss s ine e eng ngin e the e /tr of th ine eeng ghtmov wei re the

Accelerator cable adjustment compo¬

f"*The procedure for pulling the engine requires removing the transaxle along with it. As a result, when the halfshafts are pulled from the transaxle, a special

■ *

MAZDA 00 626 • MIATA

BLL

• MILLENIA • PROTEGE

I .IT—

I

{10.2—15.2,8.9—13.2}

1 2 3

Splash shield Battery clamp

4

Battery cover Battery

5

Battery carrier

6 7 8 9 10 11

Battery air duct Air cleaner component Upper seal board Radiator reservoir hose

12 Condenser 13 14 15 16

Cooling fan motor connector Cooling fan component Oil cooler hose Radiator hose

17 18

Radiator bracket Radiator

19 20

Radiator reservoir

21

Condenser

22

fan motor connector

fan component

Accelerator cable Drive belt A/C compressor P/S oil pump

Location of the engine mounting components and their torque specifications (part 1 of 3)— Millenia models equipped with the 2.5L (KL) engine

MAZDA

17.0Q

626 • MIATA • MILLENIA • PROTEGE

the number 3 and 4 mounts are free from engine weight. 9 • Number 4 engine mount bracket. Refer to the accompanying illustra¬ . tion for location. • Number 3 engine mount sub bracket. Refer to the accompanying illustration for location. • Engine and transaxle assembly

16—19(1.6—2.0, 12—14}

from the vehicle. Be careful the powertrain assembly does not swing and strike the vehicle caus¬ ing damage To install:

re Ti the fas to the spec¬ ifimcoavtal. shgohtwen in the atcenceors n mpan i ying illuIst ons nsrtaatilol na.tion is the rever se of

■ »

10. When possible, leave the engine mounting nuts/bolts loose (hand tight) until all mounts are aligned and bolted. This may help in aligning the engine and transmis¬ sion assembly in the vehicle. 1 1 . Install or connect the following: • Number 4 engine bracket retainers and hand tighten the retainers 12. Using the hoist lower the powertrain

Nm

1

Selector cable

5

Drive shaft

2 3 4

Front pipe Upper lateral link ball joint Lower ball joint

6

Joint shaft

(kgf-m, ftlbf}

42356-MAZC-GDB

with the 2.5L (KL) engine Location of the engine mounting components and their torque specifications (part 2 of 3)— Millenia models equipped

0/1 MAZDA "L4

626 • MIATA • MILLENIA • PROTEGE

assembly and hand tighten the number 3 stay and tighten retainers G to 86 inch lbs. 2 mount sub bracket retainers. (10 Nm) and H to 77 ft. lbs. (104 Nm). 17. Tighten the number 2 engine mount • Number 4 engine bracket retainers 0 bolts A to 77 ft. lbs. (104 Nm). and tighten the bolts E to 44 ft. 18. Tighten the number 3 engine mount lbs. (60 Nm) and hand tighten . bolts F. sub bracket nuts D to 77 ft. lbs. (104 Nm). 19. Tighten the number 4 engine mount 13. Remove the engine hoist and install nuts and bolts C andF to 68 ft. lbs. (93 Nm) the engine support device • Joint shaft. Install a new circlip with 14. Install the engine mount member and tighten bolts B to 68 ft. lbs. (93 Nm) the opening facing up. Tighten the and hand tighten bolts A. bolts to 32-45 ft. lbs. (43-61 Nm). 15. Install the number 1 bracket and • Halfshafts. Install new circlips on tighten the retainers to 77 ft. lbs. (104 Nm) the inner CV-joint stub shafts, if and remove the engine support. equipped, and the intermediate shaft. Grease the shaft splines 16. Install the number 1 engine mount

before installing the halfshaft/inter¬ mediate shaft into the transaxle. • Ball Frontjoints pipe • Selector cable • Power steering pump •• A/C DriveCompressor belt

cable, perfor the follow a ust ingplaydjof m mentcable, : a. Measure the free the When c it should onbenec0.04-0.1 ting t 1 inch (1— 3mm), if he not turn adjustment nutaccAeleuntil ratorthe speci¬ fication is reached. b. Fully depress the accelerator pedal

75—104 {7.6—10.7, 55X3 — 77.3}

75—104 {7.6—10.7, 55.0—77.3}

75—104 {7.6 — 1 0.7, 55X3 — 77X3}

6.87—0.80 N m {70—100 kgfcm, 60.8— 86.7 in-lbf}

67—93 {6.8— 9.5, 50—68}

44—60 {4.4— 6.2, 32—44} 67—93 {6.8—9

67—93 {6.6— 9.5, 50—68}

67—93 {6.8— 9.5, 50—68}

\ 75— 104 {7.6— 10.7, 55.0—77X3} N m {kgf-m, ftlbf)

1

No.1 engine mount stay

4

2 3

No.1 engine mount bracket Engine mount member

5 6

No.4 engine mount bracket No.3 engine mount sub bracket Engine and transaxle

42356-MAZC-GDC Location of the engine mounting components and their torque specifications (part 3 of 3)— Millenia models equipped with the 2.5L (KL) engine

MAZDA 626 • MIATA • MILLENIA • PROTEGE

and check the throttle is wide open, if not adjust using nut B. 21. Install the remaining components in the reverse of removal. 22. Fill the engine and the transaxle with

the proper type and amount of fluids. Fill the cooling system. 23. Connect the negative battery cable, start the engine and check for leaks. 24. Check the ignition timing and the idle speed. 25. Check all fluid levels.

2.3L (KJ) ENGINE (-►The procedure for pulling the engine requires removing the transaxle along with it. As a result, when the halfshafts are pulled from the transaxle, a special recom¬ plug/side mended. gear holding tool is Remove the bolts A first and then the bolts B and remove the engine mount mem¬ ber— Millenia models equipped with the

17_0i; ■ *

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Properly relieve the fuel system 3. Drain the engine oil. pressure. 4. Drain the transaxle fluid. 5. • Drain Floodthe cooling system. 6. Remove or disconnect the following: • • • • • • •

Front wheels Air cleaner assembly Intake manifold cover Splash shield Charge air cooler duct Battery clamp, cover, battery, bat¬ Air duct tery carrier and battery air duct

• Accelerator cable • Dust cover • Drive belt leys • Crankshaft and vacuum pump pul¬

2.5L (KL) engine

.

Tighten the number 3 engine mount sub

• A/C compressor with the lines still attached and position aside • Power steering pump with the lines still attached and position aside • Radiator grille

bracket nuts D to specification — Millenia models equipped with the 2.5L (KL)

• Upper seal board • Radiator reservoir

engine

• Cooling fan connector and fan • Condenser fan motor connector and the fan • Oil cooler hose

42356-MAZC-GDH

Tighten the number 4 engine bracket retainers E to specification and hand tighten bolts F— Millenia models equipped with the 2.5L (KL) engine

• Radiator hose, bracket and the radi¬ • ator Selector cable • Front exhaust pipe Upper and lower ball joints •• FHalfshafts • Joint shaft 7. Support the engine using a suitable Tighten the number 4 engine mount nuts and bolts C andF to specification— Mil¬ lenia models equipped with the 2.5L (KL)

42356-MAZC-GDF

engine

Tighten the number 1 engine mount stay

support• device. Number 1 engine mount bracket. Refer to the accompanying illustra¬ tion for location. • Engine mount member retainers. Remove the bolts A first and then the bolts B and remove the mem¬ ber. Refer to the accompanying illustration for location.

retainers G and H to specification— Mil¬ lenia models equipped with the 2.5L (KL) engine

Engine load can damage the number 4 mount bolts holes when removing the bolts so make sure all weight is off the mount.

up

t

and Lif

adjustment nuts — Millenia models equipped with the 2.5L (KL) engine

equipped with the 2.5L (KL) engine

st , hoi vice de the h rt wit uppo s ine e eng ngin e the e of th

Accelerator cable A and throttle cable B

A to specification— Millenia models

e ghtmov wei re

Tighten the number 2 engine mount bolts

OC "£U

MAZDA 626 • MIATA • MILLENIA • PROTEGE

7.9— 10.7 Nm {80—110 kg< cm, 69.5—95.4 in lbl}

1 .0—1 .5 {10.2—15.2.

8.9—13.2}

10 1 2 3 4 5 6 7 8 9

Dynamic chamber cover Splash shield Charge air cooler air duct Air cleaner component Resonator Battery clamp

Air duct 11 12 13 15 14 16

Battery and battery cover Battery carrier Battery air duct

17

Accelerator cable Dust cover Drive belt Crankshaft pulley Vacuum pump pulley A/C compressor P/S oil pump

Location of the engine mounting components and their torque specifications (part 1 of 4)— Millenia models equipped with the 2.3L (KJ) engine 42356-MAZC-GDK

i 7-97 626 • MIATA • MILLENIA • PROTEGE

the engine/transaxle assembly slightly until the number 3 and 4 mounts are free from engine weight. • Number 4 engine mount bracket. 9 . Refer to the accompanying illustra¬ tion for location. • Number 3 engine mount sub bracket. Refer to the accompanying illustration for location. • Engine and transaxle assembly from the vehicle. Be careful the powertrain assembly does not

swing and strike the vehicle caus¬ ing damage.

To install:

Tighten the fasteners to the specificat ions shown in the accompany il ing lustration. 10.I When possible, leave the engine nstallation mounting nuts/bolts tight) until is theloose revers(hand e o f r all mounts are aligned and bolted.emThis oval.may help in aligning the engine and transmis¬ sion assembly in the vehicle. 1 1 . Install or connect the following:

■ »

C- I

• Number 4 engine bracket retainers and hand tighten the retainers 12. Using the hoist lower the powertrain assembly and hand tighten the number 3 mount sub bracket retainers. • Number 4 engine bracket retainers and tighten the bolts E to 44 ft. lbs. (60 Nm) and hand tighten bolts F. 13. Remove the engine hoist and install the engine support device 14. Install the engine mount member

7.9— 11.7 N-m {80—120 kgf cm, 70—104 in-lbf)

1

Radiator grille

2 3 4

Upper seal board Radiator reservoir Fan motor connector

5

Cooling fan component

6 7

Condenser fan component Oil cooler hose

8 9 10

Radiator hose Radiator bracket Radiator 42356-MAZC-GDL

Location of the engine mounting components and their torque specifications (part 2 of 4)— Millenia models equipped with the 2.3L (KJ) engine

17

9Q

I /"£ O

MAZDA 626 • MIATA • MILLENIA

PROTEGE

2 and0 tighten bolts. B to 68 ft. lbs. (93 Nm) and hand tighten bolts A. 15. Install the number 1 bracket and tighten the retainers to 77 ft. lbs. (104 Nm) and remove the engine support. 16. Install the number 1 engine mount stay and tighten retainers G to 68 inch lbs. (10 Nm) and H to 77 ft. lbs. (104 Nm). 17. Tighten the number 2 engine mount bolts A to 77 ft. lbs. (104 Nm). 18. Tighten the number 3 engine mount sub bracket nuts D to 77 ft. lbs. (104 Nm). 19. Tighten the number 4 engine mount nuts and bolts C and F to 68 ft. lbs. (93 Nm)

21. Power steering pump • Joint shaft. Install a new circlip Instwith all orthecoopening up. Tighten nnect thefacing following: Nm). the bolts to 32-45 ft. lbs. (43-61 • Halfshafts. Install new circlips on the inner CV-joint stub shafts, if equipped, and the intermediate shaft. Grease the shaft splines before installing the halfshaft/inter¬ mediate shaft into the transaxle. •• Ball Frontjoints pipe • Selector cable

•• A/C DriveCompressor belt 22. When connecting the accelerator cable, perform the following adjustment: a. Measure the free play of the cable, it should be 0.04-0.11 inch (1— 3mm), if ' not turn adjustment nut A until the speci¬ fication is reached. b. Fully depress the accelerator pedal and check the throttle is wide open, if nol adjust using nut B. 23. Install the remaining components in the reverse of removal.

N-m (kgf-m, ft-lbf)

1 2

Selector cable Front pipe

4

Lower ball joint

5

Drive shaft

3

Upper

6

Joint shaft

lateral link ball joint

42356-MA2C-GDM

Location of the engine mounting components and their torque specifications (part 3 of 4)— Millenia models equipped with the 2.3L (KJ) engine

MAZDA

1 7_9Q

626 • MIATA • MILLENIA • PROTEGE 75—104

75—1 04

{7.6—10.7,55.0—77.3)

{7.6—10.7, 55.0—77.3}

67—93 {6.8 — 9.5, 50-68)

67—93

{6.8— 9.5, 50—68}

Nm

1 2

No.1 engine mount bracket Engine mounting member

3

No. 4 engine mount bracket

4

No.3 engine mount sub bracket

5

Engine and transaxle

{kgf-m, ft lbf)

42356-MAZC-GDN

Location of the engine mounting components and their torque specifications (part 4 of 4)— Millenia models equipped with the 2.3L (KJ) engine

Remove the bolts A first and then the bolts B and remove the engine mount mem¬ ber— Millenia models equipped with the 2.3L (KJ) engine

Tighten the number 4 engine bracket retainers E to specification and hand tighten bolts F— Millenia models equipped with the 2.3L (KJ) engine

Tighten the number 1 engine mount stay retainers G and H to specification — Mil¬ lenia models equipped with the 2.3L (KJ) engine

A • MILLENIA n 626MAZ•DMIATA no"OU

PROTEGE

24. Fill the engine and the transaxle with the proper type and amount of fluids. Fill the cooling system. 25. Connect the negative battery cable, start the engine and check for leaks. 26. Check the ignition timing and the idle speed. 27. Check all fluid levels. Miata Tighten the number 2 engine mount bolts A to specification— Millenia models equipped with the 2.3L (KJ) engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Properly relieve the fuel system pressure. 3. Drain the engine oil. 4. Drain the cooling system. ing: 5. Remove or disconnect the follow¬ • Negative battery cable • Air cleaner assembly • Radiator

42356-MAZC-GDH

Tighten the number 3 engine mount sub bracket nuts D to specification— Millenia models equipped with the 2.3L (KJ) engine

• Accelerator cable and bracket from the throttle body • Fuel hose • Vacuum hoses and engine harness connectors • Heater hose • Accessory drive belts • Power steering pump and move it aside without disconnecting the hydraulic hoses • Air conditioner compressor and move it aside without disconnect¬ ing the refrigerant lines • Transmission 6. Disconnect the following electrical connectors, if equipped: • Steering pressure sensor electrical connector

To install:

8. Install or connect the following: • Engine assembly by tilting the engine downward and aligning the engine mounts with the crossmem¬ ber holes. Torque the nuts to 42-57 ft. lbs. (57-78 Nm). • Exhaust pipe to the manifold using a new gasket. Torque the nuts to 34 ft. lbs. (46 Nm). • All vacuum hoses 9. Connect the following electrical con¬ nectors, if equipped: • Steering pressure sensor electrical connector • TP sensor electrical connector • IAC valve electrical connector • HO2S electrical connector • Ignition coil electrical connectors • CKP sensor electrical connector • Ground electrical connectors • Fuel injector electrical connectors • Alternator electrical connectors • Oil pressure sensor electrical con¬ nector • Starter electrical connectors 10. Install or connect the following: • Transmission • Air conditioner compressor and steering pump • power Drive belt(s) • Any remaining vacuum hoses • Radiator and fans and all cooling • • • 11. 12. 13. 14.

system hosescable and bracket Accelerator Air cleaner assembly Negative battery cable Fill and bleed the cooling system. Fill the engine and transmission. Start the engine and check for leaks. Check the ignition timing and idle

Tighten the number 4 engine mount nuts

• Throttle Position (TP) sensor elec¬ trical connector

and bolts C andF to specification— Mil¬ lenia models equipped with the 2.3L (KJ)

• Idle Air Control (IAC) valve electri¬ cal connector

speed.

engine

• Heated Oxygen (HO2S) sensor elec¬ trical connector

2.QL (FS) ENGINE

• Ignition coil electrical connectors • Crankshaft Position (CKP) sensor electrical connector • Ground electrical connectors • Fuel injector electrical connectors • Alternator electrical connectors • Oil pressure sensor electrical con¬ nector • Starter electrical connectors ing: 7. Remove or disconnect the follow¬ Accelerator cable A and throttle cable Badjustment nuts— Millenia models equipped with the 2.3L (KJ) engine

• exhaust pipe from the exhaust manifold and install suitable lifting equipment onto the engine. • Engine from the vehicle

Protege

•-►The procedure for pulling the engine requires removing the transaxle along with it. As a result, when the halfshafts are pulled from the transaxle, a special plug/side gear holding tool is recom¬ mended.

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Properly relieve the fuel system 3. Drain the engine oil. pressure. 4. Drain the transaxle fluid. 5. Drain the cooling system. 6. Remove or disconnect the following:

MAZDA 626 • MIATA • MILLENIA • PROTEGE

• • • • • • •

Negative battery cable Radiator Air cleaner assembly Accelerator cable Fuel hoses Front exhaust pipe Any rods, pipes or cables related to the transaxle that would hinder removal • Battery • Fuse box • Power steering pump with the lines still attached and set aside

• A/C compressor with the lines still attached and position aside • Halfshafts • Roll dampener 7. Support the engine with a suitable engine support device. • Engine mount member retainers. Refer to the accompanying illustra¬ tion for location. • Number 3 engine mount. Refer to the accompanying illustration for location. • Number 1 engine mount. Refer to

1

Roll damper

2 3 4

Engine mount member No.3 Engine mount No.1 Engine mount

-I7.Q-I ■ »

wl

the accompanying illustration for location. • Number 2 engine mount. Refer to the accompanying illustration for location. • Number 4 engine mount. Refer to the accompanying illustration for location. • Engine and transaxle assembly from the vehicle To install:

8. Installation is the reverse of removal. Tighten the fasteners to the spec-

5 6

No.2 Engine mount No.4 Engine mount

7

Engine, transaxle 42356-MA2C-GGA

Location of the engine mounting components and their torque specifications — Protege models equipped with the 2.0L (FS) engine

MAZDA

17-32

626 • MIATA • MILLENIA • PROTEGE

No.3 ENGINE MOUNT

No. 4 ENGINE MOUNT A

CLEARANCE

J

• Number 3 engine mount, refer to the number 4 mount tightening sequence. Tighten the fasteners to the specifications shown in the accompanying illustration. • Engine mount member. Tighten the fasteners to the specifications shown in the accompanying illus¬ tration. • Roll damper, refer to the illustration or proper assembly. • Halfshafts. Install new circlips on the inner CV-joint stub shafts, if equipped, and the intermediate shaft. Grease the shaft splines • •• •

before installing the halfshaft/inter¬ mediate shaft into the transaxle. A/C compressor Power Battery steering pump Fuse box

• Any rods, pipes or cables related to the transaxle • Front exhaust pipe. Always install new gaskets and/or O-rings. Use new self-locking nuts, especially or the • Fuelexhaust. hoses MTX

, 42356-MAZC-GGB

Tighten the number 4 engine bracket retainers in the sequence shown — Protege models equipped with the 2.0L (FS) engine

ifications shown in the accompanying illustration.

unt i ma l y

tig loo (h nut mo a u h Thti) asne bolnd arse/boali all ntmion ltsgn d ugn t s e and d.tr the ed eng hel intsali an sio p as gni in the veihne sm is icl n sem ng ¬ e bl . y Tig the fas to the spe t c h sho ten in the acecners illifica ust ti omp fol wn rat ons any low ion s: ing

b. Tighten the number 4 engine mount bolts and nuts A-H. c. Tighten the number 3 engine mount bolts and nuts l-N. d. Measure the number 4 mount clearance which inch (3-4mm). loosen the nuts using the same

should be 0.12-0.15 If not within specification, and bolts and retorque procedure.

as

• Number 1 engine mount. Tighten the fasteners to the specifications shown in the accompanying illustration.

M. A-

s nut

ts

d

an

bol

t

un

mo

ine

eng

Free play 1.5— 4.0 mm

{0.06—0.15

in}

'•-Ifposition. stopper B will not unlock, it may be necessary to carefully bend back tab C out a little using a suitable pry tool.

c. Push or pull the cable housing directly behind the spring. d. Turn the stopper B to the lock posi¬ tion. e. Measure the free play which should be 0.04-0.11 inch (1-3mm) and make sure the cable free play is within specification. f. Move the white locking tab to the

rc allo nst

I 11

lock position and check for proper accel¬ erator operation. 13. Install or connect the following: •• Air cleaner assembly Radiator

onn

• Negative battery cable 14. Fill the engine and the transaxle with and amount of fluids. Fill proper type the cooling the system.

ng:

owi

oll

hef ectt Assemble the roll damper as illustrated — Protege models equipped with the 2.0L (FS) engine

12. When connecting the accelerator cable, perform the following adjustment: a. Move the white locking tab to the unlock position. b. Turn stopper B to the to the unlock

Accelerator cable adjustment compo¬ nents — Protege models equipped with the 2.0L (FS) engine

15. Connect the negative battery cable, start the engine and check for leaks. 16. Check the ignition timing and the idle speed. 17. Check all fluid levels.

MAZDA 626 • MIATA • MILLENIA

1.6L (ZM) ENGINE

2. Properly relieve the fuel system

(■►The procedure for pulling the engine requires removing the transaxle along with it. As a result, when the halfshafts are pulled from the transaxle, a special plug/side gear holding tool is recom¬ mended.

the prec in the beginnin of this sec¬ g tion. autions

pressure. 3. Drain the engine oil. 4. Drain the transaxle fluid. 5. Drain the cooling system. ing: 6. Remove or disconnect the follow¬ • Battery • Air cleaner, air hose and resonance chamber • Front exhaust pipe

• PROTEGE

1

Air cleaner bracket Battery carrier bracket No.l engine mount Engine mount member

5 6 7

No.2 engine mount No. 4 engine mount No.3 engine mount

8

Engine, transaxle

OO

• Any rods, pipes or cables related to the transaxle that would hinder • removal Halfshafts • Power steering pump with the lines still attached and set aside

refer to

2 3 4

■»

• Accelerator cable and bracket •• Heater Radiatorand vacuum hoses • Drive belt • Fuel hoses

. Before s ervicin

g the ve hicle,

17_QQ

42356-MAZC-GHD

Location of the engine mounting components and their torque specifications— Protege models equipped with the 1.6L (ZM) engine

17-34

MAZDA 626 • MIATA • MILLENIA • PROTEGE

I

Remove

the number 2 engine mount nut

retainers A, then the engine mount retain¬

Number 4 engine mount retainer torque

ers— Protege models equipped with the 1.6L (ZM) engine

sequence on models with a manual transaxle— Protege models equipped with the 1.6L (ZM) engine

• A/C compressor with the lines still attached and position aside • Air cleaner bracket • Battery carrier bracket 7. Support the engine with a suitable engine support device. • Number 1 engine mount. Refer to the accompanying illustration for location. • Number 2 engine mount nut A. Refer to the accompanying illustra¬ tion for location. • Engine mount member retainers. . Refer to the accompanying illustra¬ tion for location. • Number 2 engine mount. Refer to the accompanying illustration for location. 8. Remove the engine support device and attach a hoist and chain to the engine. • Number 4 engine mount. Refer to the accompanying illustration for location. • Number 3 engine mount. Refer to the accompanying illustration for location. • Engine and transaxle assembly from the vehicle.

ATX

12. Remove the hoist and chain and install the engine support device. • Number 2 engine mount nut A, then tighten the mount member bolt and nut. Tighten the fasteners to the specifications shown in the exploded view of the engine mounting assembly illustration. • Number 1 engine mount bolts A and then the bolt B. Tighten the fasteners to the specifications shown in the accompanying illus¬ tration. • Battery carrier bracket • Air cleaner bracket •• A/C Powercompressor steering pump • Halfshafts • • • •

Number 4 engine mount retainer torque sequence on models with a automatic transaxle — Protege models equipped with the 1.6L (ZM) engine

mounting nuts/bolts loose (hand tight) until all mounts are aligned and bolted. This may help in aligning the engine and transmis¬ sion assembly in the vehicle. • Tighten the number 3 engine mount bolt and nut in the sequence illus¬ trated, then tighten the mount stay

To install:

In 9. Installation is the reverse stofall removal. orc onn Tighten the fasteners to the specifications e shown in the accompanying illustration. ct he fol

low

ing

:

bolt and nut A. Tighten the fasten¬ ers to the specifications shown in the exploded view of the engine mounting assembly illustration. • Tighten the number 4 engine mount bolts A, then tighten bolts B. Tighten the fasteners to the specifi¬ cations shown in the exploded view of the engine mounting assembly illustration.

Any rods, pipes or cables related to the Fueltransaxle hoses that were removal Drive belt Radiator

• Heater and vacuum hoses • Accelerator cable and bracket • Front exhaust pipe

Batter y •• Air cleaner, air hose and resonance chamber 13. Fill the engine and the transaxle with the proper type and amount of fluids. Fill the cooling system. 14. Connect the negative battery cable, start the engine and check for leaks. 15. Check the ignition timing and the idle speed. 16. Check all fluid levels.

1.8L (FP) ENGINE iM-The procedure for pulling the engine requires removing the transaxle along with it. As a result, when the halfshafts are pulled from the transaxle, a special plug/side gear holding tool is recom¬ mended.

1 . Before servicing the vehicle, refer to the tion.precautions in the beginning of this sec¬ 2. Properly relieve the fuel system 3. Drain the engine oil. pressure. 4. Drain the transaxle fluid. 5. Drain the cooling system. 6. Remove or disconnect the following: • Radiator Negative battery cable • Air cleaner

42356-MAZC-GHF

Tighten the number 3 engine mount bolt

42356-MAZC-GHI

and nut in this sequence and the mount

Number 1 engine mount retainer torque

stay bolt A— Protege models equipped with the 1.6L (ZM) engine

sequence —Protege models equipped with the 1.6L (ZM) engine

• Accelerator cable • Fuel hoses • Front exhaust pipe • Any rods, pipes or cables related to

MAZDA 626 • MIATA • MILLENIA • PROTEGE

• • • • • •

the transaxle that would hinder removal Battery Fuse box Drive belt Power steering pump with the lines still attached and set aside A/C compressor with the lines still attached and position aside Halfshafts

engine suppor device. t • Engine mount member retainers • Number 3 engine mount. Refer to the accompanying illustration for location. • Number 4 engine mount. Refer to the accompanying illustration for location. • Number 1 engine mount. Refer to

. Suppor t the engine

the accompanying illustration for location. • Number 2 engine mount. Refer to the accompanying illustration for location. 8. Remove the engine support device and attach a hoist and chain to the engine. • Engine and transaxle assembly from the vehicle. To install:

9. Installation is the reverse of removal. Tighten the fasteners to the specifications shown in the accompanying illustration. 10. When possible, leave the engine mounting nuts/bolts loose (hand tight) until all mounts are aligned and bolted. This may help in aligning the engine and transmis¬ sion assembly in the vehicle. 1 1 . Install or connect the following: • Engine and transaxle assembly

17.QC ■*

OU

• Number 2 engine mount . Tighten the fasteners to the specifications shown in the accompanying illus¬ tration. • Number 1 engine mount. Tighten the fasteners to the specifications shown in the accompanying illus¬ tration. • Hand tighten the number 3 and 4 engine mount bolts A-M, tighten number 4 bolts and nuts A-G, then tighten the number 3 mount bolts and nuts H-M. Tighten the fasten¬ ers to the specifications shown in the exploded view of the engine mounting assembly illustration. Measure the number 4 mount clearance, if not 0.12-0.15 inch (3-4mm), repeat the tightening sequence.

with a suita

ble

1

Engine mount member

4

No.2 Engine mount

2

No.3, No.4 Engine mount

5

Engine and transaxle

3

No.1 Engine mount 42356-MAZC-GJA

Location of the engine mounting components and their torque specifications— Protege models equipped with the 1.8L (FP) engine

MAZDA

17-36

626 • MIATA • MILLENIA • PROTEGE

No.4 ENGINE MOUNT

No.3 ENGINE MOUNT {3.8— 6 J. 28—38}

A

CLEARANCE

E C

H

B

CLEARANCE

Nm

{kgf-m, fMM)

42356-MAZC-GGD

AT;

Exploded view of the water pump assem¬ bly— 1.6L (ZM) engines

CLEARANCE • Water pump using a new gasket. Torque Nm). the main bolts to 12-17 ft. lbs. (16-23 Nm) and the upper left hand bolt to 28-38 ft. lbs. (38-51

B

CLEARANCE

• Water inlet pipe with new gasket and 0— ring and tighten the bolts to 12-17 ft. lbs. (16-23 Nm) • A/C compressor • Power steering oil pump • Timing belt MTX 42356-MAZC-GJB

Number 3 and 4 engine mount retainer torque sequence— Protege models equipped with the 1.8L (FP) engine

• Engine mount member. Tighten the fasteners to the specifications shown in the accompanying illus¬ tration and remove the support device. • Halfshafts • Power steering pump • A/C compressor • Fuse box • Battery • Any rods, pipes or cables related to the transaxle that were removed • Front exhaust pipe • Fuel hoses • Accelerator cable • Air cleaner • Radiator • Drive belt • Negative battery cable 12. Fill the engine and the transaxle with the proper type and amount of fluids. Fill the cooling system. 13. Connect the negative battery cable, start the engine and check for leaks. 14. Check the ignition timing and the idle speed. 15. Check all fluid levels.

Water Pump REMOVAL & INSTALLATION

• Exhaust manifold insulator • Fresh air duct • Negative battery cable 6. Fill and bleed the cooling system. 7. Start the engine, check for leaks and repair if necessary. 1.8L (FP) Engines

1 . Before servicing the vehicle, refer to 1.6L (ZM) Engines

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec tion. 2. Drain the cooling system. ing:3. Remove or disconnect the follow¬ • • • •

Negative battery cable Fresh air duct Exhaust manifold insulator Timing belt

• Power steering oil pump with the lines attached and set aside • A/C compressor with the lines attached and set aside • Water inlet pipe Water pumpp mounting bolts • Wat er pum To install:

4. Clean all gasket mating surfaces. 5. Install or connect the following:

the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. ing: 3. Remove or disconnect the follow¬ •• Timing Negativebelt battery cable • Power steering oil pump adjuster , • Water pump • Water pump mounting bolts To install:

4. Clean all gasket mating surfaces. 5. Install or connect the following: • Water pump using a new gasket. Make sure the gasket is installed with the sealing ring facing the the bolts to 14-18 ft TorqueNm). pump.(19-25 lbs. •• Timing Power steering oil pump adjuster belt • Negative battery cable 6. Fill and bleed the cooling system.

MAZDA 626 • MIATA • MILLENIA • PROTEGE

17_Q7 ■ *

O I

bolts to 14-18 ft. lbs. (19-25 Nm). Torque the bolt from the water pump to the alterna¬ tor bracket to 28-38 ft. lbs. (38-51 Nm). 7. Install or connect the following: • Coolant inlet pipe with a new gas¬ ket. Torque the coolant inlet pipe bolts to 14-18 ft. lbs. (19-25 Nm). • Idler, on models not equipped with • power Power steering steering pump • Timing belt and the timing belt covers • Negative battery cable 8. Fill and bleed the cooling system. 9. Start the engine and bring to normal operating temperature. Check for leaks.

19—25 {1.9—2.6,14—18}

2.0L (FS) Engines

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Remove or disconnect the following: • Negative battery cable • Timing belt

N-m {kgf-m, ft-lbf} 19—25 {1.9—2.6,14—18}

1

P/S oil pump adjuster

2

Water pump

• Power steering oil pump adjuster • Water pump • Water pump mounting bolts To install: 42356-MAZC-GJC

Exploded view of the water pump assembly— 1 .8L (FP) engines

repa

ir

if nece

ssar

y.

1.8L (BP) Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable. 3. Drain the engine coolant. 4. Remove or disconnect the following: • Timing belt covers and timing belt

• Power steering pump, leaving the lines attached and set aside • Idler, on models not equipped with power steering •• Wate Coolant pipe and gasket r puminlet p To install:

5. Clean all gasket mating surfaces. 6. Using a new gasket, install the water pump on the engine. Torque the mounting

4. Clean all gasket mating surfaces. 5. Install or connect the following: • Water pump using a new gasket. Torque the bolts to 14-18 ft. lbs. (19-25 Nm). • Power steering oil pump adjuster. Torque the bolts to 12-16 ft. lbs. (16-22 belt Nm). • Timing • Negative battery cable 6. Fill and bleed the cooling system. 7. Start the engine, check for leaks and repair if necessary.

SEALING RING

1 . P/S oil pump 2. Idler (without P/S oil pump) 3. Water hose 4. Water pump

WATER

PUMP SIDE

5. Water inlet pipe

14—18} 19— 25

{1.9— 2.6,

42356-MAZC-GJD

Make sure the gasket is installed with the sealing ring facing the pump— 1.8L (FP) engines

N-m {kgf-m, ft-lbf} 1 9—25 {1 .9—2.6, 1 4—1 8} 42356-MAZC-G94

Exploded view of the water pump assembly— 1 .8L (BP) engines

626 • MIATA 17-38 ^Z.DA

• MILLENIA • PROTEGE 6. Fill the cooling system. 7. Start the engine and check for leaks.

FS

Heater Core REMOVAL & INSTALLATION Miata

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable.

|C CAUTION After disconnecting the battery, wait for more than 1 minute for the SAS to deplete its stored energy.

Nm

19 — 25

3. Drain the cooling system into a clean container for reuse. 4. Disconnect the heater hoses from the heater core.

{kgfm, ft lbf}

{1.9— 2.6, 14—18}

1 2

P/S oil pump adjuster Water pump 42356-MAZC-G5A

Exploded view of the water pump assembly — 2.0L (FS) engines

• Water pump

2.3L (KJ) Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Remove or disconnect the following: • Negative battery cable • Timing belt and water pump together

To install:

4. Clean the mating surfaces. 5. Install or connect the following: • Water pump using a new gasket. Tighten the bolts to 14-18 ft. lbs. (19-25 Nm). • Number 3 engine mount bracket and tighten the bolts to 32-44 ft. lbs. (44-60 • Timing belt Nm)

To install:

4. Clean the mating surfaces. 5. Install or connect the following: • Water pump using a new gasket along with the timing belt. Torque the bolts to 14-18 ft. lbs. (19-25 Nm).

• Negative battery cable

5. Discharge and recover the air condi¬ tioning system refrigerant. 6. At the driver’s side, remove the SAS module and the steering wheel by removing or disconnecting the following: • Place the wheel in the straight¬ ahead position and turn the ignition switch to LOCK • Cover clips at both sides of the steering wheel • Steering wheel-to-SAS module bolts • SAS module from the steering wheel and disconnect the electrical connector • Steering wheel-to-column nut • Steering wheel from the steering column using a suitable puller 7. At the passenger's side, remove the SAS module by removing or disconnecting the following: • Glove compartment and the glove compartment cover • SAS module-to-dash bolts

• Negative battery cable 6. Fill the cooling system. 7. Start the engine, check for leaks and repair if necessary. 2.5L (KL) Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable. 3. Drain the cooling system. • Timing belt • Number 3 engine mount bracket • Water pump bolts

1 2

No.3 engine mount bracket Water pump 42356-MAZC-G06

Exploded view of the water pump assem¬ bly— 2. 5L (KL) engines

View of the SAS module and the steering wheel — Miata

33112GG0

MAZDA 17_OQ 626 • MIATA • MILLENIA • PROTEGE

■ *

• SAS module and disconnect the • electrical Console connector 8. Remove the instrument cluster by removing or disconnecting the following: • A-pillar trim at both sides • Lower panel • Instrument cluster hood • Instrument cluster-to-dash screws and the instrument cluster • Hood release lever • Control wire from the heater unit and the blower unit • Steering column-to-instrument panel bolts and lower the steering column • Instrument panel-to-chassis bolt covers and the bolts • Instrument panel with the help of an assistant 9. Remove or disconnect the following: • Heater unit-to-evaporator housing seal plate • Heater unit-to-chassis nuts and the heater unit 10. Separate the heater unit cases and remove the heater core.

87 — 130 in-lbf}

1

Connector

2

Nut

3

Bolt

4

Passenger-side

To install:

air bag module

1 1 . Install the heater core and assemble the heater unit cases.

93112GH1

View of the passenger’s side SAS module— Miata

7.9— 11.7 N m

%

{80—120 kgf-cm, 70—104 7.9— 11.7 N m

In-lbf)

7.9—11.7 N m {80 — 120 kgf-cm, 70 — 104 in-lbf)

37—53 {3.7— 5.5, 27—39}

L13

(2)

37—53 {3.7— 5.5, 27—39}

Nm

1

Cover

3

Connector

2

Bolt

4

Dashboard

{kgf-m, ft-lbf)

93112GH2

View of the instrument panel— Miata

17

/Ifl MAZDA

I I "HU

626 • MIATA • MILLENIA • PROTEGE

12. Install or connect the following: • Heater unit-to-chassis nuts and the heater unit • Heater unit-to-evaporator housing seal plate 13. Install the instrument cluster by installing or connecting the following: Instrument panel with the help of an assistant Instrument panel-to-chassis bolt covers and the bolts Steering column-to-instrument Control wire to the heater unit and panel bolts the blower unit Hood release lever Instrument cluster and the instru¬ ment cluster-to-dash screws Instrument cluster hood Lower panel A-pillar trim at both sides Console

1

Ashtray

2

Power window switch

3 4

Shift lever knob (MT) Screw

5

Console

14. At the passenger’s side, install the SAS module by installing or connecting the following:

93112GH3

View of the console— Miata

• SAS module and connect the elec¬ trical connector • SAS module-to-dash bolts • Glove compartment cover and the glove compartment 15. At the driver’s side, install the SAS module and the steering wheel by installing or connecting the following: • Steering wheel-to-column nut. Torque the steering wheel nut to 29-36 ft. lbs. (40-49 Nm). • SAS module to the steering wheel and connect the electrical connec¬ tor • Steering wheel-to-SAS module bolts. Torque the steering columnto-SAS module bolts to 70-104 inch lbs. (8-12 Nm). • Cover clips at both sides of the steering wheel 16. Connect the heater hoses to the heater core. 17. Refill the cooling system. 18. Connect the negative battery cable. 19. Evacuate, charge and leak test the aii conditioning system refrigerant.

7.9— 10.7 Nm (80—110 kgf-cm, 69.5 — 95.4 in-lbf}

20. Operate the engine to normal oper¬ temperatures; then, check the cli¬ ating mate control operation and check for leaks. 1

Heater hose

2

Nut

3

Heater unit

Millenia

93112GH4

View of the heater unit and the heater unit-to-evaporator unit seal plate— Miata

i . Before tserore servicing me 1. the verucie, vehicle, itre the precautions in the beginning of th tion.

'

MAZDA 626 • MIATA • MILLENIA • PROTEGE

17-41

7. Remove the rear console by remov¬ ing or disconnecting the following: • Bake boot Rear console's box • Center panel • Rear console 8. Remove or disconnect the following: • A-pillar trim at both sides • Undercover at the passenger’s side • Upper and lower steering column covers • Electrical connectors and remove the combination switch from the column • steering Meter hood • Electrical connectors and remove the instrument cluster • Steering column-to-chassis bolts and the steering column • Hood release lever • Both side panels

1

Cover

2

Heater core

3 4

Air mix link Airflow mode link

5

Case (RH)

6

Case (LH)

7

Air mix door

8

Airflow mode door

• Instrument panel with the help of an assistant 9. Remove the evaporator housing by removing or disconnecting the following: • Air conditioning system refrigerant lines and discard the gaskets • Aspirator hose • Power transistor connector • MAX-HI connector

93112GH5

Exploded view of the heater core and heater unit assembly— Miata

2. Disconnect the negative battery cable.

: CAUTION After disconnecting the battery, wait for more than 1 minute for the SAS to deplete its stored energy.

• Glove compartment and the glove compartment cover • SAS module-to-dash bolts • SAS module and disconnect the electrical connector

• Evaporator temperature connector • Evaporator housing assembly 10. Disconnect and remove the heater unit assembly. 1 1 . Separate the heater unit cases and remove the heater core.

3. Drain the cooling system into a clean container for reuse. 4. Discharge and recover the air condi¬ tioning system refrigerant. 5. At the driver’s side, remove the SAS module and the steering wheel by removing or disconnecting the following: • Place the wheel in the straight¬ ahead position and turn the ignition switch to LOCK • Cover clips at both sides of the steering wheel • Steering wheel-to-SAS module clips • SAS module from the steering wheel and disconnect the electrical connector • Steering wheel-to-column nut • Steering wheel from the steering column using a suitable puller 6. At the passenger's side, remove the • SAS module by removing or disconnecting the following:

1

Bolt

2

Connector

3

Driver-side air bag module 93112GE5

Exploded view of the SAS module and steering wheel assembly— Millenia

AO

MAZDA

*tL

626 • MIATA • MILLENIA • PROTEGE To install:

Bolt Connector Passenger-side air bag module

93112GE6

12. Install the heater core and assemble the heater unit cases. 13. Connect and install the heater unit assembly. 14. Install the evaporator housing by installing or connecting the following: • Evaporator housing assembly • Evaporator temperature connector • MAX-HI connector • Power transistor connector • Aspirator hose • Air conditioning system refrigerant lines using new gaskets 15. Install or connect the following: • Instrument panel with the help of an assistant • Both side panels

Exploded view of the passenger’s side SAS module— Millenia

1 2

Air bag module Locknut

3

Steering wheel

4

Dashboard, console, and steering shaft component

5

Column cover

6

Combination switch

7

Air duct

8

Flasher unit

9

Bracket

10 ii 13 12

Steering shaft component Universal joint (intermediate shaft) Cover Shaft seal Intermediate shaft

15 14 17 16

Collapsible shaft Set plate Dust cover 93112GE9

Exploded view of the steering wheel and steering column assembly — Millenia

MAZDA 17_/|Q 626 • MIATA • MILLENIA • PROTEGE

1

Rear console box

8

2

Brake boot

3 4

Center panel Bracket

9 10

5

Rear console

6

Under cover

13

Combination switch

7

Glove compartment

14

Meter hood

11 12

Glove compartment cover

Upper column cover Lower column cover Driver-side air bag module Steering wheel

Exploded view of the instrument panel and rear console assemblies — Millenia

15 16 17

■ *

HhO

Instrument cluster Passenger-side air bag module

18

Steering shaft Hood release lever

19 20

Side panel Dashboard 93112GE8

A A MAZDA 626 • MIATA • MILLENIA • PROTEGE

16 1

Heat duct

2 3 4

Tapping screw Air mix actuator Air mix crank

5 6 7

Water temperature sensor Polyurethane foam (thick) Polyurethane foam (thin)

8 9 10

Tapping screw Heater core bracket (1) Heater core bracket (2)

11 12

Rod stopper Airflow mode rod

13 14

Tapping screw Airflow mode actuator

15

Tapping screw

19 18 17 20

22 21 23 25 26 24 28 29 27

Link collar Airflow mode main link Tapping screw Link collar Airflow mode sub link (VENT) Airflow mode sub link (HEAT) Airflow mode sub link (DEFROSTER) Airflow mode crank Polyurethane protector (DEFROSTER) Polyurethane protector (VENT) Polyurethane protector (SIDE VENT) Heater case Tapping screw(4) Heater case (3)

30

33 31 32 35 37 38 36 34 39 42 40 41

Vent door Heat door Defroster door Side vent door Heater case (1) Tapping screw Heater case (2) Collar Air mix rod Air mix main door Air mix sub door Air mix guide door Heater core

93112GE7

Exploded view of the heater core and heater case assembly — Millenia

MAZDA 626 • MIATA • MILLENIA • PROTEGE

17-45

• Hood release lever • Steering column and the steering column-to-chassis bolts • Instrument cluster and connect the electrical connectors • Meter hood • Combination switch to the steering column and connect the electrical connectors • Upper and lower steering column covers • Undercover at the passenger’s side • A-pillar trim at both sides 16. Install the rear console by installing or connecting the following: • Rear console • Center panel • Brake boot • Rear console’s box 17. At the passenger’s side, install the SAS module by installing or connecting the following: • SAS module and connect the elec¬ trical connector • SAS module-to-dash bolts • Glove compartment cover and the glove compartment 18. At the driver’s side, install the SAS module and the steering wheel by installing or connecting the following: • Steering wheel to the steering column • Steering wheel-to-column nut. Torque the nut to 29-36 ft. lbs. (40-49 Nm). • SAS module to the steering wheel and connect the electrical connec¬ tor. Torque the bolts to 79-113 inch lbs. (9-13 Nm). • Steering wheel-to-SAS module clips • Cover clips at both sides of the steering wheel 19. Refill the cooling system. 20. Connect the negative battery cable. 21. Evacuate, charge and leak test the air conditioning system refrigerant. 22. Operate the engine to normal operat¬ ing temperatures; then, check the climate control operation and check for leaks.

7.9—11.7 N m {80—120 kgf-cm, 70—104

1

Cap

2

Bolt

3

Connector

4

Driver-side air bag module

inlbf}

93112GG4

Exploded view of the SAS module and the steering wheel assembly— Protege

Protege

1. Before servicing the vehicle, refer to the precautions in the beginning of this secI tion. 2. Disconnect the negative battery cable.

CAUTION After disconnecting the battery, wait for more than 1 minute for the SAS to deplete its stored energy.

{70 — 100 kgf-cm. 60.8 — 86.7 in lbf} Exploded view ot the passenger’s side SAS module— Protege

93112GG5

17-46

1 2 3 4 5 6 7 8

MAZDA 626 • MIATA • MILLENIA • PROTEGE

Airbag module Locknut Steering wheel Column cover Combination switch Lower panel Key interlock cable Steering shaft

Exploded view of the steering column assembly — Protege

9 10 12 11 15 13 14

Shaft seal Set plate Dust cover Universal joint

Steering lock mounting bolts and bracket Steering lock component Cylinder outer component

MAZDA 17.y|7 626 • MIATA • MILLENIA • PROTEGE

9

. 3. Drain the cooling system into a clean • Steering wheel-to-SAS module bolts container tor reuse. 4. Disconnect the heater hoses from the • SAS module from the steering 1 wheel and disconnect the electrical heater core. connector 0 5. Discharge and recover the air condi¬ tioning system refrigerant. • Steering wheel-to-column nut .• Steering wheel from the steering 6. Place the wheel in the straight-ahead 8 column using a suitable puller position and turn the ignition switch to LOCK. . o d SAS modul by remov 7. At the driver’s side, remove the SAS ing r isconnect e f t ing h o e llowin module and the steering wheel by removing g: or disconnecting the following: • Glove compartment and the glove compartment cover • Cover clips at both sides of the At th•e SAS module-to-dash bolts steering wheel passe nger' s side , rem ove t he

1

Defroster nozzle

2

Side demister duct

3

Duct

4

Center duct

5

Dashboard

■ »

** I

• SAS module and disconnect the electrical connector

disconnecti the following: Removneg the nsole ifbequipped • Shift lever coknob, with a yr manual transmission emoving or • Console’s cover • Console-to-chassis screws and console t f or discon removi nectin he ollowing: ng • Steering column g cover Re•movElectrical connectors and remove e the combin the combination atioswitch-to-steering n swi tch b y

6

Crush pad

7

Pad

8

Ventilator grille

9

Passenger-side lower panel

member 93112GG7

Exploded view of the dashboard assembly — Protege

17-48

MAZDA 626 • MIATA • MILLENIA • PROTEGE

electrical connectors, if equipped

column bolts and the combination switch 1 1 . Remove the instrument cluster by: • Meter hood

with the wire-type climate control unit • Electrical connectors and the bolts • Dashboard-to-chassis bolts • Dashboard from the vehicle with

• Instrument cluster-to-dash panel screws • Electrical connectors and remove the instrument cluster 12. Remove or disconnect the following: 3 • Lower panel • Hood release cable installation nut . • Side wall trim

1

1

Connector

2

Cooling unit 9311 2GG8

View of the evaporator housing assem¬ bly — Protege

• • • •

“A" pillar trim at both sides Side panel Antenna connector Blower motor and heater unit

the help of an assistant • Passenger’s side lower panel • Air intake wire from the climate O-rings unit control • Air conditioning refrigerant lines from the evaporator and discard the • Evaporator electrical connector(s) • Evaporator housing

remo

ve

Disa

the heate core. r

ssem

ble

the h eater hous ing

and

rod (2) Air Air Air Air Air

mix link rod (1)(1) crank mix mix crank (2) mix mix

Airflow Airflow Airflow Airflow

mode link(1) mode main sub link mode sub link (2)

mode case case mode Airflow case Heater Heater case Heater Heater Heater core

sub link (3) (1) (2) crank (3) (4)

93112GG9

Exploded view of the heater housing assembly — Protege

i

626 • MIATA To install:

14. Install the heater core and assemble the heater housing. 15. Install or connect the following: • Evaporator housing • Evaporator electrical connector(s) • Air conditioning refrigerant lines to the evaporator using new O-rings • Air intake wire to the climate con¬ trol unit • Passenger’s side lower panel • Dashboard to the vehicle with the help of an assistant • Dashboard-to-chassis bolts • Electrical connectors and the bolts • Blower motor and heater unit elec¬ trical connectors, if equipped with the wire-type climate control unit • Antenna connector • Side panel • A-pillar trim at both sides • Side wall trim • Hood release cable installation nut • Lower panel 16. Install the instrument cluster by installing or connecting the following: • Instrument cluster and connect the electrical connectors • Instrument cluster-to-dash panel screws • Meter hood 17. Install the combination switch by installing or connecting the following: • Electrical connectors and install the combination switch-to-steering column bolts and the combination switch

• Cover clips at both sides of the steering wheel 21 . Connect the heater hoses to the heater core. 22. Refill the cooling system. 23. Connect the negative battery cable. 24. Evacuate, charge and leak test the air conditioning system. 25. Operate the engine to normal operat¬ ing temperatures; then, check the climate control operation and check for leaks.

626 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable.

I- CAUTION After disconnecting the battery, wait for more than 1 minute for the SAS to deplete its stored energy.

3. Drain the cooling system into a clean container for reuse. 4. Discharge and recover the air condi¬ tioning system refrigerant. 5. Place the wheel in the straight-ahead

MAZDA MILLENIA* PROTEGE

17-49

position and turn the ignition switch to LOCK. 6. At the driver's side, remove the SAS module and the steering wheel removing or disconnecting the following: • Cover clips at both sides of the steering wheel • Steering wheel-to-SAS module bolts • SAS module from the steering wheel and disconnect the electrical connector • Steering wheel-to-column nut • Steering wheel from the steering column using a suitable puller 7. At the passenger's side, remove the SAS module by removing or disconnecting the following: • Glove compartment and the glove compartment cover • SAS module-to-dash bolts • SAS module and disconnect the electrical connector 8. Remove the instrument cluster by removing or disconnecting the following: • Instrument cluster meter hood • Instrument cluster-to-dash screws, the instrument cluster and discon¬ nect the electrical connectors 9. Remove the climate control assembly

• Steering column cover 18. Install the console by installing or connecting the following: • Console and the console-to-chassis screws • Console’s cover • Shift lever knob, if equipped with a manual transmission 19. At the passenger’s side, install the SAS module by installing or connecting the following: • SAS module and connect the elec¬ trical connector • SAS module-to-dash bolts • Glove compartment and the glove compartment cover 20. At the driver’s side, install the SAS module and the steering wheel by installing or connecting the following: • Steering wheel-to-column nut • SAS module from the steering wheel and connect the electrical connector • Steering wheel-to-SAS module bolts

1

Bolt

2

Connector

3

Driver-side air bag module 93112GH6

Exploded view of the steering wheel and SAS module— 626

17-50

MAZDA 626 • MIATA • MILLENIA • PROTEGE

by removing or disconnecting the follow¬ ing: • Climate control meter hood • Climate control assembly screws • Climate control assembly and dis¬ connect the electrical connector and the assembly 10. Remove the audio unit by removing or disconnecting the following: • Hole covers by inserting a small tape-wrapped flathead screwdriver into the slot and carefully pry off the hole covers • Using 2 removal tools 49 UN01 050 or equivalent, insert them into sides of the audio unit. • Slide audio unit outward and for¬ ward • Electrical connectors and the antenna jack 11. Remove the instrument panel by removing or disconnecting the following: • Upper center panel cover • Dash panel-to-chassis bolts • Dash panel with the help of an assistant 12. Remove the evaporator housing by removing or disconnecting the following: • Center lower panel • Refrigerant lines from the air condi¬ tioning evaporator and discard the gaskets • sary Blower motor assembly, if neces¬ • Evaporator assembly fasteners and remove the evaporator assembly 13. Remove or disconnect the follow¬ ing: • Rear heater duct • Heater housing fasteners and the heater housing • Airflow mode actuator 14. Separate the heater housing and remove the heater core.

1

Connector

2

Bolt

3

Passenger-side air bag module

Exploded view of the passenger’s side SAS module — 626

To install:

15. Install the heater core and assemble the heater housing. 16. Install or connect the following: • Airflow mode actuator • Heater housing and the heater housing fasteners • Rear heater duct 17. Install the evaporator housing by installing or connecting the following: • Center lower panel • Refrigerant lines to the air condi¬ tioning evaporator using new gas¬ kets sary motor assembly, if neces¬ • Blower • Evaporator assembly and the evap¬ orator assembly fasteners

Screw Connector Instrument cluster View of the instrument cluster assembly — 626

MAZDA 626 • MIATA • MILLENIA • PROTEGE

17-51

Removing the audio unit— 626

• Audio unit • Electrical connectors and the antenna jack

18. Install the instrument panel by installing or connecting the following: • Upper center panel cover • Dash panel-to-chassis bolts . • Dash panel with the help ot an assistant 19. Install the audio unit by installing or connecting the following: • Hole covers

Inst

all t

t foll or con by inst nec meterhe hood owin •alliClimate control t ng ing g: • Climate control assembly screws • Climate control assembly and con¬ nect the electrical connector

he c

lima

te c

ontr

ol a

sse

21. Install the instrument cluster by installing or connecting the following: • Instrument cluster meter hood • Instrument cluster-to-dash screws, the instrument cluster and connect the electrical connectors 22. At the passenger’s side, install the SAS module by installing or connecting the following:

mbl

y

6.87—9.80 Nm {70 — 100kgf-cm, 60.8—86.7 In-lbf} 16—22 {1.8— 2.3, 12—16} N-m {kgf-m, ft-lbf} 16— 22 {1.6— 2.3. 12—16}

1

Cover

3

Connector

2

Bolt

4

Dashboard 93112GH0

View of the instrument panel assembly— 626

MAZDA

17-52

626 • MIATA • MILLENIA • PROTEGE

1

Blower unit

8

2

Cooling unit

9 10

3 4

Evaporator Heater unit

11

5

Airflow mode main link

12

6

Heater core

13

7

Rear duct (CANADA

only)

View of the heater and air conditioning housing assemblies — 626

14

Rear heat duct (CANADA

only)

A/C compressor Condenser Orifice tube Accumulator tank Heater hose Refrigerant lines

93112GI1

MAZDA

626 • MIATA • MILLENIA • PROTEGE

• Glove compartment and the glove compartment cover • SAS module-to-dash bolts • SAS module and connect the elec¬ trical connector

module and the steering wheel by installing or connectin the following: g • Steering wheel and the steering wheel-to-column nut. Torque the

-17 CO

Airflow Airflow Airflow Airflow Air mix Air mix Air mix Air mix

mode actuator mode main link mode sub link mode crank actuator link rod crank

10 9 11 12 13 14 15 16

Polyurethane protector Seal Cover Case Heater core Air mix door Case Airflow mode door 93112GI2

Exploded view of the heater core and heater housing assembly — 626

vlO

24. Refill the cooling system. 25. Connect the negative battery cable. 26. Evacuate, charge and leak test the air conditioning system refrigerant. 27. Operate the engine to normal operating temperatures; then, check the climate control system and check for leaks.

steering wheel nut to 29-36 ft. lbs. (40-49 Nm). • SAS module to the steering wheel and connect the electrical connec¬ tor. Torque the steering column-toSAS module bolts to 70-104 inch lbs. (8-12 Nm). • Steering wheel-to-SAS module clips • Cover clips, at both sides of the steering wheel

3. At the dri ver’s side , install t he SAS

1 2 3 4 5 6 7 8

■ #

n_Gd MAZDA J4

..

626 • MIATA • MILLENIA • PROTEGE

5

Rocker. Arm (Valve) Cover

REMOVAL & INSTALLATION 626 and Protege 2.0L (FS) ENGINE

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Any components that would inter¬ fere with cover removal • Rocker arm cover bolts in the sequence illustrated • Rocker arm cover and discard the gasket 3. Clean all mating surfaces of any residual gasket material. To install:

4. Apply silicone sealant to cylinder head at the areas illustrated.

1.8L (FP) Engines

• Rocker arm cover with a new gas¬ Instal l orTorque ket. the connecthe t thbolts e follin in g:inch lbs. sequence illustrated toow95 (11 Nm). • Remaining components removed to facilitate the rocker arm cover removal • Negative battery cable 1.6L (ZM) Engines

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable Spark hose plug wires •• Vent • Positive Crankcase Ventilation • (PCV) Rocker hose arm cover bolts in the

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Spark plug wires • Vent hose • Positive Crankcase Ventilation • (PCV) Rocker hose arm cover and discard the 3. Clean all mating surfaces of any gasket residual gasket material.

sequence illustrated • Rocker arm cover and discard the 3. Clean all mating surfaces of any residual gasket material. To install:

4. Install or connect the following: 5. Apply a bead of silicone sealant to cylinder head at the areas illustrated. 6. Install or connect the following: • Rocker arm cover with a new gas-

To install:

4. Install or connect the following:

42356-MAZC-G6A

Remove

the rocker arm cover bolts in the

sequence shown-2.0L (FS) engine

5. Apply a 0.12—0.15 inch (3— 4mm) bead of silicone sealant to cylinder head at the areas illustrated. 6. Install or connect the following: • Rocker arm cover with a new gas¬ ket. Torque the bolts in the sequence illustrated to 95 inch lbs. (11 Nm). • Remaining components removed to facilitate the rocker arm cover removal • Negative battery cable

Remove the valve cover bolts in sequence— 1.8L (FP) engines

42356-MAZC-G07

42356-MAZC-G07

Apply silicone sealant to cylinder head at

Apply silicone sealant to cylinder head at

the areas illustrated -2.0L (FS) engine

the areas Illustrated -1.6L (ZM) engine

Apply silicone sealant to cylinder head at the areas illustrated -1.8L (FP) engine

(T)

o

[Q

©

42356-MAZC-G08

C®o

O

( o @

iT

42356-MAZC-GHB

Tighten the rocker arm cover bolts in the

Tighten the rocker arm cover bolts in the

Tighten the rocker arm cover bolts in the

sequence shown-2.0L (FS) engine

sequence shown-1.6L (ZM) engine

sequence shown-1.8L (FP) engine

MAZPA -17 EE 626 • MIATA • MILLENIA • PROTEGE

■ #

JO

ket. Torque the bolts in the sequence illustrated to 86 inch lbs.

Thickness 1 .5 — 2.5 mm {0.060 — 0.098 in}

(10 Nm).

• Remaining components removed to facilitate the rocker arm cover removal • Negative battery cable 2.5L (KL) ENGINE 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Any components that would inter¬ fere with cover removal • Rocker arm cover bolts • Rocker arm cover and discard the 3. Clean all mating surfaces of any residual gasket material. To install:

42356- MAZC-G09

Apply silicone sealant to cylinder head at the areas illustrated -2.5L (KL) engine

4. Apply silicone sealant to cylinder head at the areas illustrated. 5. Install or connect the following: • Rocker arm cover with a new gas¬ ket. Torque the bolts in the sequence illustrated to 95 inch lbs. (11 Nm) using 2 or 3 steps. Retighten the right hand cover number 5 and 6 bolts and the left hand cover number 6 and 7 bolts. • Remaining components removed to facilitate the rocker arm cover removal • Negative battery cable Miata

1.8L (BP) ENGINES 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable Oil pipehose •• Water Upper radiator hose • Oil Control Valve (OCV) • Rocker arm cover and discard the

gasket

42356-MAZC-G95 42356-MAZC-G10

Tighten the rocker arm cover bolts in the sequence shown-2.5L (KL) engine

Apply silicone sealant to cylinder head at the areas illustrated -1.8L (BP) engine

CC

MAZDA

vJU

626 • MIATA • MILLENIA • PROTEGE

3. Clean all mating surfaces of any residual gasket material. To install: 4. Install or connect the following: • Rocker arm cover with a new gasket. • Temporarily tighten the cover bolts A, refer to the illustration for loca-

42356- MAZC-G96

Temporarily tighten the cover bolts A-1 8L (BP) engine

tion. Torque the bolts in sequence to 80 inch lbs. (9 Nm). ENGINE

CAUTION

FRONT -

When installing the OCV valve, be careful not to damage the 0— ring, if damaged it may cause leaking. • OCV and tighten the bolts in the sequence illustrated 5. Install the oil pipe as follows: a. Oil pipe. Hold the frame of the OCV valve filter and install the OCV so it is aligned with the projected part on the flange end of the oil pipe. Coat the new washer with clean engine oil and tem¬ porarily install the upper and side oil pipe and position the pipe. b. A using several passes to 95 inch lbs. (11 Nm).

42356-MAZC-GAB

Tighten oil pipe bolts C using several passes to the specification in the text-1. 8L (BP) engine

c. Tighten oil pipe bolts B using sev¬ eral passes to 61 inch lbs. (7 Nm). d. Tighten oil pipe bolts C using sev¬ eral passes to 13 ft. lbs. (17 Nm). e. Tighten oil pipe bolts 1, 2, 3, 4 and 7 using several passes to 95 inch lbs. (11 Nm). f. Tighten oil pipe bolt 5 using sev¬ eral passes to 17 ft. lbs. (23 Nm). Tighten the rocker arm cover bolts in the sequence shown-1.8L (BP) engine

g. Tighten oil pipe bolt 6 using sev¬ eral passes to 34 ft. lbs. (47 Nm). 6. Install or connect the following: • Water hose • Upper radiator hose • Spark plug wires • Power steering hose bracket, if removed • Negative battery cable

42356-MAZC-GAC

Tighten oil pipe bolts using several passes to the specification in the text-1. 8L (BP) engine

Tighten the OCV bolts in the sequence shown-1.8L (BP) engine

Hold the frame of the OCV valve filter and install the OCV so it is aligned with the projected part on the flange end of the oil pipe-1. 8L (BP) engine

ENGINE

FRONT

“

42356-MAZC-GAA

en oil pipe bolts A and B using several passes to the specification in the text-1. 8L (BP)

MAZDA

17.C7

626 • MIATA • MILLENIA • PROTEGE ing: • Vent hose

Millenia

• Positive Crankcase Ventilation 2.3L (KJ) Engine

(PCV) hose • Rocker arm cover and discard the

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Ignition coils

3. Clean all mating surfaces of any gasket residual gasket material. To install: 4. Install or connect the following: 5. Apply a 0.004-0.07 inch (1-2mm) bead of sealant to rocker arm cover. • New rocker arm gasket 6. Apply a 0.059-0.098 inch (1.5-2.5mm) to the areas illustrated • Rocker arm cover. Torque the bolts in sequence to 86 inch lbs. (10 Nm), then retighten in sequence to 86 inch lbs. (10 Nm). • PCV hose • Vent hose • Ignition coils • Negative battery cable

Apply a 0.004-0.07 inch (1-2mm) bead of sealant to rocker arm cover —Millenia

2.5L (KL) ENGINE

models equipped with the 2.3L (KJ) engine

pre

cau

in the beg inn ing

tio

ns

of this sect ion.

I *

Of

2. Remove or disconnect the follow¬ • Negative battery cable • Any components that would inter¬ fere with cover removal. • Rocker arm cover bolts • Rocker arm cover and discard the 3. Clean all mating surfaces of any residual gasket material. To install: 4. Apply silicone sealant to cylinder head at the areas illustrated. 5. Install or connect the following: • Rocker arm cover with a new gasket. Torque the bolts in the sequence illustrated to 95 inch lbs. (11 Nm) using 2 or 3 steps. Retighten the right hand cover number 5 and 6 bolts and the left hand cover number 6 and 7 bolts. • Remaining components removed to facilitate the rocker arm cover removal • Negative battery cable

Thickness 1 .5 — 2.5 mm {0.060 — 0.098 in} RH 1

Bef

ore

ser

Apply a 0.059-0.098 inch (1.5-2. 5mm) to the areas shown— Millenia models equipped with the 2.3L (KJ) engine

vic

ing

the

vehi

cle,

refe

r to

the

LH

Rocker arm cover bolt sequence — Millenia models equipped with the 2.3L (KJ) engine

42356- MAZC-G09

Apply silicone sealant to cylinder head at the areas illustrated -2.5L (KL) engine

CO "UO

MAZDA 626 • MIATA • MILLENIA • PROTEGE 7. Install new head gasket on the engine block. 8. Install the cylinder head. 9. Lubricate the bolt threads and seat surfaces with clean engine oil and install them as follows: a. Torque the bolts in 2-3 steps to 56-60 ft. lbs. (75-81 Nm) in the proper sequence. 10. Install or connect the following: • Accelerator cable bracket manifold bracket •• Intake Fuel hose • All engine harness connectors removed to access the cylinder head • Vacuum hoses ket • Exhaust manifold using a new gas¬ •• Timing Front pipe beltand air cleaner assembly • Negative battery cable 11. Fill and bleed the cooling system. 12. Change the oil and filter. 13. Run the engine and check for proper operation. 626 and Protege

2.0L (FS) ENGINE

42356-MAZC-G10

1. Before servicing the vehicle, refer to

Tighten the rocker arm cover bolts in the sequence shown-2.5L (KL) engine

Cylinder Head REMOVAL & INSTALLATION 1.8L (BP) Engines

thr in the blo ck ead fre s in the blo . ely ck.

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Relieve the fuel system pressure. 1 9—25 3. Drain the cooling system. 4. Remove or disconnect the following: • Negative battery cable Cle an t • Timing belt he yli pipe • Air cleaner assembly and cfront nde • Exhaust manifold rhe ad • Vacuum hoses bol ts • All engine harness connectors nec¬ and t he essary to access the cylinder head • Fuel hose • Intake manifold bracket • Accelerator cable bracket • Cylinder head bolts, in 2-3 steps, in sequence • Cylinder head To install: 5. Thoroughly, clean the cylinder head and the block contact surfaces. Examine the head gasket and check the cylinder head for cracks. Check the cylinder head for warpage

the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Drain the cooling system. 5. Remove or disconnect the following: •• Timing Negativebelt battery cable

using a feeler gauge and straightedge. The maximum allowable distortion is 0.004 inch (0.10mm). Be sur the bol tur ts n e

76—81

{7.7— 8.3, 56—60}

{1 .9—2.6, 1 4—1 8}

8.9 — 12.7 N m {90—130

39—46

kgfcm,

79—112

in lbf}

{3.9— 4.7, 28—33}

Accelerator cable bracket Cylinder head Cylinder head gasket

Exploded view of the cylinder head assembly— 1 ,8L (BP) engines

N-m {kgf-m, ft lbf}

42356-MAZC-GAE

MAZDA 626 • MIATA • MILLENIA • PROTEGE

17-59

9301 MG02

Replace any bolts that exceed the maxi¬ mum length ot 4.154 inch (105.5mm)— 2.0L (FS) engines

Cylinder head loosening sequence— 1.8L (BP) engines

CRANKSHAFT PULLEY SIDE

10. Paint a mark on the edge of each cylinder head bolt to use as a reference. Turn each bolt, in sequence, 85-95 degrees. Again, turn each bolt, in sequence, an additional 85-95 degrees. 11. Support the engine assembly with a suitable lifting device and remove the num¬ ber 3 mount. 12. Install or connect the following: • Intake manifold bracket • Camshafts • Camshaft pulley, make sure the camshaft sprocket pulleys are posi¬ tioned with the pins facing up. Hold the camshaft pulley with a back-up wrench while tightening the pulley

Cylinder head bolt tightening sequence — 1 ,8L (BP) engines

• Front exhaust pipe • Air cleaner assembly • Power steering pump with the lines attached and set aside, if necessary on Protege models • Accelerator cable • Fuel hose • Ignition coil • Camshaft pulley. Hold the camshaft pulley with a back-up wrench while loosening the pulley bolt. • Camshaft • Intake manifold bracket

on 62 the eng mo eng to su pp un 6 ine mo ine o t r de , t ls . • Cylinder head bolts by loosening

them, in 2-3 steps, in the sequence illustrated • Cylinder head To install: 7. Install or connect the following: • New cylinder head gasket • Cylinder head 8. Apply clean engine oil to the bolt threads and seating faces. 9. Install new cylinder head bolts and torque in 2-3 steps, in sequence, to 13-16 ft. lbs. (17-22 Nm). If reusing old bolts, which is not recommended; make sure the maximum length of the bolt is 4.154 inch (105.5mm). The standard length of the bolt should be 4.103-4.125 inch recommended; (104.2-104.8mm).

ENGINE FRONT

bolt to 37-44 ft. lbs. (50-60 Nm). •• Fuel Ignition hosecoil • Accelerator cable • • • •

Power steering pump, if removed Air cleaner assembly Front exhaust pipe Timing belt

• Negative battery cable 13. Fill and bleed the cooling system. 14. Change the oil and filter. 15. Run the engine and check for proper operation.

1.6L (ZM) ENGINES 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Properly relieve the fuel system 3. Drain the engine coolant. pressure. 4. Remove or disconnect the following: • Negative battery cable • Timing belt • Front exhaust pipe • Exhaust manifold insulator and the Pipe Exhaust Gas Recirculation (EGR) • Assembly Fresh air duct and air cleaner • Accelerator cable and bracket • All vacuum hoses • Engine wiring harness connectors • Fuel supply and return hoses

Cylinder head bolt removal sequence — 2.0L (FS) engines

17

fill MAZDA

E / "DU

626 • MIATA • MILLENIA • PROTEGE

CRANKSHAFT PULLEY SIDE

9301 MG02

Replace any bolts that exceed the maxi¬ mum length — 1.6L (ZM) and 1.8L (FP) engines

1.8L (FP) ENGINES

Cylinder head bolt tightening sequence— 2. OL (FS) engines

1 . Before servicing the vehicle, refer to

. DOWEL

• New head gasket • Cylinder head

PIN

the precautions in the beginning of this sec¬ tion. 2. Properly relieve the fuel system

as foll ows. ca. e, Step 1:13-16 ft. lbs. (17-22 Nm). b. Step 2: Turn 85-95 degrees. c. Step 3: Turn an additional 85-95 degrees. 10. Install or connect the following: • Camshafts Tor que the cyl•i Camshaft pulleys, install the pul¬ nder leys he so that the 1 mark on the intake side adorboEl mark on the exhaust side ts, in Torque the bolts to are facing up. 37-44 ft. lbs. (50-60 Nm). • Heater hoses uen

Make sure the camshaft sprocket pulleys are positioned with the pins facing up— 2.0L (FS) engine

.

0

seq

• Intake manifold support bracket • Heater hoses • Camshaft pulleys by holding the them with a wrench • Camshafts • Cylinder head bolts in sequence • Cylinder head To install: 5. Thoroughly, clean the cylinder head and the block contact surfaces. 6. Clean the cylinder head bolts and the threads in the block. Be sure the bolts turn freely in the block. 7. Measure the length of the cylinder head bolts, as shown, maximum bolt length is 3.956 inch (100.5mm). 8. Install or connect the following:

©

©

• Front exhaust pipe • Air cleaner assembly • Power steering pump and bracket, if necessary, and move it aside leaving the hoses attached • Accelerator cable • Fuel supply and return hoses • Ignition coil • Camshaft pulleys by holding the them with a wrench • Camshafts

• Intake manifold support bracket • Fuel hoses • Engine wiring harness connector • Any vacuum hoses that were removed • Accelerator cable and bracket • Air cleaner assembly and fresh air duct • EGR system • Exhaust manifold insulator and front exhaust pipe • Timing belt

• Cylinder head bolts in sequence • Cylinder head To install: 5. Thoroughly, clean the cylinder head and the block contact surfaces. 6. Clean the cylinder head bolts and the threads in the block. Be sure the bolts turn freely in the block. 7. Measure the length of the cylinder head bolts, as shown, maximum bolt length is 4.153 inch (105.5mm). 8. Install or connect the following: • New head gasket

• Negative battery cable 11. Fill the cooling system. 12. Start the vehicle, check for leaks and repair if necessary.

/

✓

y

R

y

R

y y

S/I S/I

Ignition timing

✓

90

✓

'

Idle speed Steering operation & linkages Engine coolant Timing belt (except Calif.)

✓

97.5 82.5

✓

v'

S/I S/I

67.5

✓

S/I

Front suspension ball joints Fuel lines & hoses

60

✓

✓ ✓

S/I S/I S/I

75 (xIOOO)

INTERVAL

✓

S/I S/I

Exhaust system heat shields

R: Replace

7.5

MILEAGE 45

y v'

S/I: Service or Inspect

© Timing belt (Calif ): replace at 105,000 miles, unless previously replaced. @ Emission hoses & tubes: replace at 80,000 miles.

FREQUENT

OPERATION

MAINTENANCE

(SEVERE

SERVICE)

If a vehicle is operated under any of the following conditions it is considered severe service: - Extremely dusty areas.

- 50% or more of the vehicle operation is in 32°C (90°F) or higher temperatures, or constant operation in temperatures below 0°C (32°F). - Prolonged idling (vehicle operation in stop and go traffic). - Frequent short running periods (engine does not warm to normal operating temperatures). - Police, taxi, delivery usage or trailer towing usage. Air cleaner filter: service or inspect every 15,000 miles Engine oil & filter: replace every 5000 miles. Ball joints & dust covers: service or inspect every 7500 miles. Bolts & nuts on chassis & body: tighten every 15,000 miles. Spark plugs: replace every 15,000 miles. Automatic transmission fluid & filter: replace every 30,000 miles. Front & rear axle oil: replace every 30,000 miles. Transfer case oil (4WD): replace every 30,000 miles 42356-MMPV-C12

MAZDA

MPV

MAINTENANCE

SCHEDULED TYPE OF TO BE SERVICED

SERVICE

Engine oil & filter Drive belt(s) PCV valve

R

MAZDA— 2002 MPV SLEW IILEAGE INTERVAL (xIOOO) VEHI 15 60 67.5 75 82.5 45 22.5 7.5 37.5 52.5 30 ✓ y ✓ y ✓ y ✓ ✓ y ✓ y

S/I 1

Spark plugs(platinum tip) Air cleaner filter

R R

y

Brake lines and hoses

1

Brake fluid Brake pads/shoes Bolts & nuts on chassis & body Cooling system hoses Driveshaft dust boots

INTERVALS

every

19-7 90

97.5

y

y

y

y y

00,000 miles y

y

V

y

y

R

y

y

y

1

y

y

y

y

y

y

y

y

y

S/I S/I

y

y

y

Exhaust system heat shields

S/I S/I

y

y

y

Front suspension ball joints Fuel lines & hoses

y

y

y

S/I S/I

y

y

y

Steering operation & linkages

y

y

y

S/I R

Engine coolant R: Replace

FREQUENT

✓

y

S/I: Service or Inspect

OPERATION

MAINTENANCE

(SEVERE

SERVICE)

If a vehicle I* operated under any of the following conditions It Is considered severe service: - Extremely dusty areas. In temperatures below 0*C (32*F). - 50% or more of the vehicle operation Is In 32*C (90*F) or higher temperatures, or constant operation traffic). go and stop In operation - Prolonged idling (vehicle • Frequent short running periods (engine does not warm to normal operating temperatures). - Police, taxi, delivery usage or trailer towing usage. Air cleaner filter service or inspect every 15,000 miles Engine oil & filter: replace every 5000 miles.

Bali joints & dust covers: service or inspect every 7500 miles. Bolts & nuts on chassis & body: tighten every 15,000 miles. Automatic transmission fluid & filter replace every 30,000 miles. 42356-MMPV-C13

19-8

MAZDA MPV

PRECAUTIONS Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: • Never open, service or drain the radia¬ tor or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. • Observe all applicable safety precau¬ tions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark, open flame or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. • Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. • Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes

with clean, running water for 15 minutes. If eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance. • The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas as soon as possible after expo¬ sure to used engine oil. Soap and water, or waterless hand cleaner should be used. • All new vehicles are now equipped with an air bag system. The system must be disabled before performing service on or around system components, steering col¬ umn, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in acci¬ dental air bag deployment, possible per¬ sonal injury and unnecessary system repairs. • Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a nondeployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section.

• Clean, high quality brake fluid from a sealed container is essential to the safe and proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in con¬ tact with a painted surface; it will damage the paint. • Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine damage. • Timing belt maintenance is extremely important! Many models utilize an interfer¬ ence-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing poten¬ tially serious (also time-consuming and expensive) engine damage. • Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer sys¬ tem^) and may require the computer to undergo a relearning process once the neg¬ ative battery cable is reconnected. • When servicing drum brakes, only dis¬ assemble and assemble one side at a time, leaving the remaining side intact for refer¬ ence. • Only an MVAC-trained, EPA-certified automotive technician should service the air conditioning system or its components.

ENGINE REPAIR ^Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board com¬ puter system. The computer may undergo a relearning process once the negative battery cable is reconnected.

Distributor This engine is equipped with a Distribu¬ torless Ignition System (DIS).

• Right axle halfshaft and center shaft assembly • Alternator harness connectors • Center shaft support bracket • Alternator To install:

Alternator REMOVAL & INSTALLATION 2.5L Engine

the pre tio cau n. tio n

2. Remove or disconnect the followT • Negative battery cable • Accessory drive belt • Subframe transverse section • Exhaust front pipe

in the beg inn ing

of thi sec s ¬

3. Install or connect the following: • Alternator. Tighten the bolts to 29-41 ft. lbs. (40-50 Nm). • Center shaft support bracket. Tighten the bolts to 32-45 ft. lbs. (43-61 Nm). • Alternator harness connectors. Tighten the battery terminal nut to 87-130 inch lbs. (10-15 Nm).

• assembly Right axle halfshaft and center shaft • Exhaust front pipe • Subframe transverse section. Tighten the bolts to 69-96 ft. lbs. (94-131 Nm). • Accessory drive belt • Negative battery cable 3.0L Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Accessory drive belt • Exhaust front pipe • assembly Right axle halfshaft and center shaft • Alternator harness connectors • Center shaft support bracket

3.

MAZDA MPV

• Alternator To install:

• Alternator. Tighten the bolts to 29-41 ft. lbs. (40-50 Nm). • Center shaft support bracket. Tighten the bolts to 32-45 ft. lbs. Nm). Inst•all(43-61 or connectharness connectors. Alternator the followi ng: nut to Tighten the battery terminal 87-130 inch lbs. (10-15 Nm). • Right axle halfshaft and center shaft assembly • Exhaust front pipe • Accessory drive belt • Negative battery cable Ignition Timing ADJUSTMENT 2.5L Engine

This engine is equipped with a Distribu¬ torless Ignition System (DIS). No adjust¬ ment is necessary. Engine Assembly REMOVAL & INSTALLATION 2.5L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Drain the engine oil. 4. Drain the transaxle. 5. Relieve the fuel system pressure. 6. Install a support fixture to the engine lifting eyes. 7. Remove or disconnect the following: • Battery and tray • Inner fender liners • Axle halfshafts • Air intake assembly • Accelerator cable and bracket • Gear select cable • Transaxle dipstick tube • Cruise control actuator • Radiator • Fuel line • Brake booster vacuum line • Powertrain Control Module (PCM) connector. Pull the harness through the firewall into the engine com¬ partment. • Exhaust front pipe • Accessory drive belt • Alternator and bracket

• Right engine mount bracket • Power steering hoses • Front engine mount • Subframe center section • Rear engine mount • Left engine mount 8. Lower the powertrain from the vehicle. To install:

9. Raise the powertrain into position. 10. Install or connect the following: • Left engine mount • Rear engine mount • Subframe center section. Tighten the bolts to 48-65 ft. lbs. (64-89 Nm) and the nut to 50-67 ft. lbs. (67-93 Nm). • Front engine mount • Power steering hoses • Right engine mount bracket 11. Check that the right engine mount stud is centered in the mount bracket with no tension applied to the stud by the bracket. 12. Tighten the engine mount fasteners as follows: a. Step 1: Left and rear engine mount Nm). through bolts to 63-86 ft. lbs. (85-116 b. Step 2: Front engine mount nuts to 50-67 ft. lbs. (67-93 Nm). c. Right engine mount bracket nuts to 56-76 ft. lbs. (75-104 Nm). 13. Install or connect the following: • Alternator and bracket • Accessory drive belt • Exhaust front pipe • PCM connector. Pull the harness through the firewall into the pas¬ senger compartment. • Brake booster vacuum line • Fuel line • Radiator • Cruise control actuator • Transaxle dipstick tube • Gear select cable • Accelerator cable and bracket • Air intake assembly • Axle halfshafts • Inner fender liners • Battery and tray 14. Fill the crankcase and transaxle to the correct level. 15. Fill the cooling system. 16. Start the engine and check for leaks. 3.0L Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system.

3. 4. 5. 6. 7. lifting

19-9

Drain the engine oil. Drain the transaxle. Relieve the fuel system pressure. Disconnect the negative batter cable. Install a support fixture to the engine eyes.

8. Remove or disconnect the following: • Timing chain plug hole plate • Power steering hoses • • • • • • • • •

Splash shield Axle halfshafts Battery and tray Air intake assembly Accelerator cable and bracket Gear select cable Transaxle dipstick tube Cruise control actuator Radiator Fuel line

• Powertrain Control Module (PCM) connector. Pull the harness through the firewall into the engine com¬ • Exhaust front pipe partment. • Accessory drive belt • A/C compressor with lines still attached • Alternator and bracket • Engine mounts To install:

9. Installation is the reverse of removal. Observe the following torques: • Subframe center section. Tighten the bolts to 48-65 ft. lbs. (64-89 the nut to 50-67 ft. lbs. Nm) and Nm). (67-93 Nm).and rear engine mount through • Left bolts to 63-86 ft. lbs. (85-116 • Front engine mount nuts to 50-67 ft. lbs. (67-93 Nm). • Right engine mount bracket nuts to 56-76 ft. lbs. (75-104 Nm). Water Pump REMOVAL & INSTALLATION 2.5L and 3.0L Engines

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Remove or disconnect the following: • Battery and tray • Water pump drive belt • Water pump drive pulley • Thermostat housing • Water pump belt tensioner • Oil cooler hose

DA 19-10 rvZ.

7

• Water outlet pipe • Water pump

To install:

4. Install or connect the following: • Water pump. Tighten the bolts to 89 inch lbs. (10 Nm) plus 90 degrees. • Water outlet pipe • Oil cooler hose • Water pump belt tensioner • Thermostat housing • Water pump drive puliey • Water pump drive belt • Battery and tray 5. Fill the cooling system. 6. Start the engine and check for leaks.

SAS module by performing the following procedure: a. Remove the glove compartment by sliding it to the left; then, pull the right side forward to remove the stopper and the pin, then, move it to the right to remove it.

formingRethe following procedure: move the rument trim a. Remove theinst A-pillar panelfrom by peboth r¬ sides. b. Remove the front side trim and the

b. Remove the SAS module-to-dash bolts. c. Carefully, lift the SAS module and disconnect the electrical connector.

I; CAUTION Place the SAS in a safe place with the module facing upward.

side panel trim. c. Remove the hood release handle and the lower panel. d. Remove the meter hood and the instrument cluster. e. Remove the steering column-toinstrument panel bolts and lower the steering column. f. Disconnect the electrical connec¬ tors from the blower motor and the heater housing.

Heater Core REMOVAL & INSTALLATION Front System

CAUTION After disconnecting the battery, wait for more than 1 minute for the air bag system to deplete its stored energy.

2. Drain the cooling system into a clean container for reuse. 3. Disconnect the heater hoses from the heater core.

1

Connector

2 3

Driver-side air bag module Bolt 93113GF1

4. Discharge and recover the air condi¬ tioning system refrigerant.

Exploded view of the steering wheel and SAS module

5. At the driver’s side, remove the SAS module and the steering wheel by perform¬ ing the following procedure: a. Place the wheel in the straight¬ ahead position and turn the ignition switch to LOCK. b. Remove the lower steering column cover. c. Disconnect the clock spring con¬ nector. d. Remove the steering wheel-to-SAS tter module bolts. y cab e.le. Carefully, lift the SAS module from the steering wheel.

e ba

I: CAUTION Place the SAS in a safe place with the module facing upward.

f. Remove the steering wheel-to-column nut. g. Using a steering wheel puller, press the steering wheel from the steer¬ ing column.

2

Passenger-side air bag module 93113GF2

Exploded view of the passenger’s side SAS module

MAZDA 1CL11

MPV

I 3

10 1 2

Air bag module Locknut

3 4

Steering wheel Column cover

5

Side panel

6

Lower panel

15

7

Shift-lock actuator

16

8

Selector cable

17 18

Fixing bolt (universal joint/pinion shaft) Fixing bolt (intermediate shaft/universal joint) Universal joint

9

Retaining ring, wave washer, adjustment washer(s)

19

Intermediate shaft

12 11 13 14

Selector lever component Combination switch Joint cover

Fixing bolt (steering shaft/intermediate shaft) Steering shaft

Dust cover 93113GF3

Exploded view of the steering column and related components

1Q19 I “

IC

MAZDA MPV

g. Remove the instrument panel hole cover and the instrument panel-to-chassis bolts. h. Disconnect the electrical connec¬ tors. i. Using an assistant, carefully remove the instrument panel. 8. Remove the heater housing-to-chassis nuts.

15. Install the heater housing-to-chassis nuts. 16. Install the instrument panel by per¬ forming the following procedure: a. Using an assistant, carefully, install the instrument panel. b. Connect the electrical connectors.

9. Remove the heater housing-to-air conditioning housing fastener and seal plate. 10. Remove the heater housing. 1 1 . Disassemble the heater housing and remove the heater core. To install:

12. Install the heater core and assemble the heater housing. 13. Install the heater housing. 14. Install the heater housing-to-air con¬ ditioning housing seal plate and fastener.

c. Install the instrument panel-tochassis bolts and the instrument panel hole cover. d. Connect the electrical connectors ing.the blower motor and the heater hous¬ to e. Install the steering column and the steering column-to-instrument panel bolts. Torque the bolts to 12-16 ft. lbs. (16-22 Nm). f. Install the instrument cluster and the meter hood. g. Install the hood release handle and the lower panel.

h. Install the front side trim and the side panel trim. i. Install the A-pillar trim to both sides. 17. At the passenger's side, install the SAS module by performing the following procedure: a. Carefully, install the SAS module and connect the electrical connector. b. Install the SAS module-to-dash bolts. Torque the bolts to 12-16 ft. lbs. (16-22 Nm). c. Install the glove compartment by sliding it to the right; then, push the right side rearward to install the stopper and the pin, then, move it to the right. 18. At the driver’s side, install the SAS module and the steering wheel by perform¬ ing the following procedure: a. Install the steering wheel and the steering wheel-to-column nut. Torque the

16— 22(1.6—2.3, 12— 16}

1

Hole cover

2

Bolt

3 4

Connector Dashboard

16—22(1.6-2.3,12—16} N m { kgf m , ft lbf } 93113GF4

View ol the instrument panel and related components

MAZDA MPV

19-13

1

Air mix link

2 3

Airflow mode link Wire clamp

4

Polyurethane protector

5

Front heater core

6

Drain hose

7

Joint

8

Duct

9

Case (bottom)

10 11

Airflow mode door Case (left)

12

Air mix door

13

Case (right No. 1)

14

Case (right No.2)

93113GF5

steering wheel nut to 29-36 ft. lbs. (40-49 Nm). b. Carefully, install the SAS module to the steering wheel. c. Install the steering wheel-to-SAS module bolts. Torque the bolts to 70 — 104 inch lbs. (7.9-11.7 Nm). d. Connect the clock spring connec¬ tor. e. Install the lower steering column cover. 19. Connect the heater hoses to the heater core. 20. Refill the cooling system. 21 . Connect the negative battery cable. 22. Run the engine to normal operating temperatures; then, check the climate con¬ trol operation and check for leaks. Rear Auxiliary System

1 . Disconnect the negative battery cable. 2. Set the rear heater control knob to the WARM position to open the water valve. 3. Drain the cooling system into a clean container for reuse. 4. Remove the driver’s seat. 5. Disconnect the heater hoses. 6. Disconnect the rear heater unit wire connector.

View of the rear auxiliary heater assembly and related components— Mazda MPV

19-14 rr 2

1 . Rear heater blower motor 2. Resistor assembly 3. Rear heater relay 4. Heater core 5. Water valve 6. Switch panel

6

.

3 93113G43

Exploded view of the rear auxiliary heater unit— Mazda MPV

7. Remove the rear heater unit attaching bolts and remove the assembly. 8. Separate the rear heater unit attach¬ ing bolts and remove the heater core.

several passes and in the sequence shown.

• Heated Oxygen (HO2S) sensor con¬ nectors • Exhaust front pipe • Exhaust Gas Recirculation (EGR)

To install:

i"»The cylinder head bolts are a torqueto-yield design and must be replaced.

To install:

9. Install the heater core and assemble the rear heater unit. 10. Install the assembly and the rear heater unit. 11. Connect the rear heater unit wire connector. 12. Connect the heater hoses to the heater core. 13. Install the driver’s seat. 14. Refill the cooling system. 15. Connect the negative battery cable.

Exhaust •• Oil pan manifolds pipe • Alternator • • • • •

A/C compressor Valve covers Front cover Timing chains Camshafts

• Cylinder heads. Loosen the bolts in

as the bol in seq Tig g ts hte uen foalskets n loNm). ce ws:. a. Step 1: 28-31 ft. lbs. (37-43 Inst

all

the

b. Step 2: Plus 90 degrees. cyl c. Step 3: Loosen one full turn. ind. der Step 4: 28-31 ft. lbs. (37-43 Nm). hea ds wit hn ew

Cylinder Head REMOVAL & INSTALLATION 2.5L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Drain the engine oil. 4. Relieve the fuel system pressure. 5. Remove or disconnect the follow¬ ing: • Battery and tray • Accessory drive belt • Water pump and drive pulley • Intake manifold • Power steering pump • Intake Manifold Runner Control (IMRC) actuator • Spark plug wires • Ignition coil

9308TG05

Cylinder head loosening sequence— 2. 5L and 3.0L engine

MAZDA

MPV

19-15

e. Step 5: Plus 90 degrees. f. Step 6: Plus 90 degrees.

Rocker Arms/Shafts REMOVAL & INSTALLATION 2.5L and 3.0L Engines 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Relieve the fuel system pressure. 3. Drain the engine oil. 4. Remove or disconnect the following: • Negative battery cable • Intake manifold •• Accessory drive pump belt Power steering • Intake Manifold Runner Control • • • •

Cylinder head torque sequence — 2.5L and 3.0L engines

e. Step 5: Plus 90 degrees. f. Step 6: Plus 90 degrees. 7. Install or connect the following: • Camshafts • Timing chains • Front cover • Valve covers • A/C compressor • Alternator • Oil pan • Exhaust manifolds • EGR pipe • Exhaust front pipe • HO2S sensor connectors • Ignition coil • Spark plug wires • IMRC actuator • Power steering pump • Intake manifold • Water pump and drive pulley • Accessory drive belt • Battery and tray 8. Fill the crankcase to the correct level. 9. Fill the cooling system.

ks.

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3.0L Engine 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system.

3. Drain the engine oil. 4. Relieve the fuel system pressure. 5. Remove or disconnect the following: • Accessory drive belt • Water pump and drive pulley • Timing chains • No.3 engine mount rubber and joint bracketpipe • Ventilation • Water bypass tube • Camshafts (■►Remove the Nos. 1 and 5 caps first. Don’t loosen any other cap bolts until these caps are removed. • Rocker arms • Cylinder heads. Loosen the bolts in several passes and in the sequence shown. To install: 6. Installation is the reverse of removal. Observe the following torques: (■•The cylinder head bolts are a torque-to-yield design and must be replaced. 7. Install the cylinder heads with new gaskets. Tighten the bolts in sequence as follows: Nm). a. Step 1:24-28 ft. lbs. (32-38

b. Step 2: Plus 90 degrees. c. Step 3: Loosen one full turn. d. Step 4: 24-28 ft. lbs. (32-38 Nm).

(IMRC) actuator Spark plug wires Ignition coil Water pump drive belt and pulley Camshaft seal housing

•• Wiring harness connector bracket Oil pancovers Valve • • • •

Front cover Timing chains Camshafts Rocker arms

’••-Keep all valvetrain components in order for assembly. To install: 5. Install or connect the following: • Rocker arms • Camshafts • Timing chains Frontpancover • Oil • Valve covers • Wiring harness connector bracket • Camshaft seal housing • • • •

Water pump drive belt and pulley Ignition coil Spark plug wires Intake Manifold Runner Control

• (IMRC) Power steering actuator pump • Accessory drive belt • Intake manifold • Negative battery cable 6. Fill the crankcase to the correct level. 7. Start the engine and check for leaks.

i9-i6 rr Intake Manifold REMOVAL & INSTALLATION 2.5L Engine 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: • Negative battery cable • Air cleaner housing and fresh air duct • • • •

Mass Air Flow (MAF) sensor Throttle body intake hose Accelerator cable and bracket Intake Manifold Runner Control (IMRC) cable at the IMRC housing • Throttle body • Exhaust Gas Recirculation (EGR) valve • Idle Air Control (IAC) valve • Pressure Regulator Control (PRC) solenoid • Intake manifold • Fuel lines

3.0L Engine

in sequence (8-12 Nm). to 72-105 inch lbs.

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: • Negative battery cable • Air cleaner housing and fresh air duct • Resonance chamber • Mass Air Flow (MAF) sensor • Throttle body intake hose • Accelerator cable and bracket • IMCC actuator • Throttle body • Exhaust Gas Recirculation (EGR) valve • Idle Air Control (IAC) valve • Dynamic chamber • Intake manifold To install: 4. Install or connect the following: • Intake manifold. Tighten the bolts

• Dynamic chamber. Tighten the bolts in sequence to 72-105 inch lbs. (8-12 Nm). 5. The remainder if installation is the reverse of removal. 6. Start the engine and check for leaks. Exhaust Manifold REMOVAL & INSTALLATION 2.5L and 3.0L Engines 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Negative battery cable • Subframe transverse section • Pleated Oxygen (HO2S) sensor con¬ nectors • Exhaust front pipe

• Fuel pressure regulator vacuum line • Fuel supply manifold • IMRC housing To install: 4. Install or connect the following: • IMRC housing. Tighten the bolts in sequence to 72-105 inch lbs. (8-12 Nm). • Fuel supply manifold. Tighten the bolts to 72-105 inch lbs. (8-12 Nm). • Fuel pressure regulator vacuum line • Fuel lines • Intake manifold. Tighten the bolts in sequence to 72-105 inch lbs. (8-12 Nm). • PRC solenoid. Tighten the bolt to 45-61 inch lbs. (5-7 Nm). • IAC valve. Tighten the bolts to 72-105 inch lbs. (8-12 Nm). • EGR valve • Throttle body. Tighten the bolts to 72-105 inch lbs. (8-12 Nm). • IMRC cable • Accelerator cable and bracket Tighten the bolt to 71-94 inch lbs. (8-11 Nm). • Throttle body intake hose • MAF sensor • Air cleaner housing and fresh air duct • Negative battery cable 5. Start the engine and check for leaks.

® Intake manifold torque sequence— 3. OL engine

(.4;

£ 42356- MMPV-G01

MAZDA

MPV

19-17

Camshaft and Valve Lifters REMOVAL & INSTALLATION 2.5L Engine 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.2. Relieve the fuel system pressure. 3. Drain the engine oil. 4. Remove or disconnect the following: • Negative battery cable • Intake manifold •• Accessory drive pump belt Power steering • Intake Manifold Runner Control Right exhaust manifold torque sequence-2. 5L and 3.0L engine

• • •

(IMRC) actuator Spark plug wires Ignition coil Exhaust Oil pan front pipe

• • • •

Alternator and bracket A/C compressor Water pump belt and drive pulley Camshaft oil seal housing

• • • •

Wiring harness connector bracket Valve covers Front cover Timing chains

^Keep all valvetrain components in order for assembly

9308TG11

^Remove the camshaft thrust bearing caps before loosening any of the other bearing cap bolts.

Left exhaust manifold torque sequence-2. 5L and 3.0L engine

• Exhaust Gas Recirculation (EGR) pipe manifolds • Exhaust To install: 3. Install or connect the following: • Exhaust manifolds. Tighten the nuts in sequence to 14 ft. lbs. (20 Nm). • EGR pipe • Exhaust front pipe • HO2S sensor connectors • Subframe transverse section. Tighten the bolts to 69-96 ft. lbs. (94-131 Nm). • Negative battery cable 4. Start the engine and check for leaks.

Front Crankshaft Seal REMOVAL & INSTALLATION Refer to the Timing Chain, Sprockets, Front Cover and Seal procedure in this section.

9308TG12

Right bank camshaft thrust cap loosening sequence— 2.5L and 3.0L engine

19-18 rvZDA • Camshaft thrust bearing caps. Loosen the bolts evenly in several • Remaining camshaft bearing caps. passes. Loosen the bolts evenly in several • Camshafts • Rocker passes. arms • Hydraulic lifters To install: i' WARNING The crankshaft keyway must be at the 11 o’clock position before reassem¬ bly. Failure to do so may lead to engine damage. Left bank camshaft thrust cap loosening sequence — 2.5L and 3.0L engine

5. Rotate the crankshaft so that the key¬ way is at 11 o’clock position for installa¬ tion of thethecamshafts. 6. Install or connect the following: • Hydraulic lifters • Rocker arms. • Camshafts. Align the sprocket tim¬ ing marks. f»Do not install the camshaft journal thrust caps until the rocker arms and timing chains have been installed and the camshaft journal caps are secured into position. • All camshaft journal caps except the thrust caps. • Timing chains. Tighten the camshaft journal cap bolts in reverse of the loosening order and 9308TG13

Right bank camshaft bearing cap loosening sequence— 2. 5L and 3.0L engine

in several steps to 71-106 inch lbs. (8-12 Nm). • Thrust caps. Tighten the bolts to inch lbs. (8-12 Nm). • 71-106 Front cover • Valve covers • • • • • •

Wiring harness connector bracket Camshaft oil seal housing Water pump belt and drive pulley A/C compressor Oil pan Alternator and bracket

• Exhaust front pipe • • • •

9308TG15

Left bank camshaft bearing cap loosening sequence — 2.5L and 3.0L engine

Ignition coil Spark plug wires IMRC actuator Power steering pump

• Accessory drive belt • Intake manifold • Negative battery cable 7. Fill the crankcase to the correct level. 8. Fill the cooling system. 9. Start the engine and check for leaks.

MAZDA

MPV

3.0L Engine 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Drain the engine oil. 4. Relieve the fuel system pressure. 5. Remove or disconnect the following: • Accessory drive belt • Water pump and drive pulley • Timing chains • No.3 engine mount rubber and joint bracket • Ventilation pipe • Water bypass tube • Camshafts ^Remove the Nos. 1 and 5 caps first. Don’t loosen any other cap bolts until these caps are removed. • Rocker arms To install: 6. Installation is the reverse of removal. Observe the following torques: 7. Install the camshaft caps. Tighten the bolts in sequence to 71-106 inch lbs.

Valve Lash ADJUSTMENT The engine covered in this section are equipped with hydraulic lash adjusters. Valve clearance adjustments are not possible.

Starter Motor REMOVAL & INSTALLATION 2.5L and 3.0L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Battery and tray • Air intake assembly • Gear select cable • Starter harness connectors • Starter motor To install: 3. Install or connect the following: • Starter motor. Tighten the bolts to 28-38 ft. lbs. (38-51 Nm). • Starter harness connectors. Tighten the battery cable nut to 87-104 inch lbs. (10—12 Nm). • Gear select cable • Air intake assembly • Battery and tray

Oil Pan REMOVAL & INSTALLATION 2.5L Engine 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the engine oil. ing:3. Remove or disconnect the follow¬ • Negative battery cable • Subframe transverse section • Exhaust front pipe • Flywheel access panel • Transaxle housing bolts • Oil pan bolts. Loosen the bolts in reverse of the tightening sequence in several steps. • and Oil pan To install:

4. Apply a bead of silicone sealer to the gasket area where the pan meets the parting lines of the lower cylinder block and the front engine cover.

19-19

5. Install or connect the following: • Oil pan. Use a new gasket, tighten the pan bolts in several passes to 15-22 ft. lbs. (20-30 Nm), then tighten the transaxle case bolts to 28-38 ft. lbs. (38-51 Nm). • Flywheel access panel • Exhaust front pipe • Subframe transverse section. Tighten the bolts to 69-96 ft. lbs. (94-131 Nm). • Negative battery cable 6. Fill the crankcase to the correct level. 7. Start the engine and check for leaks. 3.0L Engine 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the engine oil. 3. Remove or disconnect the following: • Negative battery cable • Exhaust front pipe • Flywheel access panel • Transaxle housing bolts

1 9-20 m?vzda • Oil pan bolts. Loosen the bolts in the sequence shown. • Oil pan To install: 4. Apply a bead of silicone sealer to the gasket area where the pan meets the parting lines of the lower cylinder block and the front engine cover. 5. Install or connect the following: • Oil pan. Use a new gasket, tighten the pan bolts in several passes to 15-22 ft. lbs. (20-30 Nm), then tighten the transaxle case bolts to 28-38 ft. lbs. (38-51 Nm). • Flywheel access panel • Exhaust front pipe • Negative battery cable 6. Fill the crankcase to the correct level. 7. Start the engine and check for leaks.

Oil Pump REMOVAL & INSTALLATION 2.5L and 3.0L Engine 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the engine oil. 3. Remove or disconnect the following: • Negative battery cable • Oil pan • Timing chains • Oil pump pick up tube • Oil pump. Loosen the bolts in

49 UNG1 070 CYLINDER BLOCK KL 0 — 2 mm {0—0.079 In)

OIL SEAL

303*384 9308T618

Rear main seal installation— 2. 5L and 3.0L engines

reverse of the tightening

Rear Main Seal

sequence. To install: 4. Install or connect the following: • Oil pump. Tighten the bolts in sequence to 71-106 inch lbs. (8-12 Nm). • Oil pump pick up tube. Tighten the bolts to 71-106 inch lbs. (8-12 Nm) and the nut to 44 inch lbs. (5 Nm) plus 45 degrees. •• Timing Oil pan chains • Negative battery cable 5. Fill the crankcase to the correct level. 6. Start the engine and check for leaks.

REMOVAL & INSTALLATION 2.5L and 3.0L Engines 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: •• Transaxle Negative battery cable • Flywheel • Oil seal To install: 3. Install or connect the following: • Oil seal. Press the seal in evenly with Special Service Tools 49 UN01 070 and 303-384 as shown. • Flywheel. Tighten the bolts to 54-64 ft. lbs. (73-87 Nm). • Transaxle • Negative battery cable 4. Start the engine and check for leaks.

Timing Chain, Sprockets, Front Cover and Seal REMOVAL & INSTALLATION 2.5L and 3.0L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Relieve the fuel system pressure. ing: 3. Drain the engine oil. 4. Remove or disconnect the follow¬ 9308TG17

Oil pump torque sequence— 2. 5L and 3.0L engines

• Negative battery cable • Intake manifold

MAZDA MPV

19-21

Accessory drive belt Intake Manifold Runner Control (IMRC) actuator Spark plug wires Exhaust coil front pipe Ignition Oil pan Alternator and bracket A/C compressor Wiring harness connector bracket Water pump drive belt and pulley Camshaft oil seal housing Valve covers Right motor pulley mount and bracket Crankshaft Front crankshaft seal Front cover. Loosen the bolts in the • sequence Crankshaft shown. Position (CKP) sensor

9308TG21

Front cover bolt removal sequence— 2. 5L and 3.0L engine

VIEW FROM

pulse the wheel 5. Rotate crankshaft so that the key¬ position to locate is at the 11at o’clock way crankshaft the TDC for No. 1 cylinder. 6. Verify that the alignment arrows on the camshafts are aligned. If not, rotate the crankshaft 1 complete revolution and recheck. 7. Rotate the crankshaft so that the key¬

way is at the 3 o’clock position. This posi¬ tions the right cylinder head camshafts to the neutral position. ^Keep all valvetrain components in order for assembly. ing:

BACK

8. Remove or disconnect the follow¬ • Right timing chain tensioner • Right timing chain tensioner arm • Right timing chain and crankshaft timing sprocket • Right bank camshafts 9. Rotate the crankshaft 1 and % turns and set the crankshaft keyway at the 1 1

11 O'CLOCK POSITION

9308TG22

— 2.5L and 3.0L engine Camshaft alignment with the crankshaft in the 11 o’clock position

Using a thin prytool, release and hold the timing chain tensioner ratchet/pawl mech¬ anism — 2.5L and 3.0L engine

1Q99

I V~L.L.

MAZDA MPV

(1) (2) (3) (4)

Timing chain crankshaft sprocket Chain guide Timing chain Tensioner arm COLORED

LINK

^-Be sure that the crankshaft keyway is still at the 11 o’clock position. 12. Install or connect the following: • Left timing chain and crankshaft sprocket. Align the colored links with the index marks on the camshaft and crankshaft sprockets. • Left timing chain tensioner arm • Left timing chain tensioner. Tighten the retaining bolts to 15-22 ft. lbs. (20-30 Nm). 13. Remove the left timing chain ten¬ sioner retaining wire. 14. Rotate the crankshaft so that the key¬ way is at the 3 o’clock position. 15. Install the right bank camshafts with the exhaust camshaft index mark at 12 o’clock and the intake camshaft index mark at 3 o’clock as shown. 16. Install or connect the following: • Right timing chain and crankshaft sprocket. Align the colored links with the index marks on the camshaft and crankshaft sprockets. • Right timing chain tensioner arm • Right timing chain tensioner. Tighten the retaining bolts to 15-22 ft. lbs. (20-30 Nm).

Left bank timing chain alignment— 2. 5L and 3.0L engine

17. Remove the right timing chain ten¬ sioner retaining wire. 18. Install or connect the following: • CKP sensor pulse wheel • Front cover. Tighten the bolts in the reverse of the loosening sequence to 15-22 ft. lbs. (20-30 Nm). • Front crankshaft seal • Crankshaft pulley 19. Tighten the crankshaft pulley bolt as follows: a. Step 1:88 ft. lbs. (120 Nm). b. Step 2: Loosen the bolt one turn. c. Step 3: 35-39 ft. lbs. (47-53 Nm). d. Step 4: Plus 85-95 degrees. 20. Install or connect the following: •• Valve Right motor covers mount and bracket

o'clock position. This places the left bank camshafts in the neutral position. 10. Remove or disconnect the following: • Left timing chain tensioner • Left timing chain tensioner arm • Left timing chain and crankshaft timing sprocket To install: 11. Prepare the timing chain tensioners for installation as follows:

a. Place the left chain tensioner in a vise. b. Using a small prytool, release and hold the timing chain tensioner ratchet/pawl mechanism through the access hole in the timing chain tensioner. c. Slowly compress the tensioner. d. Lock the piston with a 1.5mm wire or paperclip. e. Repeat for the right chain tensioner.

• • • •• •

Camshaft oil seal housing Water pump drive belt and pulley Wiring harness connector bracket A/C compressor Oil pan Alternator and bracket

• Exhaust front pipe • Ignition coil • Spark plug wires • IMRC actuator • Accessory drive belt • Intake manifold • Negative battery cable 21 . Fill the crankcase to the correct level. 22. Start the engine and check for leaks.

RING COMPRESSION TOP RING BOTTOM COMPRESSION ' AND EXPANDER OIL CONTROL RINGS

CENTER LINE OF PISTON PARALLEL TO WRIST PIN BORE

Piston ring positioning, end-gap spacing, and piston positioning. The small direc¬ tional arrow must face the front of the

Right bank timing chain alignment— 2. 5L and 3.0L engine

engine — 2.5L and 3.0L engine

FUEL SYSTEM Fuel System Service Precautions Safety is the most important factor when performing not only fuel system maintenance but any type of maintenance. Failure to con¬ duct maintenance and repairs in a safe man¬ ner may result in serious personal injury or death. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adher¬ ing to the following rules and guidelines. • To avoid the possibility of fire and per¬ sonal injury, always disconnect the negative battery cable unless the repair or test proce¬ dure requires that battery voltage be applied. • Always relieve the fuel system pres¬ sure prior to disconnecting any fuel system component (injector, fuel rail, pressure reg¬ ulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may pene¬ trate the skin or any part of the body that it contacts. • Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage

(should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suit¬ able waste container. • Always keep a dry chemical (Class B) fire extinguisher near the work area. • Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. • Always use a back-up wrench when loosening and tightening fuel line connec¬ tion fittings. This will prevent unnecessary stress and torsion to fuel line piping. Always follow the proper tighten specifications. • Always replace worn fuel fitting Fi¬ rings with new. Do not substitute fuel hose or equivalent, where fuel pipe is installed.

Fuel System Pressure RELIEVING

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the fuel pump relay, located at the ECM. 3. Start the engine. 4. After the engine stalls, crank the engine several times. 5. Turn the ignition switch OFF.

Fuel pump relay— 2002

6. When repairs are complete, connect the fuel pump relay.

PLASTIC

ing:2. Relieve the fuel system pressure. 3. Remove or disconnect the follow¬

FUEL HOSE

• Negative battery cable • Air cleaner housing and fresh air duct • Mass Air Flow (MAF) sensor • Intake manifold

Fuel Filter REMOVAL & INSTALLATION The fuel filter is located in the fuel tank as part of the fuel pump module.

Fuel Pump

injector harness connectors • Fuel lines Fuel hose quick release connector

REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: • Negative battery cable • Front seats • Center console • Door sill plates • Parking brake lever • Carpet • Access panel • Fuel lines *

e

.

19-24 mpvzda

• • ••

Fuel pump module harness con¬ nector Fuel lines Access Carpet panel

• • • •

Parking brake lever Door sill plates Center console Front seats

• Negative battery cable

• Fuel injector harness connectors • Intake manifold • MAF sensor

Fuel Injector REMOVAL & INSTALLATION

*

• Fuel pump module harness con¬ nector • Fuel pump module 2.5L and 3.0L Engine To install: 4. Install or connect the following: of thi sec in the beg pre • Fuel pump module Star s tio cau inn t th n. t i ion ng e en s gin DRIVE TRAIN e an dc hec • Shift cable k fo Automatic Transaxle r le • aTransaxle oil cooler hoses ks. Assembly • Subframe transverse section • Axle halfshafts REMOVAL & INSTALLATION • Flywheel access panel • Torque converter 1 1 . Before servicing theB vehicle, refer to • Left engine mount bracket efo • Subframe center section r the precautions in the beginning ese of this sec¬ rvi tion. • Rear engine mount c 2. Drain the transaxle fluid. ingthe • Transaxle flange bolts. Support the veh transaxle. i 3. Attach a support fixture to the engine cle , r e 5. Lower the transaxle from the fer lifting eyes. to t vehicle. he 4. Remove or disconnect the following: To install: • Battery and tray 6. Install or connect the following: • Air cleaner assembly • Transaxle. Tighten the flange bolts • Mass Air Flow (MAF) sensor • Front wheels to 28-38 ft. lbs. (38-51 Nm). • Inner fender liner • Rear engine mount. Tighten the • Starter motor bracket bolts to 50-68 ft. lbs. • Transaxle solenoid valve connec¬ (67-93 Nm) and the through bolt tor to 63-86 ft. lbs. (86-116 Nm). • Subframe center section. Tighten • Range switch connector • Wiring harness bracket the bolts to 48-65 ft. lbs. (64-89 • Turbine speed sensor connector Nm) and the nuts to 50-67 ft. lbs. (67-93 Nm). • Vehicle Speed (VSS) sensor connprtnr

•

I aft onnino

• Pressure regulator vacuum hose • Fuel supply manifold with injectors attached • Fuel injectors To install: 4. Install or connect the following: • Fuel injectors with new O-ring seals • Fuel supply manifold with injectors attached. Tighten the bolts to 72-101 inchlbs. (8-11 Nm). • Fuel Pressure lines regulator vacuum hose

mount

hronl/ot

Tinhton

• Air cleaner housing and fresh air duct • Negative battery cable 5. Start the engine and check for leaks.

the bracket fasteners to 50-68 ft. lbs. (67-93 Nm) and the through bolt to 63-86 ft. lbs. (86-116 Nm). • Torque converter. Tighten the nuts to 26-36 ft. lbs. (35-49 Nm). • Flywheel access panel • Axle halfshafts • Subframe transverse section. Tighten the bolts to 69-97 ft. lbs. (94-131 Nm). • Transaxle oil cooler hoses • Shift cable • • • • •

VSS sensor connector Turbine speed sensor connector Wiring harness bracket Range switch connector Transaxle solenoid valve connec¬

• • • •

Starter motor tor Inner fender liner Front wheels MAF sensor

• Air cleaner assembly • Battery and tray 7. Fill the transaxle to the correct level.

MAZDA MPV

Nm). • Lower ball joint • Strut bracket bolts • Steering knuckle. Separate the stub shaft from the wheel hub. • Center shaft support bracket • Axle halfshaft and center shaft assembly

Halfshaft REMOVAL & INSTALLATION

7 3Left

1 . Before servicing the vehicle, refer to . . the precautions in the beginning of this sec¬ tion. 2. Drain the transaxle fluid. 3. Remove or disconnect the following: • Front wheel • Wheel speed sensor • Hub locknut • Outer tie rod end • Lower ball joint • Stabilizer bar link 4. Separate the stub shaft from the hub and pry the inner joint from the transaxle. To install:

center shaft as follow s: a. Step 1: Place the center shaft in a vise. b. Step 2: Insert a pry tool between Septhe shaft and the axle halfshaft. aratcenter e the axle halfshon the pry tool to sepa¬ c. Step 3: Tap aft from rate the axle halfshaft and t the center he shaft.

• Lower ball joint. Tighten the pinch bolt to 32-43 ft. lbs. (44-58 Nm). • Outer tie rod end. Tighten the nut to 24-32 ft. lbs. (32-44 Nm). • Hub locknut. Tighten the nut to 174-235 ft. lbs. (236-318 Nm). • Brake caliper and rotor. Tighten the caliper bracket bolts to 66-79 ft. lbs. (89-107 Nm). • Wheel speed sensor • Front wheel as neces sary.

CV-Joint align

ment

and

Outer CV-Joint

adjus

t

The outer CV-joint is serviced with the axle halfshaft as an assembly. The outer CVjoint boot may be serviced by removing the inner joint.

5. Insert the stub shaft into the wheel hub. 6. Lubricate the oil seal with transaxle fluid, then push the axle halfshaft into the transaxle. Pull on the inner joint to confirm that the circlip is seated. 7. Install or connect the following: • Stabilizer bar link • Lower ball joint. Tighten the pinch bolt to 32-43 ft. lbs. (44-58 Nm). • Outer tie rod end. Tighten the nut to 24-32 ft. lbs. (32-44 Nm). • Hub locknut. Tighten the nut to 174-235 ft. lbs. (236-318 Nm). • Wheel speed sensor • Front wheel

Separating the axle halfshaft from the cen¬ ter shaft

Inner CV-Joint 1. Before servicing the vehicle, refer to

To install: ^Use a new split pin, locknut, and new circlips for assembly.

sha by tap t c ins tal he ente ft pin r l as sh ha pla g o m sti wn me . c r

it wit

h

a

the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Axle halfshaft from the vehicle • Inner CV-joint boot clamps • Housing retainer clip • CV-joint housing • Snapring • CV-joint balls and cage • CV-joint inner race • CV-joint boot To install: ’»Use new snaprings, clips, and boot clamps for assembly.

Right

■c WARNING

bolts to 76-90 ft. lbs. (103-122

Check the w heel OVERHAUL

^Use a new circlip, split pin and lock¬ nut for assembly.

19-25

Pla

3. Install or connect the following: • CV-joint boot • Snapring • CV-joint inner race

cet he a xle axle Attempting to remove the right h halfshaft while the center shaftalfshsup¬ afit in port bracket is installed may result na damage to the center shaft support visea n bracket.

d

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the follow¬ ing: • Front wheel • Wheel speed sensor • Hub locknut • Brake caliper and rotor • Outer tie rod end

5. Lubricate the oil seal with transaxle fluid, then push the center shaft into the transaxle. Pull on the inner joint to confirm that the circlip is seated. 6. Install or connect the following: • Center shaft support bracket. Tighten the nuts to 16-22 ft. lbs. (22-30 Nm). • Steering knuckle. Guide the stub shaft into the wheel hub. • Strut bracket bolts. Tighten the

• CV-joint balls and cage • CV-joint housing • Housing retainer clip 4. Fill the CV-joint housing and boot with CV-joint grease and tighten the boot clamps. 5. Install the axle halfshaft. Inner Tri-Pot Joint 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

19-26 rvZDA

• Snapring To install:

• Axle halfshaft from the vehicle 3 • Inner tri-pot joint boot clamps • Tri-pot joint housing . • Snapring 2. pot joint Re•moTrive or di sconnect the following:

Air Bag _ ** CAUTION Some vehicles are equipped with an air bag system. The system must be disarmed before performing service on, or around, system components, the steering column, instrument panel components, wiring and sen¬ sors. Failure to follow the safety precautions and the disarming pro¬ cedure could result in accidental air bag deployment, possible injury and unnecessary system repairs. PRECAUTIONS Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible per¬ sonal injury. • Never carry the inflator module by the wires or connector on the underside of the module. • When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed away. • Place the inflator module on a bench or other surface with the bag and trim cover facing up. • With the inflator module on the bench, never place anything on or close to the

'■►Use new snaprings, clips, and boot clamps for assembly. • Tri-pot joint

AND SUSPENSION ISTEERING nstall or con nect he fthrown module which may tbe ollow in the event of an accidental deployment. ing: DISARMING 1. Turn the ignition switch to the LOCK position. 2. Disconnect the negative battery cable and wait at least 1 minute to allow the back-up power supply to deplete its stored 3. When repairs are complete, connect power. the negative battery cable.

Power Rack and Pinion Steering Gear REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Attach a support fixture to the engine lifting eyes. 3. Remove or disconnect the following: • Front wheels • • • • • •

Wheel speed sensors Steering shaft pinch bolt Outer tie rod ends Subframe transverse section Subframe center section Power steering pressure and return lines • Steering gear

• Tri-pot joint housing 4. Fill the tri-pot joint housing and boot with grease and tighten the boot clamps. 5. Install the axle halfshaft.

To install: 4. Install or connect the following: • Steering gear. Tighten the fasteners in sequence to 55-77 ft. lbs. (75-104 Nm). • Power lines steering pressure and return • Subframe center section. Tighten the bolts to 48-65 ft. lbs. (64-89 Nm) and the nuts to 50-68 ft. lbs. (67-93 Nm). • Subframe transverse section. Tighten the bolts to 69-96 ft. lbs. (94-131 Nm). • Outer tie rod ends. Tighten the nuts to 24-32 ft. lbs. (32-44 Nm). Nm). • Steering shaft pinch bolt. Tighten the bolt to 14-19 ft. lbs. (19-26 • Wheel speed sensors • Front wheels 5. Fill the power steering reservoir. 6. Check the wheel alignment and adjust as necessary.

Strut REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. •Remove or disconnect the following: Front wheel • Brake hose clip • Stabilizer bar link • Steering knuckle bolts •• Strut Upper assembly strut mount nuts To install: 3. Install or connect the following: • Strut assembly. Tighten the upper strut mount nuts to 34-46 ft. lbs. (47-62 Nm) and the steering knuckle bolts to 76-90 ft. lbs. (103-122 Nm). • Stabilizer bar link. Tighten the nut 32-44 lbs. (44-60 Nm). • to Brake hoseft.clip • Front wheel

Steering gear torque sequence

4. Check the wheel alignment and adjust as necessary.

MAZDA

5

MPV

.

Shock Absorber REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the rear axle with a jack or stands. 3. Remove or disconnect the following: • Rear wheel • Shock absorber To install: 4. Install or connect the following: • Shock absorber. Tighten the upper nut to 56-76 ft. lbs. (76-102 Nm) and the lower bolt to 71-94 ft. lbs. (97-127 Nm). • Rear wheel

Coil Spring

To install: 5. Place the coil springs on the spring seats and raise the axle into position. 6. Install or connect the following: • Shock absorber. Tighten the upper nut to 56-76 ft. lbs. (76-102 Nm) and the lower bolt to 71-94 ft. lbs. (97-127 Nm). • Lateral rod. Tighten the fastener to 76-101 ft. lbs. (102-137 Nm). • Rear wheels

Lower Ball Joint REMOVAL & INSTALLATION The lower ball joint is serviced with the lower control arm as an assembly.

Lower Control Arm

REMOVAL & INSTALLATION

REMOVAL & INSTALLATION

Front

2000-01

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the strut assembly from the vehicle. 3. Compress the coil spring and remove the piston rod nut. 4. Remove or disconnect the following: • Upper strut mount • Strut mount bearing • Spring upper seat • Coil spring To install: 5. Install or connect the following: • Coil spring • Spring upper seat • Strut mount bearing

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the arm. 3. Remove or disconnect the following: • Front wheel • Lower ball joint • Front inner control arm bolt • Rear inner control arm bracket • Lower control arm To install: 4. Install or connect the following: • Lower control arm. Tighten the front inner bolt to 69-93 ft. lbs. (94-126 Nm). • Rear inner control arm bracket.

• Upper strut mount. Tighten the pis¬ ton rod nut to 66-94 ft. lbs. (90-127 Nm). 6. Remove the spring compressor and install the strut assembly to the vehicle. 7. Check the wheel alignment and adjust as necessary.

Tighten the nut to 69-97 ft. lbs. (94-131 Nm). • Lower ball joint. Tighten the pinch bolt to 32-43 ft. lbs. (44-58 Nm). • Front wheel

Rear 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the vehicle at the frame and support the axle with a jack. 3. Remove or disconnect the following: • Rear wheels • Lateral rod • Shock absorber 4. Lower the rear axle and remove the coil springs.

Rear bushing alignment marks

19-27

as neceChssary. eck the wheel alignment and adjust

2002

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Support the arm. 3. Remove or disconnect the following: • Front wheel • Pivot bolt • • • • •

Dynamic damper Nut Ball joint bolt Ball joint bracket Nm) arm Lower

4. Installation is the reverse of removal. Observe the following torques: • Nut: 76-97 ft. lbs. (103-131 Nm) • Bracket bolt: 32-43 ft. lbs. (43-59 . Pivot bolt: 74-101 ft. lbs. (101-137 Nm) CONTROL ARM BUSHING REPLACEMENT 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the control arm from the vehicle. 3. Mark the control arm to indicate the alignment of the rear bushing as shown. 4. Remove the control arm bushings with a hydraulic press. To install: 5. Lubricate the control arm bushings with liquid soap. 6. If replacing the rear bushing, align the direction marks as shown. 7. Press the bushings into the control arm until the bushing flange contacts the housing edge of the control arm. 8. Install the control arm to the vehicle. 9. Check the wheel alignment and adjust as necessary.

19-28 rvZDA Wheel Bearing

2. Remove or disconnect the following: • Front wheel • • • • • • • •

ADJUSTMENT 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Front wheel • Brake caliper and rotor 3. Position a dial indicator gauge against the wheel hub. Push and pull the wheel hub in and out and measure the endplay of the wheel bearing. 4. End-play should not exceed 0.002 in. (0.05mm). 5. If end-play is excessive, replace the hub retainer locknut and tighten it to speci¬ fication. Recheck the end-play. 6. If end-play is not within specification, replace the wheel bearing assembly.

ons

1 . Before servicing the vehicle, refer to

• Wheel bearing cartridge To install:

’•'Use new locknuts, split pins and oil seals for assembly. 3. Install or connect the following: •• Sna Wheel pringbearing cartridge • Hub • Inner oil seal • Steering knuckle. Tighten the strut bracket bolts to 76-90 ft. lbs. (103-122 Nm). • Hub retainer locknut. Tighten the nut to 174-235 ft. lbs. (236-318 Nm).

Front

auti

Rear

• Snapring

REMOVAL & INSTALLATION

prec

Brake caliper and rotor Wheel speed sensor Outer tie rod end Lower ball joint Hub retainer locknut Strut bracket bolts Steering knuckle Inner oil seal Hub

in the begi o t s nnin f his ection. g

• Lower ball joint. Tighten the pinch bolt to 32-43 ft. lbs. (44-58 Nm). • Outer tie rod end. Tighten the nut to 24-32 ft. lbs. (32-44 Nm). • Wheel speed sensor. Tighten the bolt to 14-18 ft. lbs. (19-25 Nm). •• Brake caliper and rotor Front wheel

the precautions in the beginning of this sec¬ tion. 2. •Remove or disconnect the following: Rear wheel Dust cap • Brake drum • Hub retaining lock nut • Wheel bearing and hub assembly To install: 3. Install or connect the following: • Wheel bearing and hub assembly. • Tighten Dust capthe locknut to 131-173 ft. lbs. (177-235 Nm). • Brake drum • Rear wheel

BRAKES 84— 93(8.5— 9.5,62— 68}

Brake Caliper

(3)

REMOVAL & INSTALLATION 2000-01

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Wheel assembly • Banjo bolt and disconnect the brake hose from the caliper. Plug the hose to prevent fluid leakage. • Caliper mounting bolt and pivot the caliper about the mounting pin and off the brake rotor • Caliper from the pin 3. Installation is the reverse of the removal procedure. Lubricate the caliper mounting bolts or bolt and pin prior to e, re fer installation. to th e 4. Tighten the caliper mounting bolt(s) to 61-69 ft. lbs. (83-93 Nm). 5. Bleed the brake system. 2002 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

1 2

Brake hose Clip

3

Lock bolt

4 5

Brake caliper component Disc pad

6

Shim

7

Guide plate

8 9

Bolt Mounting support

10

Disc plate

Front disc brake assembly — 2000-01

N m { kgf m , ft Ibf } 93026G35

MAZDA MPV

1 2 3 4 5

Flexible hose Caliper Disc pad (See 04-1 1-16 Disc Pad Installation Note) Outer shim Inner shim

6 7 8 9

19-29

Guide plate Mounting support Dust boot Disc plate (See 04-1 1-15 Disc Plate Removal Note) (See 04-1 1-15 Disc Plate Installation Note) 42356-MMPV-G04

Front disc brake assembly — 2002

2. Remove or disconnect the following: • Wheel assembly • Banjo bolt and disconnect the brake hose from the caliper. Plug the hose to prevent fluid leakage. • Caliper mounting bolts 3. Installation is the reverse of the removal procedure. Lubricate the caliper mounting bolts or bolt and pin prior to installation. 4. Tighten the caliper mounting bolts to 61-69 ft. lbs. (83-93 Nm). 5. Bleed the brake system.

Disc Brake Pads REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Wheel assembly • Lower lock pin bolt from the caliper 3. Rotate the caliper upward and remove the brake pads, shims, guide plates and if equipped, the springs. To install: 4. Remove the master cylinder reservoir cap and remove about 1/2 of the fluid from the reservoir. 5. Using a large C-clamp and piece of wood, depress the caliper piston(s) until they bottom in their bores. 6. Install the shims, guide plates, new pads and if removed, the springs.

7. Reposition the caliper and install the lock pin bolt. Torque the lockbolt to 62-68 ft. lbs. 84-93 Nm). 8. Install the wheels, lower the vehicle, refill the master cylinder and depress the brake pedal a few times to restore pressure. Bleed the system if required.

Brake Drum REMOVAL & INSTALLATION 1 . Raise and safely support the vehicle. Remove the wheel and tire assembly. 2. Remove the screws, if equipped, and remove the brake drum. 3. Inspect the brake drum surface for wear, scoring and runout. Machine or replace, as necessary. To install: 4. Install the brake drum and secure in place with the screws, if equipped. Torque the screws to 10 ft. lbs. (14 Nm). 5. Adjust the rear brakes. 6. Install the wheel. Lower the vehicle.

Brake Shoes REMOVAL & INSTALLATION

1 . Raise and safely support the vehicle. Remove the wheel and tire assembly and the brake drum. 2. Pull backward on the adjusting lever

cable to disengage the adjusting lever from the adjusting screw. Move the outboard side of the adjusting screw upward and back off the pivot nut as far as it will go. 3. Pull the adjusting lever, cable and automatic adjuster spring down and toward the rear to unhook the pivot hook from the large hole in the secondary shoe web. Do not pry the pivot hook from the hole. 4. Remove the automatic adjuster spring and adjusting lever. 5. Remove the secondary shoe-toanchor spring using a suitable brake spring removal/installation tool. Using the tool,

remove the primary shoe-to-anchor spring and unhook the cable anchor. Remove the anchor pin plate, if equipped. 6. Remove the cable guide from the secondary shoe. 7. Remove the shoe hold-down springs, shoes, adjusting screw, pivot nut and socket. Note the color and position of each hold-down spring so they can be reassembled in the same position. 8. Remove the parking brake link and spring. Disconnect the parking brake cable from the parking brake lever. 9. Remove the secondary brake shoe. Remove the retainer clip and spring washer and remove the parking brake lever. To install: 10. Clean the backing plate ledge pads and sand lightly. Apply a light coating of high temperature lithium grease to the points where the brake shoes touch the

HQ Of) MAZDA I D“OU MPV backing plate. Lubricate the adjusting cable eye and the anchor pin area. 11. Install the parking brake lever on the secondary shoe. 12. Position the brake shoes on the backing plate and install the hold-down spring pins, springs and cups. Install the parking brake link, spring and washer. Con¬ nect the parking brake cable to the parking brake lever. 13. Install the anchor pin plate, if equipped, and place the cable anchor over the anchor pin with the crimped side toward the backing plate. 14. Install the primary shoe-to-anchor spring using the brake spring removal/instal¬ lation tool. 15. Install the cable guide on the sec¬ ondary shoe with the flanged hole fitted into the hole in the secondary shoe. Thread the cable around the cable guide groove.

'"•’Make sure the cable is positioned in the groove and not between the guide and shoe web.

16. Install the secondary shoe-to-anchor (long) spring. '■►Make sure the cable end is not cocked or binding on the anchor pin when installed. All parts should be flat on the anchor pin. 17. Apply high temperature lithium grease to the threads and the socket end of the adjusting screw. Turn the adjusting screw into the adjusting pivot nut to the end of the threads and then loosen, Vfe turn. 18. Place the adjusting socket on the screw and install the assembly between the shoe ends with the adjusting screw nearest the secondary shoe. ^Be sure to install the adjusting screw on the same side of the vehicle from which it came. To pre¬ vent incorrect installation, the socket end of each adjusting screw is stamped with R or L, to indicate installation on the right or left side

of the vehicle. The adjusting pivot nuts have lines machined around the body of the nut, 2 lines indicating the right side nut and 1 line indicating the left side nut. 19. Hook the cable hook into the hole in the adjusting lever from the outboard plate side. The adjusting levers are also stamped with an R or L to indicate right or left side installation. 20. Place the hooked end of the adjuster spring in the large hole in the primary shoe web and connect the loop end of the spring to the adjuster lever hole. 21. Pull the adjuster lever, cable and automatic adjuster spring down toward the rear to engage the pivot hook in the large hole in the secondary shoe web. 22. Adjust the brake shoes using either a brake adjustment gauge or manually with the drums installed. 23. Install the wheels, and lower the vehicle.

*

1

Hub cap

10

Screw Brake drum Return spring

11 13 12

Ajuster lever O-ring Adjuster component Brake pipe lever Operating

14

Wheel cylinder

6

Hold pin and hold spring Anti-rattle spring

15

7

Leading shoe

16

Parking brake cable Trailing shoe

17

2 3 4 5

8 9

Locknut Wheel hub Backing plate

18 42356-MMPV-G05

Exploded view of the rear brake shoes and components

MAZDA Tribute 20-33 BRAKES . 20-27 DRIVE TRAIN . 20-10 . ENGINE REPAIR 20-26 FUEL SYSTEM . 20-10 PRECAUTIONS . SPECIFICATION CHARTS . 20-2 STEERING AND 20-30 SUSPENSION . A

Air Bag . Arming The System . Disarming . Precautions . Alternator . Installation . Removal . Axle Housing . ion . Removal & Installat B

20-30 20-30 20-30 20-30 20-10 20-10 20-10 20-30 20-30

Brake Caliper . Removal & Installation . Brake Drum . Removal & Installation . Brake Pads . Removal & Installation . Brake Rotor . Removal & Installation . Brake Shoes . ion . Removal & Installat C

20-33 20-33 20-33 20-33 20-33 20-33 20-33 20-33 20-34 20-34

Camshaft and Lifters . Removal & Installation . Clutch . Adjustments . Removal & Installation . Coil Spring . Removal & Installation . CV-Joints . Overhaul .

20-19 20-19 20-28 20-28 20-28 20-31 20-31 20-29 20-29

Cylinder Head . Removal & Installat D ion .

20-14 20-14

Oil Pump . Removal & Installati P on .

20-22 20-22

Distributor . E

20-10

Engine Assembly . Removal & Installation . Exhaust Manifold . Removal & Installati F on .

20-11 20-11 20-17 20-17

Piston and Ring . Positioning . . .

20-25 20-25

Rear Main Seal . Removal & Installati S on .

20-23 20-23

Front Crankshaft Seal . Removal & Installation . Fuel Filter . Removal & Installation . Fuel Injectors . Removal & Installation . Fuel Pump . Removal & Installation . Fuel System Pressure . Relieving . Fuel System Service Precautions . H

20-19 20-19 20-26 20-26 20-26 20-26 20-26 20-26 20-26 20-26

Shock Absorber . Removal & Installation . Starter Motor . Removal & Installation . Steering Gear . Removal & Installation . Strut . T ion . Removal & Installat

20-31 20-31 20-21 20-21 20-30 20-30 20-31 20-31

20-23 20-23

Halfshaft . Removal & Installation . Heater Core . Removal & Installation . Hydraulic Clutch System . Bleeding .

20-29 20-29 20-13 20-13 20-29 20-29

Timing Belt and Covers . Removal & Installation . Timing Gears, Front Cover and Seal . Removal & Installation . Transfer Case . Removal & Installation . Transmission Assembly . U ion . Removal & Installat

Upper Control Arm . M ion . Removal & Installat

20-32 20-32

Ignition Timing . Adjustment . Intake Manifold . Removal & Installa L tion .

20-11 20-11 20-16 20-16

Valve Lash . W Adjustment .

20-21 20-21

Lower Control Arm . Removal & Installa 0 tion .

20-32 20-32

Water Pump . Removal & Installation . Wheel Bearings .

20-13 20-13 20-32

Oil Pan... . Removal & Installation .

20-21 20-21

20-26

20-24 20-24 20-29 20-29 20-27 20-27

MAZDA

20-2

TRIBUTE

SPECIFICATION CHARTS ENGINE AND VEHICLE IDENTIFICATION Model Year

Engine Code ©

Liters (cc)

B

2.0(1998)

1

3.0 (3049)

Cu. In.

Cyl.

Fuel Sys.

4

121 182

Engine Type DOHC

SFI

6

Eng. Mfg. Ford

DOHC

SFI

Code©

Year

1

2001 2002

2

Ford

SFI: Multi-port Fuel Injection

3

2003

DOHC: Double Overhead Camshafts

4

2004

©8th digit of VIN © 10th digit of VI N 42356-TRIB-C01

GENERAL

ENGINE SPECIFICATIONS

Engine Displacement Year _ 2001 2002 2003

Model _

Tribute

Liters (cc) 2.0(1998)

Engine

System

ID/VIN

Horsepower

Type _

Net Torque @ rpm

@rpm _

(ft. lbs.)

SFI

135@5500

135@4500

SFI

200@5500

200@4500

3.0 (3049)

1

Tribute

2.0(1998)

B

Tribute

3.0 (3049)

1

Tribute

2.0 (1998)

B

SFI SFI SFI

1

3.0 (3049)

Net

B

Tribute

Tribute

Fuel

SFI

135@4500

135@5500

Borex Stroke (in.)

3.34x3.46

Ratio

45 @ 54-80 rpm©

3.34x3.46

9.6:1 10.0:1

200@4500

135@5500

135@4500

3.34x3.46 3.50x3.13

200@4500

Pressure

9.6:1 10.0:1

3.50x3.13

Oil

pression

3.50x3.13

200@5500

200@5500

Com-

45 54-80

9.6:1

54-80

10.0:1

45

SFI: Multi-port Fuel Injection © The manufacturer does not provide an engine speed specification for oil pump pressure. 42356-TRIB-C02

ENGINE TUNE-UP SPECIFICATIONS ignition Engine Year 2001

Displacement Liters (cc) 2.0(1998)

Engine ID/VIN

Spark Plug

Gap (in.)

B 0.043 0.039-

3.0 (3049)

2002

2.0(1998)

Timing

_

(deg.) _ AT — 10 BTDC MT

B

0.056 0.0520.051

2.0(1998)

65

©

HYD.

HYD.

©

HYD.

HYD.

HYD.

HYD.

HYD.

HYD.

HYD.

HYD.

65

(psi)

BTDC

10

—

65

10

65

BTDC 10

— 10

1

10 0.056 0.052-

BTDC: Before Top Dead Center HYD: Hydraulic lash adjusters © Refer to Vehicle Emission Control Information Label

©

—

BTDC

©

BTDC

BTDC 3.0 (3049)

IntakeClearanceExhaust HYD. HYD.

© 0.056 0.0520.051

Valve

(rpm) AT — ©

1

B

_

Speed MT

BTDC

10

2003

Pump

10

BTDC 3.0 (3049)

Fuel

10

1

Idle

BTDC

65 65

©

©

—

©

MAZDA TRIBUTE

20-3 ©® © ® © ©

(DdXD©

© ®

®

Front of the Vehicle

FRONT

® ©

OF VEHICLE

* 79223G35

2.0L (VIN B) Engine Firing order: 1 -3-4-2 Distributorless ignition system

79223626

3.0L (VIN 1) Engine Distributorless ignition system Firing order: 1-4-2-5-3-6

20-4

MAZDA TRIBUTE

Power

steering

Drive

belt

A/C

pump

clutch

pulley

Crankshaft

pulley

Drive

tensioner

belt

Generator

pulley

pulley 93551 CLN

Accessory serpentine belt routing— 3. 0L engines without A/C

MAZDA TRIBUTE

20-5

CAPACITIES

Cooling

Drive Engine Oil with

Engine Year 2001

Model

Displacement Liters (cc)

Tribute

2.0(1998)

Tribute Tribute

2002

Tribute Tribute

2003

Tribute

Engine ID/VIN B

3.0 (3049)

1

2.0(1998)

B

3.0 (3049)

1

2.0 (1998)

B

Filter (pts.) Auto. Manual 4.5 — (qts.) 5.7

4.5 5.8

5.7 5.7

5.5 4.5

5.7

Transfer Case

Axle

Front

Fuel Tank

Rear

—

—

3.0

20.0

(pts.) ©

—

—

(pts.) 2.6 —

(pts.)

15.0 16.0

3.0

(gal.) 15.0

3.0

20.0

©

—

—

— 2.6

©

2.6

5.7 5.7

5.5

1

3.0 (3049)

Transmission

16.0 15.0

3.0

7.0 System 10.5

(qts.) 7.0 10.5 7.0

10.5

16.0

20.0

obtained. NOTE: All capacities are approximate. Add fluid gradually and check to be sure a proper fluid level is ©

The transfer case is lubricated for life and is not to be checked unless a leak is suspected or a repair is necessary. 42356-TR1B-C04

CRANKSHAFT

AND CONNECTING

All measurements

Year

Displacement Liters (cc)

Engine ID/VIN

2001

2.0(1998)

B

Main Brg. Journal Dia.

Clearance

on No.

©

3

2002

2.0 (1998)

0.0102 0.0035-

1 2.47912.4800 B

0.0018 0.0010©

2.28272.2835 3.0 (3049)

2.0(1998)

0.0102 0.0035-

B

0.0018 0.0010©

2.28272.2835 3.0 (3049)

0.0091 0.00430.0102 0.0035-

1 2.47912.4800

© Journals 1, 2 and 4: 0.0010 - 0.0017 in.

0.0091 0.0043-

1 2.47912.4800

2003

are given in inches.

Crankshaft Shaft Journal Main Brg. Oil Thrust End-play

2.28272.2835 3.0 (3049)

ROD SPECIFICATIONS

0.0018 0.0010-

0.0091 0.0043-

Side Clearance

Diameter

Clearance

1.8468

0.0028

0.0110

0.0006-

0.0040-

0.0025

0.0118

Oil

3

1.8460-

3

1.9681 1.9673-

3

1.8468 1.8460-

3

1.9681 1.9673-

3

Connecting Rod

0.00100.0028 0.00060.0026 0.0011-

0.00390.0110 0.00400.0118

0.0039-

1.8468

0.0028

1.8460-

0.0006-

1.9681 1.9673-

0.0026

0.00400.0118

0.0011-

0.0039-

0.0110

Journal 3: 0.0012 - 0.0019 in. 42356- TRIB-C05

MAZDA

20-6

TRIBUTE

VALVE SPECIFICATIONS Engine Year 2001

Displacement Liters (cc)

Engine ID/VIN

Seat

Face

Spring Test

Angle (deg.)

Angle (deg.) 45

Pressure (lbs. @ in.)

45

B

2.0(1998)

1

3.0 (3049)

Spring Stem-to-Guide Installed Clearance

Height Intake (in.)

45.5

1.57

0.0025 0.0007-

1.346

0.0027 0.0008-

1.57

0.0025 0.0007-

1.346

0.0027 0.0008-

153(5) 1.18 45

2002

B

2.0(1998)

1

3.0 (3049)

2003

45

©

44.75

45.5

45

45

153@ 1.18

B

2.0(1998)

1

3.0 (3049)

© 44.75

45.5

(in.) Intake Exhaust

(in.)

1.346

© 44.75

Stem Diameter

1.57

153(5) 1.18

0.0025 0.00070.0027 0.0008-

©Intake: 82. 1@ 0.988

Exhaust

0.2374

0.2374

0.0037

0.2360

0.2350

0.0018-

0.23520.2374

0.23430.2374

0.0025 0.0007-

0.0025 0.00070.0037

0.2360

0.0018-

0.23520.2374

0.2350 0.2374 0.2343-

0.0025 0.00070.0037 0.0018-

0.2360

0.2350

0.2352-

0.2343-

Exhaust: 95@ 1.0275 42356-TRIB-C06

Top snug

Top RING SPECIFICATIONS PISTON AND

All measurements

are given in inches. Ring Gap

Engine Displ.

Engine

Year

Liters (cc)

ID/VIN

2001

2.0(1998)

B

3.0 (3049)

Piston Clearance

Comp.

Bottom Comp.

0.00040.0012

0.0300 0.0100-

0.0300 0.0100-

2.0(1998)

3.0 (3049)

2003

2.0(1998)

3.0 (3049)

Oil Control 0.0660 0.0160-

1 0.00050.0009

2002

Ring Side Clearance Comp. Comp. Bottom

0.00390.0098

0.0165 0.0106-

0.0256 0.0059-

B

0.0032

s

nug Control Oil snug

0.00150.0030 0.0016-

0.00040.0012

0.01000.0300

0.0300 0.0100-

0.0660 0.0160-

0.0032 0.0015-

0.00050.0009

0.0098 0.0039-

0.0165 0.0106-

0.0256 0.0059-

0.0030 0.0016-

0.00040.0012

0.0300 0.0100-

0.0300 0.0100-

0.0660 0.0160-

0.0032

1

0.0035

snug

0.00150.0033

snug

0.00160.0035

snug

0.0015-

B

1 0.00050.0009

0.0098 0.0039-

0.0165 0.0106-

0.0256 0.0059-

0.00150.0030

0.0033 0.00160.0035 0.00150.0033

0.00160.001642356-TRIB-C07

MAZDA TRIBUTE

TORQUE

20-7

SPECIFICATIONS

All readings in ft. lbs. Cylinder

Engine Displacement

Engine ID/VIN

Head Bolts

Main Bearing Bolts

Bolts

Liters (cc)

2001

2.0(1998)

B

©

©

©

3.0 (3049)

1

©

©

©

2.0 (1998)

B

©

©

©

3.0 (3049)

1

©

©

©

2.0(1998)

B

©

©

©

3.0 (3049)

1

©

©

©

2003

Flywheel 13Manifold 15 Bolts Intake Exhaust Bolts

Damper

Bearing

Year

2002

Crankshaft

Rod

80-87 © 80-87 ©

12

83

59

©

83

13

59

© 13

80-87 ©

83

15 12 15 12

©

Spark

Lug

Plugs

Nuts

11 11

98

11

98 98

11 11 11

98 98

59 ©Step

1:15 ft. lbs. (20 Nm).

Step 2: 30 ft. lbs. (40 Nm). Step 3: Plus an additional 90 degrees. ©Step

1:18 ft. lbs.

Step 2: +60 degrees ©Step

1:26 ft. lbs.

Step 2: +90 degrees ©Step

1:30 ft. lbs. (40 Nm).

Step 2: Tighten the bolts 90 degrees. Step 3: Loosen the bolts one full turn. Step 4:30 ft. lbs. (40 Nm). Step 5: Tighten the bolts 90 degrees. Step 6: Tighten the bolts 90 degrees. ©

Step 1: Fasteners 1-8: 18ft. lbs. Step 2: Fasteners 9-19: 30 ft. lbs. Step 3: Fasteners 1-16: +90 degrees Step 4: fasteners 17-22: 18 ft. lbs.

©Step

1:17 ft. lbs.

Step 2: 32 ft. lbs. ©Step

1:89 ft. lbs.

Step 2: Loosen 1 full turn Step 3: 37 ft. lbs. Step 4: 66 ft. lbs. ©89

inch lbs. 42356-TRIB-C08

WHEEL Caster Range

Tear 2001 2002

+1.93

Mooei ALL

ALL

F R

NA NA

F

NA

R

2003

ALL

Setting Preferred

F R

NA NA

NA +1.93

Steering

ALIGNMENT Camber Range

Setting Preferred

Axis

-0.04

Inclination

-0.84

NA

NA

-0.84

Toe-in

11.40

-0.04 -0.84

0.12+/-0.12

NA

-0.04

0.12+/-0.12

NA +1.93 NA

NA

0.09+/-0.11 NA NA

NA NA

0.09+/-0.11

0.1 2+V-0.1 2 0.09+7-0.1 1

11.40 NA 11.40 NA

OH

Q

MAZDA

lU"

O

tribute

TIRE, WHEEL

AND BALL JOINT SPECIFICATIONS Tire Pressures (psi)

OEM Tires Year

Model

Standard

2001

Tribute

P225/70SR1 5

P235/70R16

2002

Tribute

P21 5/70R1 6

P225/70SR15

NA

P235/70R16

NA

P225/70SR15

NA

2003

Tribute

Front

Optional

P215/70R16

Rear

Ball Joint

Wheel Size

Inspection

NA

NA

0.030 in.

NA

NA

0.030 in.

NA

NA

0.030 in.

P235/70R16 OEM: Original Equipment Manufacturer PSI: Pounds Per Square Inch STD: Standard OPT: Optional NA: Not Available 42356-TRIB-C10

BRAKE

SPECIFICATIONS

All measurements Brake Disc Year 2001 2002 2003

in inches unless noted

Minimum Thickness

Maximum

Model

Original Thickness

Original Inside

Run-out

Diameter

Tribute

0.940

0.860

0.002

Tribute

0.940

0.860

0.004

9.06 9.06

Tribute

0.940

0.860

0.004

9.06

0.06 0.06 0.06

Lining

Minimum

Mounting Brake Caliper Bracket Bolts Bolts

Thickness

(ft. lbs.)

8.92

0.039

Ill 111

8.92

0.039

Brake Drum _ Max. Maximum Machine Wear Diameter Limit

8.92

26

0.039

(ft.26 lbs.)

111 26

42356-TRIB-C1 1

MAZDA TRIBUTE

20-9

INTERVALS

MAINTENANCE

SCHEDULED

Mazda Tribute VEHICLE 25 TYPE TO BE SERVICED

OF

SERVICE

50

30

20

15

R

Accessory drive belt

S/I

S/I

Cooling fan operation

S/I

Cooling system hoses

S/I

CV-joint boots & axle seals

S/I R

Engine coolant

R

Engine oil & filter

✓ ✓

V

V

V

Ten years or 150,000 miles \ \ \

✓

s \ v \ v

Check monthly ✓

PCV valve

S/I S/I

Exhaust system & heat shields

S/I

Parking brake system

S/I

Every 6 months

Power steering fluid

S/I

Every 6 months

S/I

V

Rotate tires Steering linkage

✓

S/I R

Spark plugs Suspension components

©

65

✓

Exterior Lights

R: Replace

60

S/I

Clutch pedal operation

S/1: Inspect and service, if necessary

55

35

Air cleaner filter

Brake system ©

10

5

45 40 INTERVAL (xIOOO)

MILEAGE

S/I L: Lubricate

V

✓

V

Change at 100,000 miles

EZ A: Adjust

E

_

hh

1

_

_

hi

_

C: Clean

cylinders Inspect the reservoir fluid level, rotor and or drum, brake lines, hoses, calipers and or wheel

FREQUENT OPERATION MAINTENANCE

(SEVERE SERVICE)

If a vehicle is operated under any of the following conditions it is considered severe service: • Extremely dusty areas. operation in temperatures below 0°C (32»F). • 50% or more of the vehicle operation Is in 32°C (90°F) or higher temperatures, or constant - Prolonged idling (vehicle operation in stop and go traffic). T-

• Frequent short running periods (engine does not warm to normal operating temperatures). • Police, taxi, delivery usage or trailer towing usage. Oil & oil filter change: change every 3000 miles. Air filter element: change every 15,000 miles. 42356-TRIB-C12

on in MAZDA

4U“

I U TRIBUTE PRECAUTIONS

Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: • Never open, service or drain the radia¬ tor or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. • Observe all applicable safety precau¬ tions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. • Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. • Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance.

• The EPA warns that prolonged con¬ tact with used engine oil may cause a number of skin disorders, including can¬ cer! You should make every effort to mini¬ mize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas as soon as pos¬ sible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. • All new vehicles are now equipped with an air bag system, often referred to as a Supplemental Restraint System (SRS) or Supplemental Inflatable Restraint (SIR) sys¬ tem. The system must be disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling proce¬ dures could result in accidental air bag deployment, possible personal injury and unnecessary system repairs. • Always wear safety goggles when working with, or around, the air bag sys¬ tem. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When plac¬ ing a non-deployed air bag on a work sur¬ face, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the addi¬ tional air bag system precautions later in this section. • Clean, high quality brake fluid from a sealed container is essential to the safe and proper operation of the brake system. You

should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in con¬ tact with a painted surface; it will damage the paint. • Never operate the engine without the proper amount and type of engine oil; doing damage.so WILL result in severe engine • Timing belt maintenance is extremely important! Many models utilize an interfer¬ ence-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing poten¬ tially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this section for the recommended replace¬ ment interval for the timing belt, and to the timing belt section for belt replacement and inspection. • Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer sys¬ tem^) and may require the computer to undergo a relearning process once the neg¬ ative battery cable is reconnected. • When servicing drum brakes, only dis¬ assemble and assemble one side at a time, leaving the remaining side intact for refer¬ ence. • Only an MVAC-trained, EPA-certified automotive technician should service the air conditioning system or its components.

ENGINE REPAIR Distributor The Tribute uses a Direct Ignition System (DIS). No distributor is used.

Alternator

while moving the alternator to the rear of the engine • Alternator. Torque the mounting and adjusting bolts to 33 ft. lbs. (45Nm). 3.0L Engine

REMOVAL 2.0L Engine

1 . Remove or disconnect the follow¬ ing: • Negative battery cable • Drive belt • Alternator electrical connectors and loosen the upper alternator bolt

1. Remove or disconnect the following: • Negative battery cable • Right side intermediate axle shaft • Right side splash shield and retain¬ ers • Drive belt • Alternator electrical connectors • Alternator. Torque the mounting and adjusting bolts to 35 ft. lbs. (48Nm).

INSTALLATION 2.0L Engine

1. Install or connect the following: • Alternator with the upper bolt in the Nm). alternator before installation. Torque the bolts to 18 ft. lbs. (25 •• Alternator Drive belt electrical connectors • Negative battery cable 3.0L Engine

1. Install or connect the following: • Alternator. Torque the bolts to 35 ft. lbs. (48 Nm).

MAZDA TRIBUTE

• Alternator electrical connectors • Drive belt • Negative battery cable

Ignition Timing ADJUSTMENT Ignition timing is controlled by the Pow¬ ertrain Control Module (PCM). No adjust¬ ment is necessary or possible.

Engine Assembly

• • • •

Front transmission through bolt Engine-to-transmission bolts Lower radiator hose Power steering pump

• Clutch slave cylinder line from the bracket and move it aside • Rear transmission mount • Left side transmission mount • Lower ground cable • Engine mount upper bracket • Engine and transmission as an assembly by using a proper lifting device • Alternator electrical connectors

REMOVAL & INSTALLATION

• Knock Sensor (KS) electrical con¬ nector

2.0L Engine

• Oil pressure sender electrical con¬ nector • Starter electrical connector

MANUAL

TRANSMISSION

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Properly recover the air conditioning system refrigerant. 3. Properly relieve the fuel system pressure. 4. Drain the cooling system. 5. Drain the engine oil. 6. Remove or disconnect the follow¬ ing: • Hood • • • • • • • • • •

Battery and battery tray Air cleaner housing Fuel lines Throttle cable and speed control cable, if equipped Exhaust Gas Recirculation (EGR) vacuum valve regulator EGR electrical connectors and vac¬ uum hoses Brake booster vacuum hose Powertrain Control Module (PCM) wire harness and ground Wire harness connector Power distribution board electrical connectors

• Vehicle Speed Sensor (VSS) elec¬ trical connector • Park Neutral Position (PNP) electri¬ cal connector • Fuel charging wire harness electri¬ cal connector • PCM wire harness from the bracket • PCM ground wire • Back nectorup lamp switch electrical con¬ • Wire harness • Differential Pressure Feedback (DPFEE) EGR sensor 7. Separate the engine from the trans¬ mission. 8. Lock the flywheel to the engine. 9. Clutch pressure plate and disc. 10. Flywheel and rear cover plates. To install:

1 1 . Install or connect the following:

20-11

• Flywheel. Torque the bolts to 83 ft. lbs. (112 Nm). • Clutch disc to the flywheel • Pressure plate to the flywheel. Torque the bolts in the proper sequence to 18 ft. lbs. (25 Nm). • Transmission to the engine. Torque the bolts to 33 ft. lbs. (45 Nm). • Starter. Torque the bolts to 18 ft. lbs. (25 Nm). • Wire harness and attach it to the powertrain assembly • DPFEE sensor electrical connector • Reverse lamp switch electrical con¬ nector • Ground wire. Torque the bolt to 80 inch lbs. (9 Nm). • PCM wire harness to the bracket • Fuel charging wire harness electri¬ cal connector • PNP switch electrical connector • VSS electrical connector • KS, Oil pressure sender and starter electrical connector. Torque the fas¬ teners to 9 ft. lbs. (12 Nm). • Alternator electrical connectors. Torque the fasteners to 71 inch lbs. (8 Nm). • Powertrain assembly in the vehicle • Left side transmission mount. Torque the side bolts to 41 ft. lbs. (55lbs. Nm)(90andNm). the center bolt to 66 ft. • Engine mount upper bracket. Torque the side bolts to 72 ft. lbs. (98lbs. Nm)(77andNm). the center bolt to 57 ft. • Ground wire. Torque the bolt to 25 ft. lbs. (34 Nm).

• Evaporative emissions (EVAP) can¬ ister vacuum lines • Upper radiator hose • Power steering line bracket • Upper power steering pump bolts • Coolant hose • Heater hoses • Speed control unit, if equipped • Catalytic converter • A/C compressor • Both halfshafts • Shifter linkages • Block heater electrical connector, if equipped

9308TG07

Tighten the pressure plate bolts in the proper sequence-2. OL engine

20-12

MAZDA TRIBUTE

• Rear transmission mount. Torque the bolts to 41 ft. lbs. (55 Nm). • Speed control unit, if equipped. Torque the bolts to 89 inch lbs. (10 Nm). • Power steering pump and hand tighten the bolts • Lower power steering line bracket. Torque the bolt to 89 inch lbs. (10 Nm). • Upper power steering line bolt. Torque the bolt to 15 ft. lbs. (20 Nm). • Slave cylinder line and clip. Torque the bolts to 16 ft. lbs. (22 Nm). • Power steering lines. Torque the retaining bolts to 89 inch lbs. (10 Nm). Torque the power steering pump bolts to 18 ft. lbs. (25 Nm). • Lower radiator hose • Engine-to-transmission bolts. Torque the bolts to 33 ft. lbs. (45 Nm). • Front transmission through bolt. Torque the bolt to 66 ft. lbs. (90 Nm). • Block heater electrical connector • Shifter linkages. Torque the upper bolt to 33 ft. lbs. (45 Nm) and the lower bolt to 15 ft. lbs. (20 Nm). • Coolant hose • Catalytic converter • Heater hoses • Upper radiator hose • EVAP canister vacuum lines • Power distribution box electrical connector. Torque the fastener to 9 ft. lbs. (12 Nm). • Wire harness electrical connector • Ground wires • PCM wire harness and ground • Brake booster vacuum supply hose to the intake manifold • EGR vacuum regulator valve hoses and electrical connector • Throttle cable and speed control cable, if equipped • Fuel lines • Battery tray and battery • Air cleaner • Hood 12. Fill the engine with clean oil. 13. Fill and bleed the cooling system. 14. Recharge the A/C system. 15. Start the vehicle, check for leaks and repair if necessary. 3.0L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

2. Properly recover the air conditioning system refrigerant. 3. Properly relieve the fuel system pressure. 4. Drain the cooling system. 5. Drain the engine oil. Hood or disconnect the following: 6.• Remove • • • •

Battery and battery tray Air cleaner outlet tube and housing Lower radiator air deflectors Fuel lines

• Water pump drive belt • Accelerator cable and speed control cable, if equipped • Vapor Management Valve (VMV) • Powertrain Control Module (PCM) • PCM ground wire • Thermostat housing and hose assembly and move them aside • Power distribution box electrical connector • Power distribution box cover • Nuts and cables from inside the power distribution box • Transmission linkage • Brake booster vacuum hose • Heater hoses Power steering return line Power Steering Pressure (PSP) switch electrical connector Power steering supply line Oil level indicator Catalytic converter A/C compressor Both front wheels Intermediate drive shaft, if equipped 7. Separate both side ball joints. 8. Separate both side tie rod ends from the steering knuckles. 9. Separate both sway bar links from the strut mounts. 10. Separate the struts from the steering knuckles. 1 1 . Remove or disconnect the following: • Both wheel speed sensors, if equipped • Brake calipers from the steering knuckles and properly support the struts • Steering shaft from the rack • Transmission line bracket bolt • Transmission cooler lines • Torque converter inspection cover • Torque converter nuts • Block heater wiring, if equipped 12. Install a powertrain lifting devise and raise the vehicle. • Engine support bracket • Transmission support • 2 rear subframe bolts • 2 subframe side bolts

• Motor mount support bolts • assembly Engine and transmission as an • Heated Oxygen (HO2S) sensor • Transmission Range (TR) sensor • Transmission harness electronic control switch • Transmission control harness from the bracket • Starter and wire harness • Knock Sensor (KS) electrical connector • Output Shaft Speed (OSS) sensor electrical connector • HO2S sensor and Exhaust Gas Recirculation (EGR) tube from the exhaust manifold • Alternator and electrical connectors • Right side exhaust manifold and • Halfshaft support bracket and move it aside gasket 13. Separate mission assemblythe engine from the transTo install:

14. Install or connect the following: • Powertrain assembly on the subframe Nm). Transmission-to-engine bolts. Torque the bolts to 30 ft. lbs. (40 Halfshaft bracket. Torque the bolts to 18 ft. lbs. (25 Nm). Right side exhaust manifold and new gasket. Torque the bolts to 15 ft. lbs. (25 Nm). Alternator. Torque the larger bolts to 18 ft. lbs. (25 Nm) and smaller bolt to 89 inch lbs. (10 Nm). EGR tube and HO2S sensor electri¬ cal connectors OSS sensor electrical connector KS jumper electrical connector Starter. Torque the bolts to 18 ft. lbs. (25 Nm). Transmission control harness to the bracket. Torque the bolt to 18 ft. lbs. (25 Nm). Transmission harness Transmission range sensor Powertrain assembly Motor mount support. Torque the bolts to 66 ft. lbs. (90 Nm). Subframe side nuts. Torque the nuts to 76 ft. lbs. (103 Nm). Raise the vehicle and support the powertrain assembly with a lifting device. Transmission mount. Torque the bolts to side bolts to 66 ft. lbs. (90 Nm) and the other bolts to 76 ft. lbs. (103 Nm). Motor mount. Torque the bolts to

MAZDA

TRIBUTE

• • • • •

side bolts to 66 ft. lbs. (90 Nm) and the other bolts to 76 ft. lbs. (103 Nm). Remove the powertrain lift. Block heater electrical connector, if equipped Torque converter. Torque the nuts to 27 ft. lbs. (37 Nm). Transmission cover plate and plug Transmission cooler lines Transmission cooler line bracket. Torque the bolt to 15 ft. lbs. (20 Nm).

• Steering shaft to the rack. Torque the bolt to 18 ft. lbs. (25 Nm). • Struts to the steering knuckles. Torque the bolts to 75 ft. lbs. (102 Nm). • Brake calipers to the steering knuckles • Wheel speed sensors, if equipped. Torque the bolts to 89 inch lbs. (10 Nm). • Sway bar links to the strut mount. Torque the bolts to 41 ft. lbs. (55 Nm). • Tie rods to the steering knuckles. Torque the bolts to 41 ft. lbs. (55

Nm).

• Ball joints. Torque the bolts to 52 ft. lbs. (70 Nm). • Intermediate drive shaft, if equipped • Both front wheels • A/C compressor • Lower radiator air deflectors • Catalytic converter • Oil level indicator dipstick tube • Power steering line and bracket. Torque the bolt to 13 ft. lbs. (17 Nm). • PSP switch electrical connector • Power steering return line • Heater hoses • Vacuum lines • Transmission linkage • Wire harness cables and nuts to the power distribution box. Torque the nuts to 89 inch lbs. (10 Nm). • Power distribution box wire har¬ ness • Thermostat housing and connect the hoses • Ground wire. Torque the bolt to 89 inch lbs. (10 Nm). • PCM electrical connector • VMV electrical connector • Accelerator cable and speed control cable, if equipped • Air cleaner assembly • Water pump drive belt • Battery and tray

16. Fill the engine with clean oil. 17. Recharge the A/C system.

OH

•• Water belt tensioner Wat er pump pum Coolant hoses p

18. Inspect and top off the power steer¬ ing fluid. 19. Start the vehicle, check for leaks and repair if necessary.

Water Pump

• Water pump from the housing To install:

• Water pump to the housing. Torque the bolts to 89 inch lbs. (10 Nm). • Water pump. Torque the bolts to 89 inch lbs. (10 Nm). • Coolant hoses

REMOVAL & INSTALLATION 2.0L Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Remove or disconnect the following: • Negative battery cable • Right front wheel • Splash shield • Drive belt •• Wat Water pump pulley er pum p To install:

4. Install or connect the following: • Water pump. Torque the bolts to 89 inch lbs. (10 Nm). • Water pump pulley. Torque the bolts to 89 inch lbs. (10 Nm). • Drive belt • Splash shield • Right front wheel • Negative battery cable 5. Refill the cooling system. 6. Start the vehicle and check for leaks, repair if necessary. 3.0L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Remove or disconnect the following: • Negative battery cable • Air cleaner outlet tube

• Water pump belt tensioner • Air cleaner outlet tube • Negative battery cable 4. Refill the cooling system. 5. Start the vehicle and check for leaks, repair if necessary.

Heater Core REMOVAL & INSTALLATION 1. 2. heater 3. 4.

Drain the engine coolant. Disconnect the heater hoses from the core. Remove the driver air bag module. Remove the two front door scuff

5. Remove the four pin-type retainers. 6. Remove the two front door scuff plates. 7. Remove the two A-pillar lower trim plates. 8. Remove the two pin-type retainers. panels. 9. Remove the two A-pillar lower trim 10. Disconnect the electrical connectors panels. located by the LH cowl. 11. Position the hood latch release handle aside. 12. Remove the bolts. 13. Position the hood latch release handle aside. 14. Remove the utility compartment. 15. Remove the four pin-type retainers. 16. Remove the utility compartment. 17. Disconnect the electrical connector. 18. Remove the instrument panel steer¬ ing column cover. 19. Release the upper clips and rotate the cover outward to release the lower pivot retainers. 20. Remove the steering column lower cover. 21. Remove the screws. 22. Remove the steering column lower

9308TG08

Exploded view of the water pump-2. OL engine

cover. 23. If equipped, disconnect the shift cable. 24. Disconnect the shift cable. 25. Disconnect the shift cable from the retaining bracket.

MAZDA A tribute on-IIH

lU

26. Remove the steering column coupler access cover. 27. Disconnect the steering column cou¬ pler. 28. Remove the steering column coupler bolt and nut. 29. Disconnect the steering column cou¬ pler. 30. Remove the cover panel. 31 . Remove the pin-type retainer. 32. Release the retaining clip. 33. Disconnect the electrical connectors. 34. Disconnect the climate control vac¬ uum harness connector. 35. Disconnect the in-line electrical con¬ nector. 36. Remove the four instrument panel center brace bolts. 37. Remove the passenger air bag mod¬ ule. 38. Disconnect the vacuum harness con¬ nector. 39. Disconnect the temperature control cable. 40. Position the locator pin. 41. Release the locking tab. 42. Disconnect the temperature control cable from the blend door shaft. 43. Close the glove compartment. 44. Press the release tabs inward while raising the glove compartment. 45. Disconnect the electrical connectors at the blower motor. 46. Disconnect the antenna cable in-line connector. 47. Open the four A-pillar passenger assist handle covers.

60. Remove the two instrument panel finish end panels. 61 . Remove the four instrument panel cowl side bolts. '•This step requires an assistant. 62. Remove the instrument panel. 63. Remove the heater blending door levers. 64. Remove the screw for heater blend¬ ing door. 65. Remove the door. 66. Remove the 67. Remove the 68. Remove the and pull the heater

levers for the blending heater core. three screws. cover for the heater core core out of the housing.

’•-Before installing the temperature control cable, make sure the blend door, cable and temperature switch are correctly positioned. 69. To install, reverse the removal proce¬ dure.

CAUTION Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage may result.

•' CAUTION Once the new module is installed, it is necessary to download the module configuration information from the

scan tool into the new instrument cluster.

Cylinder Head REMOVAL & INSTALLATION 2.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Properly relieve the fuel system 3. Drain the engine oil. pressure. 4. Remove or disconnect the following: • Negative battery cable • Ignition coil bracket • Thermostat housing • Positive Crankcase Ventilation • Intake (PCV) manifold tube • Exhaust manifold • Power steering bracket and move it • aside Valve tappets • Engine mount lower bracket • Engine mount upper bracket • Cylinder head bolts in the proper sequence and discard the gasket To install: 5. Install a new head gasket and the cylinder head. 6. Lubricate the cylinder head bolt threads.

48. Remove the two A-pillar passenger assist handles. 49. Remove the four bolts. 50. Remove the two A-pillar passenger assist handles. 51. Remove the two windshield side gar¬ nish mouldings. 52. Remove the instrument panel cowl top cover. 53. Remove the instrument panel cowl top bolt. 54. Loosen the tilt lever (if equipped) and lower steering column. 55. Position the transmission range selector lever (if equipped) down to provide access to the instrument cluster finish panel and instrument cluster. 56. Remove the screws and the instru¬ ment cluster finish panel. 57. Remove the screws. 58. Disconnect the electrical connectors and remove the instrument cluster. 59. Through the instrument cluster opening, remove the instrument panel nut.

9308TG04

Cylinder head bolt torque sequence 2.0L engine

MAZDA TRIBUTE 7. Torque the cylinder head bolts in the proper sequence as follows: a. Step 1: 15 ft. lbs. (20 Nm). b. Step 2: 30 ft. lbs. (40 Nm). c. Step 3: Plus an additional 90 degrees. 8. Install or connect the following: • Engine mount upper bracket. Torque the 2 upper bolts to 72 ft. lbs. (98 Nm) and the center bolt to 57 ft. lbs. (77 Nm). • Engine mount lower bracket. Torque the bolts to 37 ft. lbs. (50 Nm). • Valve tappets • Power steering pump bracket. Torque the bolts to 20 ft. lbs. (28 Nm). • Exhaust manifold • Intake manifold • PCVtube • Thermostat housing • Ignition coil bracket • Negative battery cable 9. Fill the engine with clean oil and replace the filter.

20-15

9308TG05

Left side cylinder head bolt torque sequence 3.0L engine

i n ir f ecessar

repa

3.0L Engine

y.

The procedure for the left side cylinder head and right side are similar. Changes in the procedure will be noted for either side cylinder head. 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

2. Properly relieve the fuel system pres¬ sure. • Drain the cooling system. 3. Remove or disconnect the following: • Negative battery cable • Camshaft • Exhaust Gas Recirculation (EGR) tube, right side only • Exhaust manifold • Camshaft followers • Hydraulic lash adjusters and matchmark them for proper instal¬ lation • Cylinder head bolts in sequence and discard them eck for l eaks, • Cylinder head and discard the gas¬ ket To install: 4. Install a new head gasket and the cylinder head. 5. Lubricate the cylinder head bolt threads. 6. Torque the cylinder head bolts in the proper sequence as follows:

9308TG06

Right side cylinder head bolt torque sequence 3.0L engine

a. b. c. turn. d.

Step 1:30 ft. lbs. (40 Nm). Step 2: Additional 90 degrees. Step 3: Loosen the bolts one full

e. Step 5: Plus an additional 90 degrees. f. Step 6: Plus an additional 90

Step 4: 30 ft. lbs. (40 Nm).

degrees. 7. Install or connect the following:

OH

tU"

Ifi MAZDA IU

TRIBUTE

• PCM wire harness to the bracket • Main engine control sensor wiring • IAC valve electrical connector and attach the harness to the bracket • TP sensor electrical connector • Fuel injection supply manifold • Negative battery cable

6 .

repair if necessa

ry. 3.0L Engine Start t he vehi cle an d chec UPPER k for leakrefer s, to 1 . Before servicing the vehicle,

9308TG09

Right side exhaust manifold bolt torque sequence-3. OL engine

• • • •

Hydraulic lash adjusters Camshaft followers Camshaft Exhaust manifold. Torque the bolts in sequence to 15 ft. lbs. (20 Nm), right side only • EGR tube, right side only • Coolant bypass tube • Negative battery cable 8. Fill the coolant to the proper level. 9. Start the vehicle and check for leaks, repair if necessary.

Intake Manifold REMOVAL & INSTALLATION 2.0L Engine 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Properly relieve the fuel system pres¬ sure. 3. Remove or disconnect the follow¬ ing: • Negative battery cable • Fuel injection supply manifold • Throttle Position (TP) sensor elec¬ trical connector • Idle Air Control (IAC) electrical connector and unclip the harness from the bracket • Main engine control sensor wiring • Connector from the bracket • Powertrain Control Module (PCM) wire harness from the bracket • Brake booster vacuum hose • 4 additional vacuum lines • Positive Crankcase Ventilation

(PCV) hose from the intake mani¬ fold

the precautions in the beginning of this sec¬ tion. 2. Properly relieve the fuel system pres¬ sure. 3. Drain the coolant system. 4. Remove or disconnect the following: • Negative battery cable • Air cleaner outlet tube •• Throttle Engine appearance cover cable

• Knock Sensor (KS) electrical con¬ nector • Alternator

• Speed control cable, if equipped • Throttle cable bracket

• Intake manifold and discard the

• Throttle Position (TP) sensor elec¬ trical connector

4. Clean the mating surfaces. gasket To install: 5. Install or connect the following: • New gasket

• Idle Air Control (IAC) valve electri¬ cal connector • Exhaust Gas Recirculation (EGR) valve vacuum hose and tube

• Intake manifold. Torque the bolts, in sequence, to 13 ft. lbs. (18 Nm). • Alternator

• EGR vacuum regulator valve electri¬ cal connector and hose • Chassis vacuum hose

• • • •

• Engine vacuum hose • Positive Crankcase Ventilation

KS electrical connector PCV vacuum line 4 vacuum lines Brake booster vacuum supply hose

(PCV) Management hose • Vapor Valve (VMV) vacuum hose

MAZDA TRIBUTE

20-17

Nm). bracket bolts to 89 inch lbs. (10 • Air cleaner outlet tube

• Engine appearance cover. Torque the bolts to 53 inch lbs. (6 Nm). • Negative battery cable 7. Fill the coolant system to the proper level. 8. Start the vehicle and check for leaks, repair if necessary. LOWER 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Properly relieve the fuel system pres¬ sure. 3. Remove or disconnect the following: • Negative battery cable • Fuel line spring lock coupling • Upper Fuel railintake manifold

9308TG02

Tighten the lower intake manifold bolts in the sequence shown— 3. OL engine

• • • •

Fuel injector electrical connectors Fuel pressure damper vacuum line Lower intake manifold Lower intake manifold from the fuel rail

• Fuel injectors from the manifold and discard the gasket 4. Clean the mating surfaces. To install: 5. Inspect the fuel injector O-rings and replace if necessary. 6. Install or connect the following: • Fuel injectors into the lower intake manifold • Fuel rail. Torque the bolts to 89 inch lbs. (10 Nm). • New gasket Nm). manifold. Torque the bolts, • Intake in sequence, to 89 inch lbs. (10

9308TG03

Tighten the upper intake manifold bolts in the sequence shown— 3. OL engine

• Electrical connectors from the left side of the upper intake manifold • Power Steering Pressure (PSP) sensor electrical connector • Upper intake manifold and discard the gasket 5. Clean the mating surfaces. To install: 6. Install or connect the following: • New gasket • Intake manifold. Torque the bolts, in sequence, to 89 inch lbs. (10 Nm).

• PSP electrical connector • Electrical connectors on the left side of the upper intake manifold • VMV vacuum hose • Chassis, engine and PCV hoses • EGR valve vacuum regulator • EGR valve vacuum hose and tube. Nm). the nut to 30 ft. lbs. (40 Torque • TP sensor electrical connector • IAC valve electrical connector • Throttle cable and speed control cable, if equipped. Torque the

• Fuel rail electrical connectors • Fuel injector electrical connectors • Fuel pressure damper vacuum line • Upper intake manifold • Fuel line spring lock coupling • Negative battery cable 7. Start the vehicle and check for leaks, repair if necessary.

Exhaust Manifold REMOVAL & INSTALLATION 2.0L Engine 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following:

MAZDA 18 I O TRIBUTE

OH • • • •

Negative battery cable Catalytic converter Oil level indicator tube and bracket Exhaust manifold and discard the

gasket To install: 3. Clean the sealing surfaces of any old gasket material. 4. Install or connect the following: • Exhaust manifold and new gasket. Torque the bolts to 12 ft. lbs. (16 Nm). • Oil level indicator tube and bracket. Torque the bolt to 89 inch lbs. (10 Nm). • Catalytic converter • Negative battery cable 5. Start the vehicle and check for leaks, repair if necessary. 3.0L Engine

LEFTSIDE 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Heated Oxygen (HO2S) sensor and catalyst monitor • Splash shield • Exhaust crossover pipe • Drive belt • A/C compressor and move it aside • Exhaust manifold and discard the gasket To install: 3. Clean the sealing surfaces of any old gasket material. 4. Install or connect the following: • Exhaust manifold and new gasket. Torque the bolts to 15 ft. lbs. (20 Nm). • A/C compressor. Torque the bolts to 18 ft. lbs. (20 Nm). • Drive belt • Exhaust crossover pipe. Torque the bolts to 30 ft. lbs. (40 Nm). • Splash shield. Torque the bolts to 80 inch lbs. (9 Nm). • Left side HO2S sensor and catalyst monitor • Negative battery cable 5. Start the vehicle and check for leaks, repair if necessary.

RIGHT SIDE 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable

9308TG11

Left side exhaust manifold bolt torque sequence-3. OL engine

MAZDA TRIBUTE

• Exhaust Gas Recirculation (EGR) tube • 4 Alternator •. Right side Heated Oxygen (HO2S) sensor • Right side exhaust manifold and discard the gasket To install: 3. Clean the sealing surfaces of any old gasket material. . 4. Install or connect the following: • Exhaust manifold and new gasket. Torque the bolts to 15 ft. lbs. (20 Nm).

• Crankshaft pulley • Negative battery cable

ing: 2. Remove or disconnect the follow¬ • Negative battery cable

repair if necessary.

• Camshaft timing sprocket and ver¬ ify the valve clearance • Camshaft journal cap bolts by loosening them in several passes the proper sequence • in Camshafts

Camshaft and Lifters Start t

he vehicle and check for leaks, REMOVAL & INSTALLATION

2.0L Engine

of this sec¬ in the begin ning s

t p tihoen. recautio n

3. Inspect the camshaft for wear and discard the oil seals To install: 4. Install or connect the following: • Camshaft cam followers, lubricate

• Right side HO2S sensor • Alternator • EGR tube • Negative battery cable 5. Start the vehicle and check for leaks, 1 Befo re se rvici repair if necessary. ng th e veh icle, refer Front Crankshaft Seal to REMOVAL & INSTALLATION 2.0L Engine 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the follow¬ ing: • Negative battery cable • Timing belt • Crankshaft sprocket and timing belt guide • Crankshaft oil seal "»Be careful not to damage the seal surface of the cover.

9308TG13

Remove

the camshaft bearing caps in sequence-2. OL engine

To install: 3. Install or connect the following: • New front crankshaft oil seal • Timing belt guide and crankshaft sprocket • Timing belt • Negative battery cable 4. Start the vehicle and check for leaks, repair if necessary. 3.0L Engine 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Crankshaft pulley • Front oil seal To install: 3. Install or connect the following: • New front crankshaft oil seal

20-19

9308TG14

Camshaft bearing cap tightening sequence-2. OL engine

on

9fl MAZDA

LXJ-CU

TRIBUTE

the bearing journals thoroughly. Torque the caps to 14 ft. lbs. (19 Nm). • Exhaust camshaft oil seal • Camshaft timing sprocket • Negative battery cable 3.0L Engine

LEFTSIDE 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Water pump belt • Timing drive components • Camshaft oil seal • Camshaft oil seal retainer • Camshaft cap bolts by loosening them in sequence • Camshafts To install: 3. Install or connect the following: • Camshaft bearing caps in their original position • Align the camshafts • Bearing thrust caps and hand tighten the bolts. When aligned properly, torque the bolts to 89 inch lbs. (10 Nm). • Timing drive components • Camshaft oil seal retainer • Crankshaft oil seal • Water pump drive pulley • Water pump belt • Negative battery cable

RIGHT SIDE 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Timing drive components • Camshaft cap bolts by loosening them in sequence • Camshafts caps • Camshafts To install: 3. Install or connect the following: • Camshaft bearing caps in their original position • Align the camshafts • Bearing caps and hand tighten the bolts • Bearing thrust caps and hand tighten the bolts. When aligned properly, torque the bolts to 89 inch lbs. (10 Nm). • Timing drive components • Negative battery cable

9308TG15

Remove

and install the left side camshaft bearing caps in sequence-3. OL engine

MAZDA TRIBUTE • Starter

Valve Lash

Starter Motor

ADJUSTMENT

REMOVAL & INSTALLATION

2.0L Engine

2.0L Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the follow¬ ing: • Negative battery cable • Timing belt 3. Measure each valve’s clearance at the base circle with the lobe facing away from the tappet. 4. Use a feeler gauge to measure and record each valve's clearance 5. Remove or disconnect the follow¬ ing: • Camshafts • Valve tappets from the cylinder head 6. A mid range clearance is recom¬ mended as follows: a. Intake: 0.006 inch (0.15mm). b. Exhaust: 0.012 inch (0.3mm). To install: 7. Install or connect the following: • Valve tappets after lubricating them with clean engine oil • Camshafts and verify each valve’s clearance at the base circle with the lobe facing away from the tap¬ • Timing pet belt • Negative battery cable 3.0L Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Starter bolts • • • •

Exhaust system, AWD vehicles only Halfshaft support bracket bolts Starter electrical connectors Starter

To install: 3. Install or connect the following: • Starter. Torque bolts to 20 ft. lbs. (27 Nm). • Starter electrical connectors • Halfshaft support bracket. Torque the bolts to 11 ft. lbs. (15 Nm). • Exhaust system on AWD vehicles. Torque Nm). the bolts to 18 ft. lbs. (25 • Negative battery cable 3.0L Engine 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Remove or disconnect the following: • Negative battery cable • Air cleaner outlet tube • Coolant hoses and move the ther¬ mostat aside • Starter electrical connectors

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

20-21

To install: 4. Install or connect the following: • Starter. Torque bolts to 20 ft. lbs. (27 Nm). • Starter electrical connectors and reposition the thermostat • Connect the 4 coolant hoses • Air cl,eaner outlet tube • Negative battery cable 5. Fill the cooling system to the proper level. 6. Start the vehicle and check for leaks, repair if necessary.

Oil Pan REMOVAL & INSTALLATION 2.0L Engine 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the engine oil. 3. Support the powertrain assembly. 4. Remove or disconnect the following: • Negative battery cable • Catalytic converter • Oil pan and gasket 5. Thoroughly clean the gasket mating surfaces. To install: 6. Apply silicone sealer to the oil pan. 7. Install a new gasket on the oil pan. 8. Oil pan. Torque the bolts in sequence to: a. Step 1: 53 inch lbs. (6 Nm). b. Step 2: 106 in lbs. (12 Nm). 9. Install or connect the following:

2. Remove or disconnect the follow¬ ing: • Negative battery cable • Camshaft followers • Hydraulic lash adjusters (•Mark the position of the hydraulic lash adjusters to assure they are assembled in their original position 3. Inspect the adjusters for scoring or uneven wear in the bore and replace them as required. To install: 4. Install or connect the following: • Hydraulic lash adjusters after lubricating them with clean engine oil • Camshaft followers • Negative battery cable

9308TG17

Removal of the starter motor-2. OL engine

TRIBUTE 20-22 MAZDA with a new gasket. Torque the bolts to 89 inch lbs. (10 Nm). • Oil pan • Oil pump to the oil pan • Negative battery cable 6. Refill the engine with clean oil. 7. Start the engine and check for leaks; repair if necessary. 3.0L Engine 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. ing:2. Drain the engine oil. 3. Remove or disconnect the follow¬ • • • •

Tighten the oil pan bolts in sequence-2. 0L engine

• Catalytic converter • Negative battery cable 10. Fill the engine with clean oil. 1 1 . Start the engine and check for leaks, repair if necessary.

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: • Negative battery cable • Flexible exhaust pipe • Downstream catalyst monitor sensor • Oil pan and gasket 4. Thoroughly clean the gasket mating surfaces. To install: 5. Apply silicone sealer to the oil pan. 6. Install or connect the following: • New gasket on the oil pan • Oil pan. Torque the bolts in sequence to 18 ft. lbs. (25 Nm). • Flexible exhaust pipe • Downstream catalyst monitor sen¬ sor • Negative battery cable 7. Fill the engine with clean oil. 8. Start the vehicle and check for leaks, repair if necessary.

Oil Pump REMOVAL & INSTALLATION 2.0L Engine

cau

ti

in the be gin ni

• Oil Negative pan battery cable • Oil pump screen cover and tube • Oil pump and discard the

3.0L Engine

pre

2. Drain the engine oil. ing:3. Remove or disconnect the follow¬

of thi sec s tio n.

4. Thoroughly gasket clean the gasket mating surfaces. To install: 5. Install or connect the following: • Oil pump screen cover and tube

Negative battery cable Timing drive components Oil pump screen cover and tube Damper bolt and crankshaft sprock¬ ets • Oil pump bolts in the proper sequence 4. Thoroughly clean the gasket mating surfaces. To install: 5. Install or connect the following: • Oil pump and bolts in the proper sequence. Torque the bolts to 89 inch lbs. (10 Nm). • Crankshaft sprockets • Oil pump screen cover and tube • Timing drive components • Negative battery cable 6. Refill the engine with clean oil.

MAZDA TRIBUTE 15. Lower the vehicle.

16. Install the special tool 303-F072. 17. Remove the ground strap. 18. Remove the engine mount upper bracket. 19. Remove the studs. 20. Remove the knock sensor connector. 21 . Remove the bolts and the upper tim¬ ing22. belt Remove cover. the water pump pulley. 23. Remove the accessory drive belt idler pulley. ••Installation of the alignment tool into the exhaust camshaft may require the camshafts to be rotated clockwise slightly.

.

eck

20-23

9308TG20

Install the oil pump bolts in the proper sequence-3. 0L engine

• Crankshaft rear oil seal • Flywheel • Negative battery cable

repai if nece ssar r y

.

Rear Main Seal REMOVAL & INSTALLATION 2.0L Engine

Timing Belt and Covers Ins

tal

REMOVAL & INSTALLATION

l or co 1 . Before servicing the vehicle, refer to nnect 2.0L Engine the fol the precautions in the beginning of this sec¬ lo1. tion. win Remove the valve cover. 2. g:Remove the spark plugs. 2. Remove or disconnect the follow¬ 3. Remove the catalytic converter. ing: 4. Remove the bolt, nut, and position • Negative battery cable the coolant tube aside. • Flywheel • Rear main seal 5. Remove the right wheel and tire assembly. To install: 3. Coat the oil seal with clean engine 6. Remove the right lower splash oil. shield. 4. Install or connect the following: 7. Rotate the crankshaft to just before • Crankshaft rear oil seal top dead center (TDC) (No. 1 cylinder). 8. Remove the stud. • Flywheel 9. Install the special tool. • Negative battery cable for l Engine 3.0L eaks;

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the follow¬ ing: • Negative battery cable • Flexplate • Rear main oil seal To install: 3. Coat the oil seal with clean engine oil.

^Make sure the correct (second) notch in the pulley is indexed to the lower cylinder block. 10. Rotate the crankshaft clockwise against the peg to bring it to TDC (No. 1 cylinder). 11. Loosen the water pump pulley bolts. 12. Disconnect the battery ground cable. 13. Remove the crankshaft pulley. 14. Remove the bolts and the lower tim¬ ing belt cover.

24. Install the special tool and align the camshafts. 25. Raise and support the vehicle. 26. Remove the bolts and the engine mount lower bracket. 27. Loosen the timing belt tensioner pul¬ ley and allow to slide down to the bottom of its travel.

If the camshaft timing belt is to be reused, mark the direction of the camshaft timing belt to rotation of camshaft prior to removal or prema¬ ture wear or failure may occur. 28. Slide the timing belt off of the sary. camshaft and crankshaft sprockets, the tim¬ ing belt for wear. Install a new belt if neces¬ To install: ’•-Make sure the correct (second) notch in the pulley is indexed to the lower cylinder block. 29. Slide the crankshaft pulley onto the crankshaft and confirm the crankshaft position is at TDC (No. 1 cylinder) by rotating it clockwise against the alignment 30. Remove the crankshaft pulley. 31. Lower the vehicle. peg.32. Confirm that the timing belt tensioner is installed correctly with the tab positioned in the slot in the inner timing cover. 33. Install the timing belt onto the timing belt sprockets. 34. Adjust the timing belt tensioner. 35. Using a 6 mm Allen wrench, rotate the adjuster counterclockwise and align the marks as shown. 36. Tighten the tensioner pulley bolt. 37. Raise the vehicle. 38. Install the front engine mount lower bracket.

TRIBUTE

*

Timing Gears, Front Cover and Seal REMOVAL & INSTALLATION

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. ing:

2. Remove or disconnect the follow¬ • Negative battery cable • Engine front cover • Ignition pulse wheel and install a damper bolt • Sparkplugs 3. Rotate the crankshaft clockwise to

position the keyway at the 1 1 o'clock posi¬ tion and the camshafts in the correct posi¬ tions. The No. 1 cylinder will be at Top Dead Center (TDC). 4. Rotate the crankshaft clockwise 120

guide 6. Rotate the crankshaft clockwise 2 times to position the keyway at the 11

• ets Damper bolt and crankshaft sprock¬ guide To install: 9. Install the crankshaft sprockets. 10. Position the timing chain tensioner in a soft jaw vise. Hold the ratchet lock mechanism away from the ratchet stem and slowly compress the timing chain ten¬ sioner 1 1 . If the timing marks on the chain are not visible, use a permanent marker to mark the left and right side timing chains. Mark the timing chains in the following sequence: a. Mark any link to use as the crank¬ shaft timing mark. b. Count 29 links from the crank¬ shaft timing mark and mark the link as the exhaust cam sprocket timinq mark.

• Crankshaft damper bolt and rotate the keyway to the 3 o’clock position 15. Verify that the right side camshafts are properly positioned and install the right side timing chain and guide. Torque the bolts to 18 ft. lbs. (25 Nm). 16. Make certain that the timing chain aligns with the marks on the camshaft and crankshaft sprockets

Install the pulse wheel with the key¬ way in the slot stamped 20— 25— 34Y— 30M (Color Blur).

c. Continue counting to 42 and mark the link as the intake sprocket timinq mark 12. Install the guide. Torque the bolts to 18 ft. lbs. (25 Nm). 13. Install the left side timing chain and align the chain in the following sequence:

• Right side timing chain tensioner and arm. Torque the bolts to 18 ft. lbs. (25 Nm) and remove the damper bolt • Spar Ignition kplupulse gs wheel

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Ins

• Engine front cover • Negative battery cable

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o’clock position. This will position the left side camshafts in the neutral posi¬ tion. 7. Verify that the left side crankshafts

• Left side timing chain and ten¬ sioner • Tensioner arm and timing chain

ON

• Right side timing chain and ten¬ sioner • Tensioner arm and timing chain

a. Mark any link to use as the crank¬ shaft timing mark. b. Count 29 links from the crankshaft timing mark and mark the link as the exhaust cam sprocket timing mark. c. Continue counting to 42 and mark the link as the intake sprocket timing mark 14. Install or connect the following: • Left side timing chain and ten¬ sioner arm. Torque the bolts to 18 ft. lbs. (25 Nm).

I UT CA

degrees to the 3 o'clock position to locate the right side camshafts in the neutral posi¬ tion. 5. Remove or disconnect the follow¬ ing:

are in the neutral position and mark the link position on the crankshaft sprocket. ing: 8. Remove or disconnect the follow¬

*

3.0L Engine .

7

39. Install the accessory drive belt idler pulley. 40. Install the water pump pulley. 41. Hand tighten the bolts. 42. Lower the vehicle. 43. Install the timing belt covers. Torque the cover bolts to 62 inch lbs. (7Nm). 44. Tighten the water pump pulley bolts. 45. Remove the special tool. 46. Install the stud. Torque to 25 ft. lbs. (34Nm). 47. Install the coolant tube. 48. Install the catalytic converter. 49. Remove the special tool. 50. Install the valve cover. 51. Install the spark plugs.

:

i

20-24

MAZDA

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MAZDA TRIBUTE

Piston and Ring POSITIONING

2.0L engine piston and connecting rod positioning ring end-gap spacing

3.0L (VIN 1) engine— piston ring end-gap spacing

20-25

OR Ofl3 CD £.1

MAZDA

TRIBUTE FUEL SYSTEM

Fuel System Service Precautions Safety is the most important factor when performing not only fuel system maintenance but any type of maintenance. Failure to con¬ duct maintenance and repairs in a safe man¬ ner may result in serious personal injury or death. Maintenance and testing of the vehicle’s fuel system components can be accomplished safely and effectively by adher¬ ing to the following rules and guidelines. 1 . To avoid the possibility of fire and per¬ sonal injury, always disconnect the negative battery cable unless the repair or test proce¬ dure requires that battery voltage be applied. 2. Always relieve the fuel system pres¬ sure prior to disconnecting any fuel system component (injector, fuel rail, pressure regu¬ lator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. 3. Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suit¬ able waste container. 4. Always keep a dry chemical (Class B) fire extinguisher near the work area. 5. Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. 6. Always use a backup wrench when loosening and tightening fuel line connec¬ tion fittings. This will prevent unnecessary stress and torsion to fuel line piping. 7. Always replace worn fuel fitting Fi¬ rings with new. Do not substitute fuel hose or equivalent, where fuel pipe is installed. Before servicing the vehicle, make sure to refer to the precautions in the beginning of this section as well.

position. 6. Install the fuel pump relay. 3.0L Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: 3. Remove the schrader valve cap at the end of the fuel injection supply manifold and attach a fuel pressure gauge. 4. Open the manual valve slowly and drain the fuel into a suitable container. 5. Continue draining the fuel system to relieve fuel pressure.

2. Properly relieve the fuel system pressure. 3. Remove or disconnect the following: • Negative battery cable • Gas cap to relieve any additional fuel pressure • Left rear seat cushion and lift the access cover on the scuff plate • Pin type retainers and move the carpet aside • Screws from the fuel pump module access cover • nectors Fuel pump module electrical con¬ • Fuel and vapor lines from the fuel tank • Fuel pump module and discard the To install:

Fuel Filter REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pres¬ sure. 3. Remove or disconnect the following: • Negative battery cable • Fuel line to the fuel filter 4. Loosen the clamp and remove the filter To install:

5. Install or connect the following: • New clips to the fuel lines • Fuel filter and tighten the clamp • Fuel lines to the fuel filter • Negative battery cable 6. Start the vehicle and check for leaks, repair if necessary.

4. Install or connect the following: gasket • New fuel pump module gasket • Fuel pump module. Torque the module to 60 ft. lbs. (81 Nm). • Fuel and vapor lines to the fuel tank • nectors Fuel pump module electrical con¬ • Fuel pump module access cover and tighten the screws securely • the Pin carpet type retainers and reposition • Gas cap • Left rear seat cushion • Negative battery cable 5. Start the engine and check for leaks, repair if necessary.

Fuel Injectors REMOVAL & INSTALLATION

Fuel Pump

1 . Before servicing the vehicle, refer to

REMOVAL & INSTALLATION

the precautions in the beginning of this sec¬ tion. 2. Release the fuel system pressure. 3. Remove or disconnect the following:

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beg the in

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Fuel System Pressure

engine 2 more times to be certain that all fuel pressure has been relieved. 5. Turn the ignition switch to the OFF-

RELIEVING 2.0L Engine

1

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: 3. Remove the fuel pump relay and start the engine. 4. After the engine stalls, crank the

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erv

ores Bef

Remove

the fuel injectors from the fuel supply manifold-2. OL engine

• Negative battery cable • Fuel injection supply manifold • Retaining clips and gently twist the fuel injector out of the mani¬ fold 4. Check the O-rings and replace if damaged.

To install: 5. Install or connect the following: • Fuel injector(s) using new 0rings lubricated with clean engine oil • Fuel injector into the supply mani¬ fold

MAZDA

90-97

TRIBUTE

*-U

£.1

• tors Retaining clips properly when the fuel injec¬ are seated • Fuel injection supply manifold • Negative battery cable 6. Start the vehicle and check for leaks, repair if necessary.

DRIVE TRAIN • Rear transmission support insulator bracket • Shifter linkage and stabilizer bar • Transverse crossmember

• Left side transmission support insulator. Torque the large bolt to 66 ft. lbs. (90 Nm) and the 3 remaining bolts to 41 ft. lbs. (55

Manual Transmission

• Left side splash shield and properly

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the transmission fluid. 3. Remove or disconnect the follow¬ ing: • Battery cables • Battery and tray • Mass Air Flow (MAF) sensor elec¬ trical connector • Accelerator cable from the air cleaner outlet tube • Emission management tube and hose • Crankcase ventilation hose • Air cleaner outlet tube • Air cleaner housing • Back-up lamp switch electrical con¬ nector • Front wire harness bracket and move it aside • Front wire harness bracket spacer • Wire harness from the rear harness bracket

support the transmission • Remaining transmission flywheel housing bolts • Transmission and separate the right side halfshaft from the transmission

• Clutch slave cylinder. Torque the bolt to 15 ft. lbs. (20 Nm). • Clutch slave cylinder line to the bracket and install the retaining clip • VSS electrical connector • Rear wire harness bracket. Torque the bolts to 80 inch lbs. (9 Nm). • PNP switch electrical connector • Wire harness to the rear bracket • Front wire harness bracket spacer and bracket. Torque the bolt to 9 ft. lbs. (12 Nm).

f Transmission Assembly REMOVAL & INSTALLATION

• Park Neutral Position (PNP) electri¬ cal connector • Rear wire harness bracket and move it aside • Vehicle Speed Sensor (VSS) elec¬ trical connector • Clutch slave cylinder line from the bracket and move it aside while properly supporting the engine • Left side transmission support insulator and bracket • Rear transmission support insulator • Front transmission support insula¬ tor and bracket • Starter and move it aside • Top transmission flywheel housing bolts

• Front transmission flywheel hous¬ ing bolts • Transfer case, if equipped • Left side halfshaft

To install:

4. Align the right side half shaft to the transmission and position the transmission to the engine. 5. Install or connect the following: • Transmission flywheel housing bolts. Torque the bolts to 33 ft. lbs. • • • • • •

and remove the transmis¬ (45 Nm) sion support Left side splash shield Front-to-aft crossmember. Torque the bolts to 66 ft. lbs. (90 Nm). Transverse crossmember. Torque the bolts to 85 ft. lbs. (115 Nm). Shifter linkage. Torque the bolt to 15 ft. lbs. (20 Nm). Stabilizer bar. Torque the bolt to 30 ft. lbs. (40 Nm). Rear transmission support bracket. Nm). the bolts to 66 ft. lbs. (90 Torque

• Left side halfshaft • Transfer case, if equipped

• Front transmission flywheel hous¬ ing bolts. Torque the bolts to 33 ft. lbs. (45 Nm). • Top transmission flywheel housing bolts. Torque the bolts to 33 ft. lbs. (45 Nm). • Starter. Torque the bolts to 33 ft. lbs. (45 Nm). • Front transmission support insula¬ tor and bracket. Torque the lower bolt to 66 ft. lbs. (90 Nm) and the 3 upper bolts to 41 ft. lbs. (55 Nm). • Rear transmission support insulator bolt. Torque the bolt to 66 ft. lbs. (90 Nm). • Left side transmission support insulator bracket. Torque the bolts to 66 ft. lbs. (90 Nm).

• • • • • •

Back-up lamp switch electrical con¬ nector Air cleaner housing MAF sensor electrical connector Air cleaner outlet tube Crankcase ventilation hose Emission management tube and hose

• Accelerator cable to the air cleaner outlet tube • Battery and tray • Both battery cables 6. Fill the transmission to the proper level. 7. Start the vehicle and check for leaks, repair if necessary. Automatic Transmission

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: Battery cables Battery and tray Breather tube Mass Air Flow (MAF) sensor Intake tube and air cleaner cover Air cleaner assembly Transmission Range (TR) sensor Heated Oxygen (HO2S) sensors Transmission harness connector and bracket Wire harness bracket spacer and move the bracket aside

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CO

MAZDA

TRIBUTE

• Shift cable • Shift cable bracket and move the bracket aside • Starter electrical connectors • Starter • Electrical connectors from the valve cover and install an engine support bar • Upper transmission retaining bolts • Left side upper transmission mounting plate • Rear transmission mount • Right side engine mount bolt and slightly raise the engine • Both front wheels and splash shields • Right side halfshaft and intermedi¬ ate shaft assembly after match¬ marking them • Cross brace • Center exhaust pipe and rubber hanger • Front exhaust pipe and flange • Rear exhaust pipe flange • Driveshaft • PTU vent tube • Lower transmission bracket • Access cover • Flexplate nuts • Output Shaft Speed (OSS) sensor • Turbine Shaft Speed (TSS) sensor • Fluid cooler tube and move it aside • Fluid cooler line and install a trans¬ mission jack • Bolts from the PTU unit • Transmission with the PTU unit attached To install:

• Transmission with the PTU unit. Torque the engine-to-transmission mounting bolts to 30 ft. lbs. (40 Nm).

• Breather tube •• MAF Batterysensor tray

• Exhaust pipe and rubber hanger. Nm). the bolts to 21 ft. lbs. (29 Torque

• Left side halfshaft assembly • Right side halfshaft and intermedi¬ ate shaft assembly by aligning the matchmarks • Splash shields • Both front wheels and lower the engine on to the right side engine mount • Right side engine mount bolt. Nm). the bolt to 89 ft. lbs. (120 Torque • Rear transmission mount. Torque the upper bolt to 89 ft. lbs. (120 Nm) and the lower bolts to 35 ft. lbs. (45 Nm). • Transmission mount assemble. Torque the bolts to 30 ft. lbs. (40 Nm) and remove the engine sup¬ bar. connectors to the valve • port Electrical cover • Starter. Torque the bolts to 20 ft. lbs. (27 Nm). • Starter electrical connectors • Shifter cable and bracket. Torque the bolt to 14 ft. lbs. (19 Nm) and connect the shifter cable. • Wire harness and install the har¬ ness bracket spacer • Wire harness bracket. Torque the bolt to 89 inch lbs. (10 Nm). • HO2S sensor • TR sensor and make certain it is properly aligned • Air cleaner assembly • Intake tube and air cleaner cover

4. to the 5. repair

• Battery and cables Fill the transmission with clean fluid proper level. Start the vehicle and check for leaks, if necessary

Clutch ADJUSTMENTS The clutch is hydraulically driven and therefore no adjustment is required. REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

2. Remove or disconnect the following: • Negative battery cable • Transmission and lock the flywheel to the engine with special tool 303-103 • them Pressure plate bolts by loosening evenly • Clutch pressure plate and disc 3. Clean the pressure plate and inspect it for burn marks, scores, flatness or ridges, replace if damaged. 4. Inspect the pressure plate diaphragm finger for wear, replace if damaged. 5. Measure the depth of the rivet heads. Minimum depth is 0.012 inch (0.3mm). 6. Inspect the clutch disc for signs of wear and replace if needed. 7. Check the clutch disc runout. Replace

• Fluid cooler line. Torque the fas¬ tener to 17 ft. lbs. (23 Nm) and remove the transmission jack. • Fluid cooler tube. Torque the bolt to 17 ft. lbs. (23 Nm). • OSS sensor • TSS sensor • Flexplate nuts. Torque the nuts to 27 ft. lbs. (36 Nm). • Access cover • Cross brace. Torque the bolts to 96 ft. lbs. (130 Nm). • Transmission bracket. Torque the bolts to 30 ft. lbs. (40 Nm). • PTU vent tube • Driveshaft. Torque the bolts to 15 ft. lbs. (20 Nm). • Exhaust pipe and flange. Torque the bolts to 21 ft. lbs. (29 Nm).

9308TG07

Torque the pressure plate bolts in the proper sequence

MAZDA TRIBUTE

the disc if not with specification: 0.027 inch (0.7mm). To install: 7 8. Install or connect the following: • Clutch disc to the flywheel . • Pressure plate to the flywheel. Torque the bolts in sequence to 21 6A 1 2 ft. lbs. (29 Nm). • Transmission • Negative battery cable 9. Check the transmission fluid level and top off if necessary.

Hydraulic Clutch System BLEEDING The following procedure is recommended for bleeding the clutch hydraulic system installed on the vehicle. It is recommended that the original clutch tube, with quickconnect fitting be replaced when servicing the hydraulic system, because air can be trapped in the quick-connect fitting and pre¬ vent complete bleeding of the system. 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Clean the dirt and grease from the dust cap. 3. Remove the cap and diaphragm and brake fluid C6AZ-19542-AB or DOT 3 equivalent fluid (ESA-M6C25-A). 4. Loosen the bleeder screw cover from the slave cylinder and attach a hose to the screw. 5. Place the hose in a container and slowly pump the clutch pedal several times. 6. With the clutch pedal depressed, loosen the bleeder screw to release the fluid and air. 7. Remove the hose and tighten the bleeder screw. 8. Repeat this procedure until all the air is removed from the hydraulic system.

Transfer Case REMOVAL & INSTALLATION

• Intermediate shaft • Exhaust crossover pipe • • • • • •

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. Place the transmission in the NEU¬ TRAL position. 2. Remove or disconnect the following: • Negative battery cable • Driveshaft

• Front brake disc • Front wheel

To install:

• Negative battery cable 4. Check the transfer case fluid level and top off if necessary. 5. Start the vehicle and check for leaks, repair if necessary.

Halfshaft REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Place the transmission in the PARK position. ing:3. Remove or disconnect the follow¬ • Negative battery cable • Front wheel • Front brake disc • Front axle wheel hub nut and dis¬ card the nut • Tie rod end and separate the lower ball from the steering knuckle • Halfshaft from the steering knuckle • Halfshaft To install:

3.0L Engine

Torque the pinch bolt to 52 ft. lbs. (70 Nm). • Tie rod end. Torque the nut to 41 ft. lbs. (55 Nm). • New Nm). front axle wheel hub nut. Torque the nut to 214 ft. lbs. (290

Right side exhaust manifold Heat shield Lower bracket Crossmember brace Transfer case bolts and vent tube Transfer case

3. Install or connect the following: • Transfer case with a new driven gear seal. Torque the bolts to 33 ft. lbs. (45 Nm). • Transfer case vent tube • Crossmember brace. Torque the bolts to 30 ft. lbs. (40 Nm). • Lower bracket. Torque the bolts to 30 ft. lbs. (40 Nm). • Exhaust manifold • Heat shield. Torque the bolts to 10 ft. lbs. (14 Nm). • Exhaust crossover pipe • Intermediate shaft • Driveshaft

4. When seated properly, the halfshaft bearing retainer circlip will snap into the differential side gear groove. 5. Position the halfshaft and joint so that the splines align with differential side gear splines. Push the halfshaft into side

6. Install or connect the following: gear. • Halfshaft into the steering knuckle • Lower ball joint to steering knuckle.

20-29

• Negative battery cable

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d.

CV-Joints Chec

k the fluid level and a djust OVERHAUL as 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Halfshaft and secure it in a soft• jawed Inboardvise halfshaft boot clamp housing • Boot from the inboard CV-joint • Tripod joint from the CV-joint housing and matchmark the tripod joint to the halfshaft • Snapring and boot from the half¬ shaft • Outboard halfshaft boot clamps • Outboard boot back to expose the CV-joint and matchmark the joint to the halfshaft • Outboard CV-joint from the half¬ shaft • Halfshaft retainer circlip and dis¬ card it • Boot from the halfshaft To install:

3. Install or connect the following: • Outboard CV-joint and boot • New halfshaft bearing circlip • Inboard CV-joint to the halfshaft • Outboard halfshaft boot forward on to the outboard CV-joint • clamps New outboard halfshaft boot • Inboard halfshaft boot • Tripod joint on the halfshaft by aligning the matchmarks • New snapring to the tripod joint and lubricate the needle bearings while filling the housing with CV• clamps Inboard halfshaft boot with new E43Z-19590-A joint grease, • Halfshaft • Negative battery cable

MAZDTEA Qfl TRIBU on OU CXJ Axle Housing REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following:

• Negative battery cable • Rotary blade coupling • Rear halfshafts • Axle assembly-to-front bracket bolts • Rear axle-to-side bracket bolts • Axle assembly To install: 3. Install or connect the following:

• Axle assembly

• Nm). Rear axle-to-side-bearing bolts. Torque the bolts to 59 ft. lbs. (80 • Axle assembly-to-front bracket bolts. Torque the bolts to 59 ft. lbs. (80 Nm). • Rotary blade coupling • Negative battery cable

STEERING AND SUSPENSION Air Bag ** CAUTION Some vehicles are equipped with an air bag system. The system MUST BE disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible per¬ sonal injury and unnecessary system repairs. PRECAUTIONS Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible per¬ sonal injury: 1 . Never carry the inflator module by the wires or connector on the underside of the module. 2. When carrying a live inflator module, hold securely with both hands and ensure that the bag and trim cover are pointed away. 3. Place the inflator module on a bench or other surface with the bag and trim cover facing up. 4. With the inflator module on the bench, never place anything on or close to the module, which may be thrown in the event of an accidental deployment. DISARMING

K CAUTION The Supplemental Inflatable Restraint (SIR) system must be dis¬ armed before performing service around SIR system components or SIR system wiring. Failure to do so may cause accidental deployment of the air bag, resulting in unnecessary SIR system repairs and/or personal injury.

The positive battery cable must be dis¬ connected for a minimum of 1 minute before beginning any air bag work to de¬ energize the back-up power supply. It is a good idea to disengage both the positive and negative battery cables to ensure that the Air Bag system is definitely discharged ARMING THE SYSTEM

WARNING If the air bag simulators have been used, the air bag simulators must be removed and the air bags recon¬ nected when the system is reacti¬ vated to avoid non-deployment in a collision resulting in possible per¬ sonal injury. 1 . Disconnect the positive battery cable. 2. Wait 1 minute, this is required for the back-up power supply in the air bag diag¬ nostic monitor to deplete its stored energy. 3. Remove the air bag simulator from the air bag sliding contact connector at the top of the steering column. Reconnect the driver’s side air bag module assembly. Posi¬ tion the driver’s air bag module on the steering wheel and secure with the 2 bolts and washers. Tighten the bolt and washer assembly to 8-10 ft. lbs. (10-14 Nm). 4. Connect the positive battery cable. 5. Turn the ignition switch from the OFF to RUN and visually monitor the air bag warning indicator. The light will illuminate continuously for approximately 6 seconds and then turn off. If a fault occurs, the air bag indicator will either fail to light, remain lighted continuously or flash. The flashing may not occur until approximately 30 sec¬ onds after the ignition switch has been turned from OFF to RUN. This is the time needed for the air bag diagnostic monitor to complete testing the system. If the air bag indicator is inoperative, an air bag system fault exists, a tone will sound in a pattern of 5 sets of 5 beeps. If this occurs, the air bag indicator will need to be serviced before fur¬ ther diagnostics can be done.

Steering Gear REMOVAL & INSTALLATION —

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Place the steering wheel in the straight-ahead position. Lock the steering wheel in place, using a steering wheel holder.

^Locking the steering wheel keeps the clockspring In alignment position. 3. Drain the power steering fluid. 4. Remove or disconnect the following: • Negative battery cable • Rear transmission insulator • Rear transmission insulator bracket, if equipped with an auto¬ matic transmission • Both front wheels • Rear transmission insulator bracket, if equipped with a manual transmission • Tie rod end cotter pin and nut • Tie rod end from the steering knuckle and record the number of turns required to remove the tie rod end • Steering gear coupling pinch bolt • Power steering pressure and return lines and bracket • Steering gear mounting bolts • Steering gear and separate the steering coupling from the steering • Steering gear gear shaft To Install: • Slide the steering gear rearward to connect the steering coupling to the steering gear shaft 5. Install or connect the following: Nm). • Steering gear mounting bolts. Torque the bolts to 93 ft. lbs. (126 • Pressure and return lines and bracket. Torque the bracket bolts to 89 inch lbs. (10 Nm).

MAZDA TRIBUTE • Power steering pressure and return lines to the steering gear. Torque the bolt to 18 ft. lbs. (25 Nm). • Steering gear pinch bolt and repo¬ sition the boot. Torque the bolt to 18 ft. lbs. (25 Nm). • Tie rod end to the tie rod using the number of turns required to remove the tie rod end • Jam nuts. Torque the nuts to 35 ft. lbs. (47 Nm). • Tie rod end to the steering knuckle. Torque the nut to 41 ft. lbs. (57 Nm) and install a new cotter pin • Rear transmission insulator bracket. Torque the bolts to 66 ft. lbs. (90 Nm). • Both front wheels • Rear transmission insulator bracket. Torque the bolts to 66 ft. lbs. (90 Nm). • Rear transmission insulator. Torque the bolts to 66 ft. lbs. (90 Nm). • Negative battery cable 6. Fill and bleed the power steering sys¬ tem. 7. Start the vehicle and check for leaks, repair if necessary. 8. Check and adjust the front end align¬ ment.

• Rear quarter trim panel • Negative battery cable

Nm). the bolts to 35 ft. lbs. (48 Torque • Brake hose bracket. Torque the bolts to 14 ft. lbs. (18 Nm). • ABS harness to the strut assembly, if equipped • Brake hose grommet to the bracket • Front wheel • Negative battery cable

Shock Absorber REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Negative battery cable • Rear quarter trim panel • Upper shock absorber nut and raise the vehicle enough to relax the sus¬ • Lower shock absorber nut pension • Shock absorber To install: 3. Install or connect the following: • Shock absorber. Torque the lower nut to 85 ft. lbs. (115 Nm). • Upper shock absorber nut. Toprque the nut to 13 ft. lbs. (18 Nm).

20-31

Coil Spring REMOVAL & INSTALLATION Front 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Install or connect the following: • Negative battery cable • Front wheel • Strut and spring assembly and mount the strut assembly in a hold¬ ing fixture and compress the coil spring using a suitable tool • Strut piston rod nut 3. Coil spring by disassembling the strut in the following sequence: Step 1 : Metal sheet plate. Step 2: f. Step 3: Upper strut mount. Thrust bearing plate. a. b. Step 4: Thrust bearing. c. Step 5: d. Step 6: Upper spring seat. spring seat isolator. Upperspring. e. Step 7: Coil Step 8: Dust boot. h.

Strut REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Install or connect the following: • Negative battery cable • Front wheel • Brake hose grommet from the bracket • Antilock Brake System (ABS) har¬ ness from the strut assembly and move the brake hose bracket aside • Stabilizer bar link nut and move the bar aside • Strut to steering knuckle bolts and support the strut assembly • Upper strut nuts • Strut and coil spring assembly To install: 3. Install or connect the following: • Strut and spring assembly. Torque the upper nuts to 59 ft. lbs. (80 Nm). • Lower strut assembly to the steer¬ ing knuckle. Torque the lower bolts to 85 ft. lbs. (115 Nm). • Stabilizer bar into position.

1

Metal sheet plate

2 3

Upper strut mount Thrust bearing plate

4

Thrust bearing

5

Upper spring seat

6 7

Upper spring seat isolator Spring

8

Dust boot

9

Rubber bump stopper

10

Lower spring seat

9-

9308TG23

Disassemble the strut assembly in the proper sequence

QO Ol

MAZDA

tribute

i. Step 9: Rubber bump stopper. j. Step 10: Lower spring seat. To install:

• Assemble the strut assembly in the reverse order of the removal proce¬ dure 4. Install or connect the following: • Strut piston rod nut. Torque the nut to 76 ft. lbs. (103 Nm) and remove the assembly from the holding fix¬ ture

• Strut and spring assembly • Front wheel • Negative battery cable Rear 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the follow¬ ing: • Wheel and install 1 lug nut to retain the brake drum

• Brake line from the wheel cylinder • Brake line bracket • Bolts from the Antilock Braking System (ABS) sensor bracket and move the sensor aside, if equipped • Rear knuckle and loosen the inside upper and lower arm bolts • Shock absorber lower nut • Spring To install: 3. Install or connect the following: • Spring to the shock absorber • Lower shock absorber nut. Torque the nut to 85 ft. lbs. (115 Nm). • Inside upper and lower arm bolts. Torque the bolts to 85 ft. lbs. (115 Nm).

• ABS sensor bracket, if equipped. Torque the bolts to 80 inch lbs. (9 Nm). • Brake line bracket. Torque the bolt to 15 ft. lbs. (20 Nm). • Brake line to the wheel cylinder. Torque the fastener to 11 ft. lbs. (15 Nm) and remove the lug nut • Wheel • Negative battery cable

Upper Control Arm REMOVAL & INSTALLATION The upper and lower ball joints are an integral part of the control arms and are not a serviceable components. Replacement of the ball joint requires replacing the appro¬ priate control arm.

• Lower control arm inner bolt • Lower control arm. Torque the bolts to 85 ft. lbs. (115 Nm). • Lower ball joint nut • Nm). Lower ball joint the knuckle. Torque the ball joint nut to 85 ft. lbs. (115

the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Rear wheel • Upper control arm from the knuckle while holding the ball joint stud from turning • Upper ball joint nut • Upper control arm • Upper control arm inner bolt To install: 3. Install or connect the following: • Upper control arm inner bolt • Upper control arm. Torque the bolts to 85 ft. lbs. (115 Nm). • Upper ball joint nut • Upper control arm to the knuckle. Torque the ball joint nut to 85 ft. lbs. (115 Nm). • Rear wheel • Negative battery cable

• Rear wheel • Negative battery cable

Wheel Bearings REMOVAL & INSTALLATION Front 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Negative battery cable • Front wheel • Brake disc • Wheel hub nut

Lower Control Arm REMOVAL & INSTALLATION Front 1 . Remove or disconnect the following: • Negative battery cable • Front wheel • Lower ball joint from the knuckle and support the subframe • Lower control arm To install: 2. Install or connect the following: • Lower control arm bolts and hand tighten them • Pinch bolt to the wheel knuckle. Torque the nut to 52 ft. lbs. (70 Nm) and remove the subframe sup¬

• Front wheel and jounce the vehicle 3. Torque portthe inner lower control arm bolt to 148 ft. lbs. (200 Nm) and outer bolt 85 ft. lbs. (115 Nm). Rear 1 . Remove or disconnect the following: • Negative battery cable • Front wheel • Lower ball joint from the knuckle while holding the ball joint stud from moving • Lower ball joint nut • Lower control arm • Lower control arm inner bolt To install: 2. Install or connect the following:

• Tie rod end cotter pin and nut • Tie rod end from the knuckle • Antilock Brake System (ABS) sen¬ bolt and move the sensor aside, sor if equipped • Lower ball joint from the knuckle • Halfshaft from the knuckle and properly support the halfshaft • Steering knuckle 3. Press the hub from the wheel bearing and knuckle 4. Press the inner wheel bearing race from the knuckle and remove the snapring 5. Press the outer wheel bearing race from the knuckle To install: 6. Install or connect the following: • Wheel bearing into the steering • knuckle Snapring

• Wheel hub into the wheel bearing by using a press • Steering knuckle. Torque the bolts to 85 ft. lbs. (115 Nm). • Halfshaft into the wheel hub • Pinch bolt to knuckle. Torque the nut to 52 ft. lbs. (70 Nm). • Ball joint stud into the knuckle • ABS sensor. Torque the bolt to 80 inch lbs. (9 Nm), if equipped • Tie rod end to the knuckle. Torque the nut to 41 ft. lbs. (55 Nm). • • • •

New cotter pin to the tie rod end nut Wheel hub. Torque the nut to 214 ft. lbs. (290 Nm). Brake disc Front wheel

• Negative battery cable

MAZDA

TRIBUTE Rear 2WD

VEHICLES

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Rear wheel • Rear brake drum • Wheel hub nut • Wheel hub • Inner wheel bearing race from the hub • Snapring • Wheel bearing outer race from the knuckle To install: 3. Install or connect the following: . • Wheel bearing in to the knuckle • Snapring • Wheel hub into the wheel bearing • Wheel hub nut. Torque the nut to 214 ft. lbs. (290 Nm). • Brake drum • Rear wheel • Negative battery cable

o

4WD

VEHICLES

p ttihoen recau t .

ion

s

in the begi nni ng

of this sec¬

2. Remove or disconnect the following: • Negative battery cable • Rear wheel • Rear brake shoes • Rear halfshaft nut and loosen the halfshaft from the hub • Wheel hub and place it in a vise • Inner wheel bearing race from the hub • Anti lock Brake System (ABS) sen¬ sor bracket and move the sensor aside, if equipped • Parking brake cable from the steer¬ ing knuckle • Brake line from the wheel cylinder and support the knuckle • Lower shock absorber nut • Lower ball joint by holding the ball joint stud • Upper ball joint • Coil spring while noting the loca¬ tion of the insulator • Steering knuckle cam • Steering knuckle • Snapring and press out the outer wheel bearing race from the knuckle To install: 3. Install or connect the following: • New wheel bearing into the steering knuckle • Snapring to the knuckle

20-33

• Wheel hub • Steering knuckle cam and hand • tighten Coil spring the bolt • Shock absorber lower nut. Torque the nut to 85 ft. lbs. (115 Nm). • Upper ball joint. Torque the nut to 85 ft. lbs. (115 Nm). • Lower ball joint. Torque the nut to 85 ft. lbs. (115 Nm). Align the steering knuckle cam and torque the bolt to 85 ft. lbs. (115 Nm). • Brake line to the wheel cylinder. Torque the brake line bracket bolt to 15 ft. lbs. (20 Nm) and the brake line fastener to 11 ft. lbs. (15 Nm). • Parking brake cable to the backing plate. Torque the bolt to 16 ft. lbs. (22 Nm). • ABS sensor bracket. Torque the bolt to 80 inch lbs. (9 Nm), if equipped • Halfshaft nut. Torque the nut to 214 ft. lbs. (290 Nm). • Brake shoes • Rear wheel • Negative battery cable 4. Fill and bleed the brake system. 5. Check and adjust the wheel alignment as needed.

BRAKES Brake Caliper REMOVAL & INSTALLATION

1 . Remove the wheel and tire assem¬ bly. 2. Remove the brake caliper clip. 3. Remove the brake caliper bolt caps and bolts. 4. Position the caliper aside. 5. Disconnect and cap the brake line from the caliper and remove the caliper. To install, reverse the removal procedure. Torque the mounting bolts to 26 ft. lbs. (35Nm). Torque the brake line to 15 ft. lbs. (20Nm). 6. Bleed the brake system.

Brake Pads REMOVAL & INSTALLATION

2. Remove the brake caliper clip. 3. Position the caliper aside. 4. Remove brake caliper bolt caps and the bolts.

Brake Drum REMOVAL & INSTALLATION

5. Position the caliper aside and sup¬ 6. Remove the brake 7. Remove the outer port. anchor. 8. Remove the inner caliper piston. 9. To install, reverse dure.

pads. brake pad from the brake pad from the Re mo the removal proce¬veth

** CAUTION Use of a brake drum puller or a torch is not recommended. Brake drum distortion can result.

. bly

e ti (■►If the brake drum is rusted to the rea naxle d w shaft pilot diameter, tap the center he las brake drum between the wheel of ethe Brake Rotor studs. semb ly. 2. Remove the brake drum. REMOVAL & INSTALLATION the brake drum 3. gIf equippe clips. d, remove retainin 1 . Remove the brake caliper anchor 4. If the brake drums will not come off, follow these steps. 2. Remove the brake disc retaining clips 5. Move the brake shoe adjusting lever plate. (if equipped) and the brake disc. off the brake adjuster screw. 3. To install, reverse the removal proce¬ 6. Loosen the brake shoe adjuster dure. Torque the anchor plate bolts to 111 ft. lbs. (150Nm). screw nut by adjusting the nut upward.

20-34

MAZDA TRIBUTE

9 7. Using the special tool, 1 34-R01 91 . . measure the brake drum inside diameter. 1 8. Install a new brake drum it the maxi¬ 0 mum inside diameter exceeds the specifica¬ . tion shown on the outside of the brake drum. To install:

WARNING Whenever a wheel is installed, always remove any corrosion, dirt or foreign material present on the mounting surfaces of the wheel or the surface of the wheel hub, brake drum or brake disc that contacts the wheel. Installing wheels without cor¬ rect metal-to-metal contact at the wheel mounting surfaces can cause the wheel nuts to loosen and the wheel to come off while the vehicle is in motion, causing loss of control. Failure to follow these instructions may result in personal injury.

face and wheel pilot. Clean the wheel hub mounting sur¬ Brake Shoes Install th REMOVAL & eINSTALLATION tire and wheel a ssembly. 1. Remove the brake drum. 2. Use the Brake/Clutch/Service Vac¬ uum to remove brake dust and dirt from the brake assemblies.

*Tf new rear brake shoes and linings are being installed, resurface the brake drums to remove glazing and to ensure an equal friction surface from side-toside. Resurfacing will also correct outof-round and bell conditions. 3. Using the special tool, measure the braking surface diameter. If the inside diameter measures more than the maxi¬ mum specification shown on the outside

of the brake drum, install a new brake drum. 4. Remove the parking brake cable from the parking brake cable lever. 5. Remove the hold-down clips and pins. 6. Remove the lower spring. 7. Remove the rear brake shoes. 8. Pull the bottom of the brake shoe forward. 9. Release the upper return spring. 10. Remove both brake shoes together. 1 1 . Remove the self adjuster lever. 12. Remove the self adjuster and spring assembly.

13. Return the self adjuster to the fully seated position. 14. Remove the parking brake lever. 15. Remove the horseshoe clip. 16. Remove the parking brake lever. 17. Inspect the rear brake shoes for min¬ imum thickness above the backing plate, and install new as necessary. 18. To install, reverse the removal proce¬ dure.

MITSUBISHI Diamante • Eclipse • Galant • Lancer • Mirage 21-135 BRAKES . 21-98 DRIVE TRAIN . 21-20 ENGINE REPAIR . 21-92 FUEL SYSTEM . 21-20 PRECAUTIONS . SPECIFICATION CHARTS . 21-2 STEERING AND 21-112 SUSPENSION . A

Air Bag . Disarming . Precautions . Rearming . Alternator . Installation . Removal . B

21-112 21-112 21-112 21-112 21-21 21-21 21-21

,.21-135 Brake Caliper . . . Removal & Installation . 21-135 21-138 Brake Drums . Removal & Installation . 21-138 21-139 Brake Shoes . Removal & Installation . 21-139 C

Camshaft and Valve Lifters . 21-68 Removal & Installation . 21-68 21-106 Clutch . 21-106 Adjustment . 21-107 . Removal & Installation 21-44 Cylinder Head . Removal & Installation . 21-44 D

Disc Brake Pads . Removal & Installation . Distributor . Installation . Removal . E

21-138 21-138 21-20 21-21 21-20

Engine Assembly . Removal & Installation .

21-23 21-23

Exhaust Manifold . Removal & Installat F ion .

21-64 21-64

Front Crankshaft Seal . Removal & Installation . Fuel Filter . Removal & Installation . Fuel Injector . Removal & Installation . Fuel Pump . Removal & Installation . Fuel System Pressure . Relieving . Fuel System Service Precautions . H

21-66 21-66 21-92 21-92 21-95 21-95 21-93 21-93 21-92 21-92

Halfshaft . Removal & Installation . Heater Core . Removal & Installation . Hydraulic Clutch System . Bleeding .

21-110 21-110 21-30 21-30 21-109 21-109

Ignition Timing . Adjustment . Intake Manifold . Removal & Installat L ion .

21-22 21-22 21-58 21-58

Lower Ball Joint . Removal & Installation . Lower Control Arm . Removal & Installa 0 tion .

21-125 21-125 21-125 21-125

Oil Pan . Removal & Installation . Oil Pump . . Removal & InstallPation .

21-74 21-74 21-78 21-78

Piston and Ring . Positioning .

21-90 21-90

21-92

R

Rack and Pinion Steering

21-112 Gear . Removal & Installation . 21-112 21-83 Rear Main Seal . Removal & Installation . 21-83 21-51 Rocker Arms/Shafts . 21-51 . ion Installat & S Removal Shock Absorber and Coil

Spring . Removal & Installation . Starter Motor . Removal & Installation . Strut and Coil Spring . T ion . Removal & Installat

21-120 21-120 21-73 21-73 21-119 21-119

21-84 Timing Belt . 21-84 . ion Installat & Removal 21-98 Transaxle assembly . 21-98 . ion Installat & Removal Transfer Case Assembly . 21-110 Removal & Installation . 21-110 21-56 Turbocharger . 21-56 . ion U Removal & Installat

Upper Ball Joint . Removal & Installation . Upper Control Arm . V ion . Removal & Installat Valve Lash . W Adjustment .

21-124 21-124 21-124 21-124 21-73 21-73

21-27 Water Pump . Removal & Installation . 21-27 21-129 Wheel Bearings . 21-129 Adjustment . Removal & Installation . 21-129

MITSUBISHI

21-2

DIAMANTE • ECLIPSE • GALANT • LANCER • MIRAGE

SPECIFICATION CHARTS

ENGINE AND VEHICLE IDENTIFICATION Engine Code© 4G15/A

Liters (cc)

Cu. In. Cyl.

1.5(1468)

4

Fuel Sys. MFI MFI

4G93/C

1.8(1834)

87 112

4G94/E

2.0(1999)

122

4

MFI

4G64/G

2.4(2351)

143

4

6G72/H

3.0 (2972)

181

6

MFI MFI

6G72/J

3.0 (2972)

6

6G72/K

3.0 (2972)

181 181

6G72/L

3.0 (2972)

6G74/P

3.5 (3497)

181 213

4

6 6 6

MFI MFI-Turbo MFI MFI

Type

Eng. Mfg.

Code©

Model Year Year 2000

SOHC

Mitsubishi

Y

SOHC SOHC

Mitsubishi

1

Mitsubishi

2

SOHC

Mitsubishi

3

2003

SOHC

Mitsubishi

4

2004

DOHC

Mitsubishi

DOHC

Mitsubishi

SOHC SOHC

Mitsubishi

2001 2002

Mitsubishi

MFI: Multiport fuel injection SOHC:

Single overhead camsha

DOHC:

Double overhead camshafts

©

Engine ID / 8th digit of the VIN

©10th

digit of the VIN 42356-GALA-C01

MITSUBISHI DIAMANTE

ECLIPSE • GALANT • LANCER • MIRAGE

21-3

GENERAL ENGINE SPECIFICATIONS Engine Displacement 2000

2001

System

Net Torque 0 rpm

9206000 11306000

93 0 3000 116 0 4500

©

148 0 3000

3.41x3.94

175 0 5500 ©

18503000 14803000

3.59x2.99 3.41x3.94

17505500

18503000

3.59x2.99

©

148 0 3000

4G15/A

MFI

Mirage

1.8 (1834)

4G93/C

MFI

Eclipse

2.4 (2350)

4G64/G

Eclipse

3.0 (2972)

Eclipse Spyder

2.4 (2350)

6G72/L 4G64/G

MFI MFI

MFI

Eclipse Spyder

3.0 (2972)

6G72/L

MFI

Galant

2.4 (2350)

4G64/G

MFI

Galant

3.0 (2972)

6G72/L

MFI

Diamante

3.5 (3497)

Mirage

1.5(1468)

6G74/P 4G15/A 4G93/C

MFI MFI MFI - MFI

Mirage

1.8 (1834)

Eclipse

2.4 (2350)

4G64/G

Eclipse

3.0 (2972)

6G72/L

Eclipse Spyder

2.4 (2350)

4G64/G

Galant

2003-04

Engine

MFI

MFI

3.5 (3497)

6G74/P

Mirage

1.5(1468)

4G15/A

Mirage

1.8 (1834)

Lancer

2.0(1999)

4G93/C 4G94/E

Eclipse

2.4 (2350)

4G64/G

30-8002000

9206000

93 0 3000

2.97x3.23

9.5

54 0 2000

11306000

11604500

3.19x3.50

©

148 0 3000

3.41x3.94

17505500

185 0 3000

3.59x2.99

©

148 0 3000

3.41x3.94

MFI

120 0 5500

9303000 116 0 4500 130 0 4250)

2.97x3.23

MFI

9206000 113 0 6000

©

148 0 3000

3.41x3.94

MFI MFI

17505500

18503000

3.59x2.99

©

148 0 3000

3.41x3.94 3.59x2.99

Eclipse Spyder

MFI

Eclipse Spyder

3.0 (2972)

6G72/L

MFI

Galant

2.4 (2350)

4G64/G

MFI

17505500 ©

185 0 3000

6G72/L

MFI MFI

175 0 5500 21405000

18503000 22803000

Galant

3.0 (2972)

Diamante

3.5 (3497)

Mirage

1.5(1468)

6G74/P 4G15/A

Mirage

1.8(1834)

4G93/C

Lancer

2.0(1999)

4G94/E

Eclipse

2.4 (2350)

4G64/G

Eclipse

3.0 (2972)

6G72/L

MFI

Eclipse Spyder

2.4 (2350)

4G64/G

MFI

MFI MFI MFI MFI

6G72/L

4102000 4102000

9.5 9.2 9.5 9.5 8.9

30-80 0 2000 4102000 30-80 0 2000

8.9 9.5

4102000 30-8002000

9.5 1 8.9 1

9.5 1 9.5 8.9 1

4102000 30-80 0 2000

9.5 1 1 8.9 1 9.5 8.9 9.5 1 1

148 0 3000

3.41x3.94

17505500

18503000

3.59x2.99

MFI

21405000

228 0 3000

3.66x3.38

41 0 2000 30-80 0 2000 4102000 30-80 0 2000 30-80 0 2000

9.2 1 9.5 9.5 1 9.5 1

185 0 3000

54 0 2000 4102000 43-100 0 3500

3.21x3.77 3.41x3.94 3.59x2.99

30-80 0 2000

9.2 1 9.5 1

1

3.41x3.94

175 0 5500

30-80 0 2000

3.19x3.50

148 0 3000

Galant

6G74/P

17505500 ©

148 0 3000

3.66x3.38 2.97x3.23

MFI MFI

MFI

3.5 (3497)

12005500 ©

3.41x3.94 3.59x2.99

18503000

6G72/L 4G64/G

3.0 (2972)

113 0 6000

9303000 116 0 4500 13004250)

3.21x3.77

©

3.0 (2972) 2.4 (2350)

Galant

92 0 6000

148 0 3000

3.19x3.50

3.59x2.99

Eclipse Spyder

41 @2000

8.9

3.66x3.38

6G72/L

9.5

3.66x3.38

3.59x2.99

4G64/G

4102000 30-80 0 2000

8.9

22803000

228 0 3000

2.4 (2350)

9.5

214 0 5000

17505500

3.0 (2972)

30-80 0 2000

8.9

18503000

21405000

MFI

4102000

17505500

18503000

MFI

5402000 4102000

3.41x3.94 3.59x2.99

3.41x3.94

Eclipse

Diamante

9.5 9.2 9.5Com¬

3.59x2.99

MFI

3.0 (2972)

3.19x3.50

148 0 3000

2.4 (2350)

Galant

pression

18503000

MFI MFI

Pressure

2.97x3.23

©

6G72/L 4G64/G

Diamante

Bore x Stroke

17505500

3.0 (2972)

6G72/L

Oil

Net Horsepower

1.5(1468)

Mirage

Eclipse Spyder

2002

Fuel

5402000 4102000 43-10003500

1

4102000 30-80 0 2000

8.9 9.5 1 8.9 1

4102000 30-80 0 2000

1

9.

1

4102000 30-80 0 2000

1

30-80 0 2000

8. MFI: Multiport fuel injection ©Manual

transaxle: 21066000

Automatic transaxle: 2056 6000

©

Manual transaxle: 214 6 3000 Automatic transaxle: 220 6 3000

©California: 1386 5500 Except California: 141 65500

9.

42356-GALA-C02

21-4

MITSUBISHI DIAMANTE • ECLIPSE • GALANT • LANCER

MIRAGE

Pump ENGINE TUNE-UP SPECIFICATIONS Gap Timing

Engine

2000

2001

2002

2003-04

NOTE:

Ignition

(in.)

(deg.) 2-8 B MT AT 2-8B

Displacement Liters (cc)

Engine ID/VIN

1.5(1468)

4G15/A

0.039-0.043

1.8(1834)

4G93/C

0.039-0.043

2.4 (2350)

4G64/G

0.039-0.043

3.0 (2972)

6G72/L

0.039-0.043

2-8B 5B

3.5 (3497)

6G74/P

0.039-0.043

2-8B

1.5(1468)

4G15/A

0.039-0.043

2-8B

1.8(1834)

4G93/C

0.039-0.043

2-8B

2.4 (2350)

4G64/G

0.039-0.043

3.0 (2972)

6G72/L

2-8B 2-8B

0.039-0.043

5B

3.5 (3497)

6G74/P

0.039-0.043

—

1.5(1468)

4G15/A

0.039-0.043

1.8(1834)

4G93/C

0.039-0.043

2.0(1999)

4G94/E

0.039-0.043

2.4 (2350)

4G64/G

0.039-0.043

3.0 (2972)

6G72/L

0.039-0.043

3.5 (3497)

6G74/P

0.039-0.043

5B — 2-8B

1.5(1468)

4G15/A

0.039-0.043

2-8B 2-8 B 2-8 B

1.8(1834)

4G93/C

0.039-0.043

2.0(1999)

4G94/E

0.039-0.043

2.4 (2350)

4G64/G

0.039-0.043

3.0 (2972)

6G72/L

0.039-0.043

3.5 (3497)

6G74/P

0.039-0.043

The Vehicle Emission Control

2-8B 2-8B 2-8 B 2-8B

5B

—

Idle

Fuel

Spark Plugs

Valve Clearance

Speed (rpm) MT

HYD

38 38

600-800

(psi)

600-800

38

650-850

38

600-800

38

600-800

600-800

38 38 38

600-800

600-800

600-800 650-850

600-800 650-850

38

600-800

600-800 600-800

HYD

38

600-800

HYD

HYD HYD

38

600-800 600-800

HYD HYD

HYD

38

600-800 600-800

2-8B

HYD

38

600-800

600-800

HYD

2-8 B 5B 2-8 B 2-8B

38

650-850 600-800

650-850

38

600-800

600-800

38 38 38

600-800

600-800

600-800

2-8B 2-8B

2-8B 5B 2-8B 2-8 B 2-8B

2-8 B 5B 2-8B 2-8B 2-8 B

2-8 B 2-8B

2-8 B 5B

38

38 38

38

600-800 600-800

HYD

650-850

HYD HYD

HYD

HYD

HYD

HYD HYD

HYD HYD

600-800

HYD

HYD HYD

HYD

HYD

HYD

HYD HYD

HYD

600-800

HYD HYD HYD HYD

HYD

600-800

HYD

HYD

600-800

600-800

650-850

650-850

HYD HYD

HYD HYD

HYD HYD

HYD HYD

600-800

600-800

600-800

600-800

Information label often reflects specification changes made during production. The label figures must be used if they differ from those in this chart.

B: Before top dead center HYD: Hydraulic 42356-GALA-C03

Igniton coil

rsx^v

ysr

Connector

/s\

1

2. Heated oxygen sensor 3. Engine oil level gauge guide 4. Air cleaner and air intake hose assembly

10. 11. 12. 13. 14. 15.

5. Air hose (A) connection 6. Water hose connection 7. Water hose connection 8. Oil pipe (A) connection 9. Heat protector (A)

16. Exhaust 18. Exhaust 17. Ring

Heat protector (B) Engine hanger Front exhaust pipe connection Flange bolts Flange nut Coned disc spring

19. Gasket

manifold manifold gasket (A)

7923PG47

Exploded view of the turbocharger mounting— Eclipse

** *

disc spring and the washers are installed in their original positions. Torque the bolts and nut to 20-23 ft. lbs. (27-31 Nm). Fur¬ ther tighten the bolts and nuts 60-70 degrees. 6. Install or connect the following:

• Oil supply pipe connection • Heat shields • Engine hanger

Install the groove of the cone-shaped disc

*

E7

21-58

MITSUBISHI DIAMANTE • ECLIPSE • GALANT • LANCER • MIRAGE

• Engine coolant hoses to the turbo • Air hose • Air cleaner and duct assembly • Dipstick tube and dipstick, with new O-ring • HO2S sensor • Condenser fan assembly if removed • Negative battery cable and refill the engine with coolant

Intake Manifold

• Manifold Absolute Pressure (MAP) sensor • Condenser

7. Place the manifold on the cylinder heads. 8. Lubricate the studs lightly with oil

and install the nuts. 9. Tighten the mounting nuts as follows: • Front bank nuts: 48-72 inch lbs (5-8 Nm). • Rear bank nuts: 14-17 ft. lbs. (20-23 Nm). • Front bank nuts: 14-17 ft. lbs (20-23 Nm).

• Throttle Position (TP) sensor and the Idle Air Control (IAC) motor connectors • nector Heated Oxygen (HO2S) sensor con¬

• Crankshaft Position (CKP) sensor connector • Air conditioning compressor con¬ nector • Engine control wiring harness bracket of theandwayposition the harness out

10. Connect the coolant hoses to the

REMOVAL & INSTALLATION

intake manifold.

Diamante

11. Using new O-rings, install the fuel rail assembly, if removed. Tighten the Nm). g bolts mountin to 84-108 inch lbs. (10-13

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Relieve the fuel system pressure.

ing:

3. Remove or disconnect the follow¬

• Negative cable and drain the cool¬ ing system • Air intake hose(s) • Accelerator control cables from the throttle body • Vacuum hoses including the brake booster hose • Wiring harness connectors • High pressure and return fuel hoses

• Exhaust Gas Recirculation (EGR) pipe and remove the EGR valve and EGR temperature sensor from the intake plenum assembly • Manifold Absolute Pressure (MAP) sensor, if equipped • Plenum retaining bracket • Plenum retaining nuts and bolts and remove the air intake plenum from the intake manifold • Upper timing belt covers • Water pump stay bracket '■•Tt is not necessary to remove the fuel injectors from the intake unless the manifold assembly is being replaced. • Fuel rail with the injectors attached • Coolant hoses from the intake manifold

• Intake manifold mounting nuts and remove the intake manifold 4. Clean the gasket mounting surfaces. To install: 5. Thoroughly clean the mating sur¬ faces of the heads, intake manifold and air intake plenum. 6. Install new intake manifold gaskets

to the cylinder heads with the adhesive side facing up.

• Vacuum hoses, label for reference • Spark plug wires from the ignition coil • Fuel lines the fuel rail • Heater hosefrom s • Fuel rail assembly

12. Install or connect the following: • Plenum, with new gasket. Tighten the retaining nuts and bolts evenly Nm). and Nm)gradually to 13 ft. lbs. (18

• Ignition coil and module • Exhaust Gas Recirculation (EGR) valve assembly

• Retaining bracket and tighten the retaining bolts to 13 ft. lbs. (18

• MAP sensor, if removed • EGR valve, using a new gasket. Nm). n the bolts to 16 ft. lbs. (22 Tighte • EGR temperature sensor and tighten the fitting to 84-108 inch lbs. (10-12 Nm) • EGR pipe and tighten the fittings to 43 ft. lbs. (60 Nm)

• hanger Intake manifold stay and the engine • Intake manifold To install:

6. Install or connect the following:

• Nm). Intake manifold. Torque the intake manifold bolts to 15 ft. lbs. (20

• Intake manifold stay and the engine hanger. Torque the mounting bolts to ft.lylbs. (26-33 Nm). • EGR19-24 assemb

• High pressure fuel hose, use a new O-ring. Tighten the retaining bolts toclamp 48 inch lbs. (5 Nm). • Fuel return hose, using a new

• Ignition coil and module • Fuel rail and insulators and recon¬ nect the high-pressure fuel hose • Heater hoses and fuel lines Sparkumplug wires to the coil towers •• Vacu hoses

• Water pump stay bracket • Upper timing belt covers • Harness connectors and vacuum hoses

• • • •

• Accelerator cables, adjust • Air intake hose(s) 13. Fill the system with coolant. 14. Connect the negative battery cable. Eclipse

Battery condenser •• Ignition • Accelerator cable, adjust

2.4L (4G64) ENGINE 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Relieve the fuel system pressure. 3. Remove the battery. 4. Drain the engine coolant. 5. Remove or disconnect the following: • Accelerator cable • Air intake hose • Ignition coil and the module wiring connectors

Engine harness in the proper posi¬ tion MAP sensor HO2S TP sensor and the IAC motor con¬ nectors

7. Refill the engine with coolant. Galant

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

2. 3. 4. 5.

Relieve the fuel system pressure. Disconnect battery negative cable. Drain the cooling system. Remove or disconnect the following:

MITSUBISHI 0-1

DIAMANTE • ECLIPSE • GALANT • LANCER • MIRAGE

1 2. 3. 4. o' 6. 7. 8. 9. 10

EGR pipe - Up to 1 993 EGR pipe - From 1 994 Intake manifold plenum Intake manifold plenum

stay, rear stay, front

^

EQ

model model

c^DVa|Ve -_t X EGR valve gasket ] Throttle body Throttle body gasket Intake manifold plenum Intake manifold plenum gasket 7923PG42

Exploded view of air intake plenum assembly— Diamante

SUBISHI fl MIT 91 -RUU DIAMANTE • ECLIPSE

L. \

• GALANT • LANCER • MIRAGE 10-13ft.lbs. Nm 7-9

5 Nm 4 ft.lbs.

1. 2. 3. 4. 5.

Connection for high-pressure fuel hose O-ring Connection for fuel return hose Connection for vacuum hoses Wiring harness connector 6. Oxygen sensor 7. Fuel rail (with injectors) Insulators 8. 10. 11. 1 2. 13. 14. 15.

Water pump stay mounting bolt Intake manifold mounting nut Intake manifold mounting nut Cone disc spring Intake manifold Intake manifold gasket

Tim

ing

bel

tu ppe rc ove r

.

bly 7923PG43

Intake manifold and related components— Diamante shown

• Accelerator cable • Air intake hose • Coolant hose from the throttle housing

remove the intake manifold assem¬ To install: 8. Clean all gasket material from the

• Vacuum lines, label for reference • High pressure fuel line and fuel return hose • Throttle control cable brackets 6. Disconnect the following:

• Engine Coolant Temperature (ECT) sensor and gauge sender • Idle Air Control (IAC) motor • Exhaust Gas Recirculation (EGR) temperature sensor • Ignition coil • Knock (KS) sensor • Heated Oxygen (HO2S) sensor • Throttle Position (TP) sensor • Distributor (if equipped) • Air conditioning temperature sen¬ sor

ng:

owi

l fetol ntehc Con

• Ignition power transistor • Fuel injectors 7. Remove or disconnect the following: • Spark plug wires • Intake manifold stay bracket • Intake manifold mounting bolts and

cylinder head intake mounting surface and intake manifold assembly. 9. Install or connect the following: • Intake manifold, using a new gas¬ ket. Torque the manifold in a criss¬ cross pattern, starting from the inside and working outwards to 15 ft. lbs. (20 Nm). • Fuel injectors, fuel rail and pres¬ sure regulator to the engine. Torque the retaining bolts to 48 inch lbs. (6 Nm).

• Intake manifold brace bracket and tighten bolts to 21 ft. lbs. (29 Nm) • Spark plug wires

• ECT sensor and gauge sender • IAC motor • EGR temperature sensor • Ignition coil • (KS) sensor • HO2S sensor • TP sensor

• Distributor (if equipped) • Air conditioning temperature sen¬ sor • Ignition power transistor • Fuel injectors

1 1 . Install or connect the following: • Throttle control cable brackets • High pressure fuel line and fuel return hose • Vacuum lines • Coolant hoses • Accelerator cable • Air intake hose 12. Fill the system with coolant. 13. Connect the negative battery cable. Lancer

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: • Battery negative cable and drain the cooling system •• Air cleaner assembly Throttle body

• Fuel rail assembly

MITSUBISHI DIAMANTE • ECLIPSE • GALANT • LANCER • MIRAGE

^

I

^

1

12 Nm 8.7 ft.lbs.

15 - 22 Nm 11 -16 ft.lbs.

9.8 Nm 7.2 ft.lbs. 26 - 33 Nm 19 -24 ft. lbs.

1 2. 3. 4. 5. 6.

Fuel rail, fuel injector and pressure regulator assembly Insulator Insulator Manifold differential pressure sensor Ignition power transistor Spark plug cable connection

7. 8. 9. 10. 11. 12.

Ignition coil Intake manifold stay Intake manifold Intake manifold gasket Throttle body EGR valve assembly 7923PG41

Intake manifold and related components— Eclipse and Galant 2.4L (4G64) engines

• Manifold Differential Pressure

• • • • • • • •

(MDP) sensor Auto cruise vacuum hose connec¬ tion Vacuum pipe Brake booster vacuum hose con¬ nection Vacuum hose and pipe assembly Exhaust Gas Recirculation (EGR) valve and gasket Engine hanger Throttle body stay Intake manifold stay

• Intake manifold bolt and manifold. • Intake manifold gasket and discard To install: 4. Clean all gasket material from the cylinder head intake mounting surface and intake manifold assembly. 5. Install or connect the following: • Intake manifold, using a new gas¬ ket. Torque the manifold in a criss¬ cross pattern, starting from the inside and working outwards to 12-16 ft. lbs. (16-22 Nm). • Intake manifold stay

• Throttle body stay • Engine hanger • EGR valve and gasket • Vacuum hose and pipe assembly

• Brake booster vacuum hose con¬ • Vacuum nection pipe • Auto cruise vacuum hose connec¬ • tion MDP sensor • Fuel rail assembly • Throttle body • Air cleaner assembly

SUBISHI 9 MIT 91-RyjL. DIAMANTE • ECLIPSE

U\

• GALANT • LANCER • MIRAGE

5.0 ± 1.0 Nm

22 ± 4 N m

o.u * i.u N-m

/l6±3ft-lb

24 ± 3 N m 18 ± 2 ft-lb

.

31 ± 3 Nm 23 ± 2 ft-lb

REMOVAL

REMOVAL

STEPS

1. MANIFOLD DIFFERENTIAL PRESSURE SENSOR 2. AUTO CRUISE VACUUM HOSE CONNECTION 3. VACUUM PIPE 4. BRAKE BOOSTER VACUUM HOSE CONNECTION 5. VACUUM HOSE AND PIPE ASSEMBLY

6. 7. 8. 9. 10. 11. 12.

STEPS (Continued)

EGR VALVE EGR VALVE GASKET ENGINE HANGER THROTTLE BODY STAY INTAKE MANIFOLD STAY INTAKE MANIFOLD INTAKE MANIFOLD GASKET

9357QG13

Exploded view of the intake manifold and related components— Lancer with 2.0L engine

6. Fill the system with coolant. 7. Connect the negative battery cable. Mirage

1.5L (4G15) ENGINE

• Heated Oxygen (HO2S) sensor • Engine Coolant Temperature (ECT) sensor • Idle Air Control (IAC) motor • Intake Air Temperature (IAT) sensor

bly wires • Spark plug • Fuel rail, fuel injectors, pressure regulator and insulators • EGR valve from the intake manifold • Intake manifold support bracket and remove the engine mount support bracket • Intake manifold mounting bolts and remove the intake manifold assem¬

Re

l

fol cthte

nne

sco

rdi

veo

mo

o focltl ontnhe Disc

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: • Battery negative cable and drain the cooling system • Upper radiator hose, heater hose and water bypass hose

• Distributor (if equipped) • Exhaust Gas Recirculation (EGR) temperature sensor

• Thermostat housing from intake manifold • Accelerator cable, breather hose and air intake hose • Vacuum hoses, label for reference • Throttle body assembly • High pressure fuel line and the fuel return hose

MITSUBISHI 0-1

DIAMANTE • ECLIPSE • GALANT • LANCER • MIRAGE To install: 6. Clean all gasket material trom the cylinder head intake mounting surface and intake manifold assembly. 7. Install or connect the following: • Intake manifold gasket, using a new gasket. Torque the manifold in a crisscross pattern, starting from the inside and working outwards to 13 ft. lbs. (18 Nm). • Intake manifold support bracket and tighten the mounting bolts to 16 ft. lbs. (22 Nm) • Engine mount support bracket and tighten the mounting bolts to 26 ft. lbs. (36 Nm) • EGR valve and tighten the mount¬ ing bolts to 15 ft. lbs. (21 Nm) • Install the fuel rail, fuel injectors and pressure regulator to the engine, using new insulators and O-rings. Torque the retaining bolts to 84-108 inch lbs. (10-13 Nm). • Spark plug wires 8. Connect the following: • HO2S sensor • ECT sensor

• IAC motor • IAT sensor • Distributor (if equipped) • EGR temperature sensor 9. Install or connect the following: • Fuel feed and return lines • Throttle body assembly

Engine Intake Intake Intake

• Vacuum hoses and pipes as neces¬ sary, including the brake booster vacuum line • Accelerator cable • Breather and air intake hose • Thermostat housing to the intake manifold and tighten the mounting bolts to 13 ft. lbs. (18 Nm) • Upper radiator hose, heater hose and water bypass hose 10. Fill the system with coolant. 11. Connect the negative battery cable.

1.8L (4G93) ENGINE 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: • Battery negative cable and drain the cooling system

hanger manifold stay manifold manifold gasket

4. Disconnect the following: • Heated Oxygen (HO2S) sensor • Engine Coolant Temperature (ECT) sensor • Idle Air Control (IAC) motor • Exhaust Gas Recirculation (EGR) temperature sensor • Throttle Position (TP) sensor • Oil pressure switch • Distributor (if equipped) • Fuel injectors 5. Label and remove all vacuum hoses. 6. Remove or disconnect the following: • Upper radiator hose, heater hose and water bypass hose • High pressure fuel line and the fuel return hose • Fuel rail, fuel injectors, pressure regulator and insulators • Intake manifold support bracket • Thermostat housing, if necessary for clearance • Intake manifold mounting bolts/nuts and remove the intake manifold assembly

5. 6. 7. 8.

Engine hanger Exhaust manifold cover Exhaust manifold Exhaust manifold gasket 7923PG38

(4G15) engine Exploded view of the intake and exhaust manifold mounting — Mirage 1.5L

CO

• Accelerator cable and the air intake hose

29 Nm 21 ft.lbs.

1. 2. 3. 4.

J

o-l

C A MITSUBISHI

4 To install: nect the Exhaust Gas Recirculation (EGR) ECL . 1 IPS DI AM E AN tube. TE * 7. Clean all gasket material» from the * GALANT • LANC • MI RAGE if removing the 6. For theER SOHC cylinder head intake mounting surface and engine, rear manifold, remove the intake plenum intake manifold assembly. 8. Install or connect the following: stay and the roll stopper bracket. 7. Remove or disconnect the following: • Intake manifold, using a new gas¬ • Electrical connector and remove the ket. Torque the manifold in a criss¬ Heated Oxygen (HO2S) sensor cross pattern, starting from the inside and working outwards to 14 • Exhaust manifold mounting bolts the manifold ft. lbs. (20 Nm). To install: • Thermostat housing • Intake manifold brace bracket 8. Clean all gasket material from the mating surfaces. • Fuel rail, fuel injectors and pres¬ 9. Install or connect the following: sure regulator to the engine. Torque the retaining bolts to 108 inch lbs • New gasket and install the mani¬ (12 Nm). fold. Tighten the nuts in a criss¬ • Fuel feed and return lines cross pattern to 21 ft. lbs. (30 Nm) • Upper radiator hose, heater hose for the J- engine or to 14 ft. lbs. and water bypass hoses for the H- engine. • (19 Heat Nm) shields • Vacuum hoses • EGR tube and intake plenum stay 9. Connect the following: • HO2S sensor and roll stopper bracket, if removed • HO2S sensor • ECT sensor • IAC motor • Electric cooling fan assembly, air conditioning compressor, dipstick • EGR temperature sensor • TP sensor tube and alternator, as required • Oil pressure switch • New flange gasket and connect the • Distributor (if equipped) exhaust pipe or converter assembly • Fuel injectors • Negative battery cable and check for exhaust leaks 10. Connect and adjust the accelerator cable and install the air intake hose. Eclipse 11. Fill the system with coolant. 12. Connect the negative battery cable.

Exhaust Manifold REMOVAL & INSTALLATION

2.4L (4G64) ENGINE < CAUTION

Diamante

The air bag system must be disarmed before removing the exhaust mani¬ fold or turbocharger.

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

2. Remove or disconnect the following:

• Battery negative cable • Exhaust pipe from the exhaust manifold

• Condenser electric cooling fan assembly 3. For the DOHC engine, remove the fol¬ lowing: • Alternator and mounting bracket • Separate the air conditioning com¬ pressor from the mounting bracket. Leaving the hoses connected, posi¬ tion the compressor aside. • Heat protector 4. If removing the front manifold, remove the oil dipstick and tube from the engine. 5. If removing the rear manifold, discon¬

2. Remove or disconnect the following:

• Negative battery cable • Front exhaust pipe from the exhaust manifold • Heat shield

• Mounting nuts, the exhaust mani¬ fold, ket and the exhaust manifold gas¬ To install: 3. Install or connect the following: • New exhaust manifold gasket to the cylinder head • Exhaust manifold. Torque the Nm). ng nuts to 21 ft. lbs. (29 mounti

• Heat shield and tighten the bolts to 10 ft. lbs. (13 Nm) • New gasket between the exhaust manifold and the front exhaust pipe

and reconnect the pipe. Torque the nuts to 32 ft. lbs. (34 Nm). • Negative battery cable

exhaust leaks. Start the Galant engine a nd check for any 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec tion. 2. Remove or disconnect the following:

• Battery negative cable • Exhaust pipe from the exhaust manifold

• Outer exhaust manifold heat shield and engine hanger • Exhaust manifold mounting nuts and the exhaust manifold from the engine To install: 3. Clean all gasket material from the mating surfaces. 4. Install or connect the following: • NewNm) gasket and install the mani¬ fold. Tighten the nuts to in a criss¬ cross pattern to 18-21 ft. lbs. (25-29 Nm). • Heat shields and tighten the mounting bolts to 10 ft. lbs. (14

• New flange gasket • Exhaust pipe. Tighten the mounting nuts to 32 ft. lbs. (44 Nm). 5. Connect the negative battery cable and check for exhaust leaks. Lancer

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

• • • • •

Negative battery cable Engine undercover Pressure hose clamp bolt Power steering pump bracket stay bolt Drive belt

• Power steering pump and bracket assembly and position it aside. Do NOT disconnect the fluid lines. • Front exhaust pipe and gasket from the manifold. Discard the gasket. • illustration) Exhaust manifold bracket “B” (see

• Heated Oxygen Sensor (HO2S) • Heat shield • Exhaust manifold retainers and manifold • Exhaust manifold gasket, and dis¬ card illustration) • Exhaust manifold bracket “A” (see

MITSUBISHI 0-1

DIAMANTE • ECLIPSE • GALANT • LANCER • MIRAGE 12-15 Nm 9-11 ftlbs.

I

CE

U\J

25-29 Nm 18-21 ftlbs.

29 Nm 21 ftlbs.

.

44 Nm 32 ftlbs.

pv

/

34 Nm 25 ftlbs.

Removal

1. 2. 3. 4. 5. 6.

steps

Front exhaust pipe connection Gasket Heat protector Engine hanger Exhaust manifold Exhaust manifold gasket 7923PG46

Exploded view of the exhaust manifold mounting— Eclipse 2.4L (4G64) engine shown, Galant similar

To install: 3. Clean all gasket material from the mating surfaces. 4. Install or connect the following:

• Exhaust manifold bracket “A" • New gasket and exhaust manifold. Tighten the upper retainers to 20-24 ft. lbs. (27-33 Nm) and the lower retainers to 10-1 4 ft. lbs. (15-19 Nm). • Heat shield • HO2S • Exhaust manifold bracket “B” • Front exhaust pipe to the exhaust manifold, using a new gasket

• Power steering pump assembly • Drive belt • Power steering pump bracket stay bolt • Pressure hose clamp bolt • Engine undercover • Negative battery cable Mirage

• Outer exhaust manifold heat shield and engine hanger • Exhaust manifold mounting bolts, pipe the inner heat shield and the exhaust manifold To install:

es. fac sur

ing

mat

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Battery negative cable

• Exhaust pipe from the exhaust manifold • Electric cooling fan assembly • Heated Oxygen (HO2S) sensor • Exhaust Gas Recirculation (EGR)

MITSUBISHI I Uli

DIAMANTE • ECLIPSE • GALANT • LANCER • MIRAGE

6. 7. 8. 9. 10. 11. 12.

1. PRESSURE HOSE CLAMP BOLT 2. POWER STEERING PUMP BRACKET STAY BOLT 3. POWER STEERING PUMP AND A/C COMPRESSOR DRIVE BELT 4. POWER STEERING OIL PUMP AND BRACKET ASSEMBLY 5. FRONT EXHAUST PIPE CONNECTION

FRONT EXHAUST PIPE GASKET EXHAUST MANIFOLD BRACKET B HEATED OXYGEN SENSOR HEAT PROTECTOR EXHAUST MANIFOLD EXHAUST MANIFOLD GASKET EXHAUST MANIFOLD BRACKET A

9357QG14

Exploded view of the exhaust manifold and related components— I

4. Using a new gasket and install the manifold. For 1.5L engines, tighten the nuts on a crisscross patter to 13 ft. lbs. (18 Nm). For 1.8L engines, tighten the inner nuts to in a crisscross pattern to 13 ft. lbs. (18 Nm) and tighten the 2 outer (larger) nuts to 22 ft. lbs. (30 Nm). 5. Install or connect the following: • Heat shields • EGR pipe • HO2S sensor • Electric cooling fan assembly • New flange gasket and connect the exhaust pipe

2.0L engine

• Negative battery cable and check for exhaust leaks

Front Crankshaft Seal REMOVAL & INSTALLATION Diamante

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following:

• Negative battery cable • Drive belts • Crankshaft pulley • Timing belt covers and the timing belt • Crankshaft Position (CKP) sensor • Crankshaft sprocket, the sensing

spacer and Woodruff® key 3. Pryblade, the seal from the bore, using a suitable tool. To install: 4. Using a seal driver, install the new crankshaft seal. Lubricate the lips of the seal with clean engine oil.

MITSUBISHI DIAMANTE • ECLIPSE • GALANT • LANCER • MIRAGE

01 ^

.R7 lUI

case

Crankshaft seal installation — Diamante

5. Install or connect the following: • Woodruff® key, spacer, sensing blade and the crankshaft sprocket • CKP sensor and tighten the retain¬ ing bolts to 84 inch lbs. (9 Nm) • Timing belt and the timing belt covers • Crankshaft pulley and retaining bolt. Torque the retaining bolt to 130-137 ft. lbs. (180-190 Nm) for the DOHC engine or to 108-116 ft. lbs. (150-160 Nm) for the SOHC engine. • Drive belts, adjust • Negative battery cable

The crankshaft pulley pin spanner tool should be used to hold pulley while bolt is removed Diamante

Lancer

• Negative battery cable • Timing belt

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following:

• Crank angle sensor •• Spring Crankshaft pin sprocket • Crankshaft sending blade

Eclipse 2.4L ENGINE

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the follow¬ ing: • Negative battery cable • Timing belt • Crankshaft sprocket 3. Carefully pry the oil seal out of the front case. Be careful not to damage the oil seal bore or the crankshaft sealing sur¬ face. To install: 4. Apply clean engine oil to the oil seal lip. Using a seal driver, install the oil seal. 5. Install or connect the following: • Crankshaft sprocket. If equipped, tighten the crankshaft bolt to 87 ft. lbs. (118 Nm). • Timing belt • Negative battery cable

2.

3. 4. 5.

SPRING PIN CRANKSHAFT CRANKSHAFT CRANKSHAFT

SENSING BLADE SPACER FRONT OIL SEAL 9357QG15

View of the front crankshaft seal— Lancer 2.0L engine

21-68

MITSUBISHI DIAMANTE

• ECLIPSE

Crankshaft spacer • Crankshaft front oil seal

To install:

3. Install or connect the following: • Engine oil to the oil seal lip • Crankshaft front using seal into the front case, using special driver tool MD998717 4. Remove all oil or other lubricants from the mounting surfaces on the crank¬ shaft, spacer, sensing blade and crankshaft sprocket. 5. Assemble the spring pin, sensing blade, and crankshaft spacer together.

6. Install or connect the following: • Crankshaft sprocket assembly onto the crankshaft • Crank angle sensor • Timing belt • Negative battery cable

Mirage

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Negative battery cable

• Crankshaft pulley retainer bolts and remove the pulley

• Vibration damper retainer bolt and washer and remove damper • Timing belt

• Crankshaft sprocket

3. Pry out the oil seal from front of engine. To install:

4. Using proper size driver, install a new front seal. 5. Lubricate the lips of the new seal with clean engine oil. 6. Install or connect the following: • Timing belt, timing covers, valve cover and remaining components

• Crankshaft sprocket and vibration damper

• Engine undercover and connect the negative battery cable

GALANT • LANCER • MIRAGE

Camshaft and Valve Lifters REMOVAL & INSTALLATION Diamante

3.0L DOHC ENGINE

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: • Negative battery cable • Intake manifold plenum • Timing belt cover and the timing belt • Center cover, breather, Positive Crankcase Ventilation (PCV) hoses, and the spark plug cables • Rocker cover and the semi-circular packing • Camshaft Position (CMP) sensor • Camshaft sprockets ^Be sure to keep the valvetrain com¬ ponents labeled and in proper order for reassembly.

4. Loosen the bearing cap bolts in 2-3 steps. Label and remove all camshaft bear¬ ing caps. 5. Mark the components and remove the intake and the exhaust camshafts. 6. Remove the rocker arms and the lash adjusters. Be sure to note the location of the valvetrain components for reinstallation pur¬

** WARNING Be sure to properly position the knock pins of the camshaft to prevent valve to piston interference.

'■►The intake camshaft on the Dia¬ mante has a B or J stamped on the hexagon. The exhaust camshaft on the Diamante has a D or K stamped on the hexagon.

10. Install the bearing caps. Tighten the caps in sequence and in 2 or 3 steps. Caps 2, 3 and 4 have a front mark. Install with the mark aligned with the front mark on the cylinder head. Torque the retaining bolts for caps No. 2, 3 and 4 to 96 inch lbs. (11 Nm) and tighten the retaining bolts for the front and rear caps to 14 ft. lbs. (20 Nm). 1 1 . ApplyNm) a coating of engine oil to the oil seals and install the oil seals to the front and rear of the camshafts. 12. Install or connect the following: • Camshaft sprockets and tighten the sprocket bolts to 65 ft. lbs. (90 • CMP sensor • Timing belt

• Rocker cover and the semi-circular packing • Intake manifold plenum • Spark plug cables, center cover, breather and PCV hoses • Negative battery cable and check for leaks

To install: poses.

3.0L SOHC ENGINE

^Lubricate the valvetrain components with clean engine oil.

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Intake manifold plenum stay bracket • Camshaft Position (CMP) sensor • Valve covers and the timing belt

7. Bleed and install the lash adjusters in their original bores in the cylinder head. 8. Install the rocker arms to the cylinder head. 9. Lubricate the camshafts with clean engine oil and position the camshafts on the cylinder head.

Proper positioning of the camshaft knock pins— Diamante 3.0L DOHC engine

MITSUBISHI 91 _RQ DIAMANTE

• ECLIPSE

• GALANT

Right bank

Right bank camshaft identification— Dia¬ mante 3.0L SOHC engine

• LANCER

• MIRAGE

I

U3

Left bank

Proper positioning of the camshafts — Diamante 3.0L SOHC engine

Arrow mark (bearing cap)

Arrow

mark

(bearing

cap) 7923PG61

SOHC engine Alignment of the rocker shafts and application of sealant — Diamante 3.0L

91-70 MITSUBISHI

9 fa- » I U DIAMANTE * ECLIPSE • GALANT • LANCER • MIRAGE . 3. Using a camshaft sprocket holding tool, hold the sprocket and loosen the bolt.

4. Remove the bolt and note the posi¬ tioning of the knock pin at the end of the camshaft and remove the sprocket. 5. Install auto lash adjuster retainer tools on the rocker arms. ^Be sure to note the position of the rocker arms, rocker shafts and bearing caps for reinstallation purposes.

6. Remove or disconnect the following: • Camshaft bearing caps but do not remove the bolts from the caps

• Rocker arms, rocker shafts and bearing caps, as an assembly • Camshaft from the cylinder head 7. Inspect the bearing journals on the camshaft, cylinder head, and bearing caps. To install:

'••The right bank camshaft is identified by a 4mm slit at the rear end of the camshaft.

8. Lubricate the camshaft journals and camshaft with clean engine oil and install the camshaft in the cylinder head. Be sure to properly position the knock pin of the camshaft as noted during removal.

3.5 Nm 2.5 ft.lbs.

ing caps and install the rocker arms, rocker shafts Ap anpl d ybese aral at psthe asenan inerg ca ds as ofsethmbe lybe.ar¬ Properly position the arrows on the bearing caps. 10. Torque the bearing cap bolts in the following sequence: No. 3, No. 2, No. 1 and No. 4 to 85 inch lbs. (10 Nm). 1 1 . Repeat the sequence increasing the torque to 14 ft. lbs. (20 Nm). 12. Remove the auto lash adjuster retainer tools from the rocker arms. 13. Install the camshaft sprocket and bolt. 14. Using a camshaft sprocket holding

31 Nm 23 ft.lbs.

04—^

Lubricate all internal parts with engine oil during reassembly.

Removal steps 1 . Rocker cover 2. Rocker cover gasket 3. Oil seal 4. Camshaft oil seal 5. Rocker arm, rocker arm shaft 6. Rocker arm, rocker arm shaft 7. Rocker shaft spring 8. Rocker arm A 9. Rocker arm B

Exploded view of the camshaft mounting— 3. 5L engine

10. 11. 12. 13. 14. 16. 15.

Rocker arm shaft Lash adjuster Rocker arm C Rocker arm shaft Lash adjuster Thrust O ring case

17. Camshaft 7923PGD3

MITSUBISHI DIAMANTE

Rear bank

• ECLIPSE • GALANT

Front bank

01.71

• LANCER • MIRAGE

I

II

Galant

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: • Negative battery cable • Accelerator cable, Positive Crankcase Ventilation (PCV) hoses, breather hoses, spark plug cables • Valve cover Timing belt belt upper and lower covers •• Timing • Camshaft sprockets

Camshaft dowel position during installation— 3. 5L engine

0 tool, hold the sprocket and tighten the bolt to 65 ft. lbs. (90 Nm). 15. Install or connect the following: • Timing belt and valve covers • CMP sensor • Intake manifold plenum stay bracket • Negative battery cable and check for . leaks

3.5L ENGINE 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Timing belt • Rocker arm cover • Lash adjuster clips on the rocker arms, then loosen the bearing cap bolts. Do not remove the bolts from the bearing caps. • Rocker arms, shafts and bearing caps as an assembly • Camshafts To install:

3. Lubricate the camshafts with engine oil and position them on the cylinder heads. 4. Position the dowel pins as shown in the drawing. 5. Install or connect the following: • Bearing caps/rocker arm assem¬ blies. Tighten the bolts to 23 ft. lbs. (31 Nm). • Rocker arm cover using a new gas¬ ket • Timing belt and remaining compo¬ nents • Negative battery cable Eclipse

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Remove the battery

• Accelerator cable bracket and posi¬ tion the cable aside • Air intake hose • Breather hose and disconnect the Positive Crankcase Ventilation (PCV) hose • Spark plug cables • Rocker cover 3. Install lash adjuster retainer tools to the rocker arm. • Timing belt covers and the timing belt • Camshaft sprocket retainer bolt and remove the sprocket from the shaft • Camshaft oil seal • Both rocker arm shaft assemblies from the head • Camshaft from the cylinder head To install:

4. Loosen the bearing cap bolts in 2-3 steps. Label and remove all camshaft bear¬ ing caps. • Intake and exhaust camshafts • Rocker arms and lash adjusters To install:

5. Install the lash adjusters and rocker arms into the cylinder head. Lubricate lightly with clean oil prior to installation. 6. Lubricate the camshafts with clean engine oil and position the camshafts on the cylinder head. 7. Be sure the dowel pin on both top. camshaft sprocket ends are located on the 8. Install the bearing caps. Tighten the caps in sequence and in 2 or 3 steps. No. 2 and 5 caps are of the same shape. Check the markings on the caps to identify the cap number and intake/exhaust symbol. Only L (intake) or R (exhaust) is stamped on No. 1 bearing cap. Also, be sure the rocker arm is correctly mounted on the lash adjuster and the valve stem end. Torque the retaining bolts to 15 ft. lbs. (20 Nm).

4. Lubricate the camshaft journals and camshaft with clean engine oil and install the camshaft in the cylinder head. 5. Install the rocker arm and shaft assemblies. Tighten the rocker arm shaft retainer bolts to 21-25 ft. lbs. (29-35 Nm). 9. Apply a coating of engine oil to the 6. Apply a coating of engine oil to the oil seal. Using the proper size driver, pressfit the seal into the cylinder head. oil seal. Using the proper size driver, pressfit the seal into the cylinder head. 7. Install or connect the following: • Camshaft sprockets and tighten the • Camshaft sprocket and retainer bolt sprocket to 65 ft. lbs. (90 Nm) (80-100 bolts Nm) to 58-72 ft. lbs. • Timing belt and belt covers • Timing belt, covers and related Ins 8. Remove the lash adjuster retaining tal components lor tools. co nn 9. Install or connect the following: ec the • Rocker cover using new gasket fol Intake side Exhaust side low material on mating surfaces ing : • Spark plug cables • Air intake hose • Breather hose and connect the PCV • hose Battery

10. Run the engine at idle until normal operating temperature is reached. Check idle speed and ignition timing; adjust as required.

Slits

Camshaft identification — 2.4L (4G64) engine

MITSUBISHI

21-72

DIAMANTE

• ECLIPSE • GALANT • LANCER • MIRAGE

Valve cover and reconnect all related components Negative battery cable

shaft assemblies. Loosen both rocker arm assemblies gradually and evenly and remove the rocker shafts from the vehicle. Do NOT disassemble! Camshaft Position (CMP) sensor connector CMP sensor support CMP sensor sensing cylinder Camshaft

• ket Rocker arm (valve) cover and gas¬

Lancer

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Negative battery cable • Air cleaner assembly • Ignition coil • Breather hose • Positive Crankcase Ventilation (PCV) hose

• Spark plug guide • Timing belt front upper cover 3. Remove the camshaft sprocket, as follows: a. Secure the cam sprocket and tim¬ ing belt with wire ties to prevent them from slipping out of place. b. While holding the sprocket from turning with special tools MB990767 and MD998719, remove the camshaft sprocket bolt and sprocket. 4. Remove or disconnect the following: • Intake and exhaust rocker arm and

•

• ••

To install:

5. •Install or connect the following: Camshaft

• CMP sensor sensing cylinder, sup port and connector

1

89 ± 17 in-lb

9. CAMSHAFT OIL SEAL 10. INTAKE ROCKER ARM SHAFT ASSEMBLY

1.

BREATHER HOSE CONNECTION

2.

PCV

3. 4. 5. 6.

ACCELERATOR CABLE CLAMP ROCKER COVER ROCKER COVER GASKET SPARK PLUG GUIDE

12. CAMSHAFT POSITION CONNECTOR

SENSOR

7.

TIMING COVER

13. CAMSHAFT SUPPORT

SENSOR

8.

CAMSHAFT

HOSE

CONNECTION

BELT

FRONT

UPPER

11. EXHAUST ROCKER SHAFT ASSEMBLY

AND

ARM

POSITION

AND

SPROCKET 9357QG17

Exploded view of the camshaft and related components— Lancer

MITSUBISHI

■

• Rocker arm and shaft assemblies • Camshaft oil seal • Camshaft sprocket. Tighten the bolt to 58-72 ft. lbs. (78-98 Nm). • Timing belt front upper cover 6 • Spark plug guide • Rocker arm cover, with a new gas¬ ket. Tighten the bolts to 23-31 inch lbs. (2.5— 3.5 Nm). • Accelerator cable clamp • PCV and breather hoses . • Negative battery cable

* DIAMANTE • ECLIPSE • GALANT • LANCER • MIRAGE

0-1

79

£

* V

Mirage

1.5L (4G15) ENGINE 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Negative battery cable • Accelerator cable, breather hose and Positive Crankcase Ventilation (PCV) hose connections • Distributor, if equipped • Valve cover and discard the gasket 3. Loosen both rocker arm assemblies gradually and evenly and remove the rocker shafts from the vehicle. 4. Remove or disconnect the following: • Timing belt covers • Timing belt • Camshaft sprocket from the camshaft. Note the positioning of the dowel pin at the end of the camshaft. • Camshaft oil seal from the front of the cylinder head • Camshaft from the head To install:

• Negative battery cable and check the ignition timing

• New camshaft oil seal. • Camshaft sprocket and tighten the retainer belt bolt to 65 ft. lbs. (90 Nm) • Timing

1.8L (4G93) ENGINE 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Spark plug cables • Manifold Absolute Pressure (MAF) sensor connector and remove the air cleaner case cover • Accelerator cable, breather hose and Positive Crankcase Ventilation

5. Lubricate the camshaft with clean engine oil and slide it into the head. Be sure

(PCV) hose connections • Rocker cover and discard the gas¬ ket

to position the dowel pin at the 12 o’clock position. 6. Install or connect the following: • New camshaft oil seal. Be sure to lubricate the lips of the seal with clean engine oil. • Camshaft sprocket and install the mounting bolt. Tighten the bolt to 51 ft. lbs. (70 Nm) • Timing belt • Timing belt covers • Rocker shaft assemblies. Torque the bolts gradually and evenly to 23 ft. lbs. (32 Nm). 7. Install the valve cover with a new gas¬ ket. Tighten the valve cover bolt to 16 inch lbs. (1.8 Nm). 8. Install or connect the following: • Distributor, if equipped • Accelerator cable, breather hose and PCV hose

3. Loosen both rocker arm shaft assem¬ blies gradually and evenly and remove the rocket shafts from the vehicle. 4. Remove or disconnect the following: • Timing belt covers • Timing belt • Camshaft sprocket from the camshaft. Note the positioning of the dowel pin at the end of the camshaft. • Camshaft oil seal from the front of the cylinder head • Camshaft from the head To install:

5. Lubricate the camshaft journals and camshaft with clean engine oil and install the camshaft in the cylinder head. Be sure to position the dowel pin at the end of the camshaft as noted during the removal pro¬ cedure.

Inst

all

or c • Timing belt covers onn • ecRocker arm and shaft assemblies. t th e fo Tightenllothe arm shaft win rocker retainer bolts g: to 23 ft. lbs. (32 Nm). • Valve cover with a new gasket. Tighten the valve cover bolts to 29 inch lbs. (3.3 Nm). • Spark plug cables • Accelerator cable, breather hose and PCV hose • MAP sensor connector and install the air cleaner case cover • Negative battery cable

Valve Lash ADJUSTMENT Valve clearance is not adjustable on these vehicles.

Starter Motor

_

_

REMOVAL & INSTALLATION

1 . Remove or disconnect the following: • Negative battery cable • Air-flow sensor assembly connector and remove the breather hose • Resonator retaining nuts and remove the air intake hose and res¬ onator assembly as required

I

91-74

MITSUBISHI

3.5L ENGINE

• Left side crossmember. If equipped '■►Use care when removing the air fc. *8 *♦ DIA with Four Wheel Steering (4WS), it MAN TE • ECLIPS cleaner cover because the air-flo w sen¬ E • GALANT • LAN CER • MIRAGE will also be necessary to remove sor is attached and is a sensitive com¬ ponent. the right side crossmember.

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable. 3. Drain the engine oil. 4. Remove the mounting bolts from the lower oil pan.

• Starter motor

2. If equipped with Active-ECS suspen¬ sion, remove the air compressor as follows: a. Disconnect the 2 electrical connec¬ tors, from the compressor. b. Disconnect the air line at the com¬ pressor. c. Remove the 3 mounting bolts, . securing the compressor to the chas¬ sis. 0

3. Raise the vehicle and support safely. 4. Remove or disconnect the following: • Engine undercover • Heat shield from beneath the intake manifold on the 1.5L engine • Speedomet. er cable connector at the transaxle end, if necessary • Starter motor electrical connections • Starter motor mounting bolts and remove the starter 5. Install or connect the following: • Starter motor mounting bolts and remove the starter. Tighten the starter mounting bolts to 22 ft. lbs. (31 Nm). • Starter motor electrical connections • Speedometer cable connector at the transaxle end, if necessary • Hat shield from beneath the intake manifold on the 1.5L engine • Engine undercover 6. Lower the vehicle 7. Install or connect the following: • Air compressor, if equipped with Active-ECS suspension • Resonator retaining nuts and remove the air intake hose and res¬ onator assembly as required • Air-flow sensor assembly connector and remove the breather hose • Negative battery cable and check the starter for proper operation

• Roll stopper stay bracket, from the rear transaxle stay bracket • Transaxle stay brackets • Bell housing lower cover • Oil pan mounting bolts • The engine oil pan

5. Place a block of wood against the side of the pan and tap the block with a hammer to break the seal and remove the lower pan. Starter or disconnect the following: 6.• Remove

To install:

bead of seal aro und the surface of the oil er

• Dipstick tube • Upper oil pan

"♦Assemble the oil pan to the cylinder block within 15 minutes after applying p . theansealant .

- WARNING

Appl

y a4. Install the oil pan mounting bolts. 0.16 (4m sequence, tighten mount¬ Followingin.proper ) c lbs. (6 Nm). ing bolts to 48 minch ont 5. Install or connectinuthe ous following: • Lower bell housing cover and the starter motor

Do not pry or use seal breaker tool to remove the oil pan. Damage to the aluminum surface can result.

7. Screw a bolt into the threaded hole to force the oil pan from the engine block and remove the pan. 8. Remove the bolt used to remove the

• Transaxle stay brackets and connect the roll stopper bracket • Crossmember(s) and tighten the mounting bolts to 43-51 ft. lbs. (60-70 Nm) 6. Fill the engine with the proper amount of oil. 7. Connect the negative battery cable and check for leaks.

To install:

9. Clean and degrease the sealing sur¬ faces of the upper oil pan and engine block.

App

alo pan.the mo unt ng ing

ly

sur

fac

e

of the upp o er il

ab

eadpa onf.s i

lic

one sea

lan

t

Oil Pan REMOVAL & INSTALLATION Diamante

3.0L ENGINES 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

2. Remove or disconnect the following: • Negative battery cable • Oil pan drain plug and drain the engine oil

Groove

Hole of bolt 7923PG67

Oil pan bolt tightening sequence and application of sealant to the pan— Diamante 3.0L (J- and H-) engines

I

Nm) MITSUBISHI DIAMANTE

91.71;

• ECLIPSE • GALANT • LANCER • MIRAGE

■

* w

7. Install or connect the following: • Oil pan to the cylinder block and tighten the bolts to 60 inch lbs. (7 • Bell Nm). housing inspection cover. Torque the bolts to 84 inch lbs. (9 • Front exhaust pipe • Engine dipstick and tube assembly using a new 0-ring 8. Refill the engine with oil. Connect the negative battery cable. Start the engine and check for leaks. Install a bolt in the threaded hole to force the oil pan from the engine block— 3. 5L engine

1 1 . Install or connect the following: • Upper oil pan. Tighten the bolts in sequence to 48 inch lbs. (6 Nm). • Dipstick tube using a new 0-ring • Starter assembly 12. Clean and degrease the sealing sur¬ face of the lower oil pan. 13. Place a bead of sealant on the mounting surface of the lower oil pan. Install the lower pan. Tighten the bolts in sequence to 84-108 inch lbs. (10-12 Nm). 14. Install the drain plug using a new washer. Tighten the drain plug to 29 ft. lbs. (39 Nm). 15. Lower the vehicle and fill the crankcase to the correct level. 16. Connect the negative battery cable. 17. Start the engine and check for leaks.

Galant

1. Before servicing the vehicle, refer to

Eclipse

2.4L (4G64) ENGINE 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the negative battery cable. 3. Drain the engine oil. 4. Remove or disconnect the following: • Engine dipstick and tube assembly • Front exhaust pipe • Bell housing inspection cover • Bolts attaching the oil pan to the cylinder block 5. Remove the oil pan assembly. To install:

6. Clean the sealing surface on the oil pan and engine block. Apply a continuous bead of sealant to the oil pan.

11

the precautions in the beginning of this sec¬ tion.2. Remove or disconnect the following: • Negative battery cable • Oil pan drain plug and drain the engine oil • Oil dipstick and tube assembly • Heated Oxygen (HO2S) sensor con¬ nector • Front exhaust pipe from the vehicle • Bell housing cover • Oil pan retainer bolts 3. Tap in between the engine block and the oil pan. (■►Do not use a pry tool when removing the oil pan. Damage to engine compo¬ nents may occur. To install:

sealant 4. ofApply pan. around the gasket sur¬ the oil faces

Flange bolt tightening sequence

Apply sealant and tighten the bolts in the order shown — 3.5L engine, lower oil pan Apply sealant and tighten the bolts in the order shown— 3. 5L engine, upper oil pan

TSUBISHI 91 7fi MI DIAMANTE • ECLIPSE

• GALANT • LANCER • MIRAGE

11 * 1 N-m 97 ± 9 in-lb

24 ± 3 N-m 18 ± 2 ft-lb

9.0 ± 3.0 N-m 79 ± 26 in-lb

9.0 ± 3.0 N-m 79 ± 26 in-lb 9.0 ± 3.0

49 ± 6 N-m 37 ± 4 ft-lb

79 ± 26 in-lb

9.0 ± 3.0 N-m 79 ± 26 in-lb

39 ± 5 N-m 29 ± 3 ft-lb

7.0 ±1.0 N-m 62 ± 9 in-lb

11 ±1 N-m 97 ± 9 in-lb

1. 2. 3.

DRAIN PLUG DRAIN PLUG GASKET LOWER OIL PAN

Exploded view of the oil pan mounting— -Lancer with 2.0L engine

4. 5. 6.

COVER UPPER OIL PAN BAFFLE PLATE 9357QG33

MITSUBISHI y • ECLIPSE Q• tGALANT

DIAMANTE

Designation

Flange Bolt

B C D

Bolts with Washers

Diameter x

Symbol

A

• LANCER

length mm (in)

• MIRAGE

91_77

Tightening torque

2

6x 10

7.0 ±1.0 N m

10

(0.2 x 0.4) 6 x 18

(62 ± 9 in-lb) 9.0 ± 3.0 N m

2

(0.2 x 0.7) 6x22

(79 ± 26 in-lb)

2

(0.2 x 0.9) 8 x 40

24 ± 3 N m

E

2

F

2

G

2

* *

C- ■

(0.3 x 1.6) 10x40 (0.4 x 1.6) 6 x 50

(18 ± 2 ft-lb) 49 ± 6 N m

(0.2 x 2.0) 6 x 127 (0.2 x 5.0)

(79 ± 26 in-lb)

(37 ± 4 ft-lb) 9.0 ± 3.0 N m

9357QG18

Upper oil pan bolt location and torque sequence

5. Install or connect the following: • Oil pan onto the cylinder block within 15 minutes after applying sealant. Tighten to 72 inch lbs. (8 Nm). • Oil drain plug and tighten to 29 ft. lbs. (39 Nm) • Bell housing cover. Tighten the mounting bolts to 84 inch lbs. (9 Nm). • Front exhaust pipe and tighten the bolts at the catalytic converter to 36 ft. lbs. (49 Nm). Tighten the nuts at the exhaust manifold to 32 ft. lbs. (44 Nm). • HO2S sensor connector 6. Fill the crankcase to the proper level. 7. Connect the negative battery cable. Start the engine and check for leaks. Lancer

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable. 3. Drain the engine oil. 4. Remove or disconnect the following: • Engine undercover • Front exhaust pipe

Lancer with 2.0L engine

•• Lower Cover oil pan bolts and lower pan

3

• Upper oil pan bolt and upper pan • Baffle plate To install:

5. Clean all gasket surfaces of the cylinder block and the upper and lower oil 6. Install or connect the following: • Baffle plate pan. 7. Apply a 0.16 in. (4mm) bead of sealant to the gasket surfaces of the upper oil pan. • Upper oil pan onto the cylinder block within 15 minutes after

Lower oil pan bolt tightening sequence— Lancer with 2.0L engine

applying sealant. Tighten the bolts as shown in the accompanying fig¬ ure. 8. Apply 0.16 in. (4mm) bead of sealant to the gasket surfaces of the lower oil pan. • Lower oil pan and tighten the bolts, in the sequence shown, to 88-106 inch lbs. (10-12 Nm) • Front exhaust pipe • Engine undercover • Oil drain plug with a new gasket and tighten to 29 ft. lbs. (40 Nm) 9. Lower the vehicle and fill the crankcase to the proper level with clean engine oil.

Make sure to the install the new drain plug gasket as shown, or leaks will occur

SUBISHI 91 -7I 8o MIT DIAMANTE • ECLIPSE

10. Connect the negative battery cable. Start the engine and check for leaks. 9 Mirage.

1.5L (4G15) ENGINE

• GALANT • LANCER • MIRAGE crankcase to the proper level with clean engine oil.

Start the engine and check for leaks.

1.8L (4G93) ENGINE

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable. 3. Drain the engine oil. 4. Remove or disconnect the following: • Bell housing lower cover • Oil pan retainer bolts "♦Do not use a pry tool when removing the oil pan.

Connect tservicing he negat the vehicle, refer to 1. Before ive batt er . sec¬ the precautions in the beginningy caofblethis tion. 2. Disconnect the negative battery cable. 3. Raise the vehicle and support safely. 4. Remove or disconnect the following: • Oil pan drain plug and drain the engine oil • fold Exhaust pipe from the engine mani¬ • Bell housing lower cover • Oil pan retainer bolts and remove the oil pan

To install:

5. Clean all gasket surfaces of the cylin¬ der block and the oil pan. 6. Apply sealant to the gasket surfaces of the oil pan. 7. Install or connect the following: • Oil pan onto the cylinder block within 15 minutes after applying sealant. Tighten to 60 inch lbs. (7 Nm). • Bell housing cover • Oil drain plug with a new seal and tighten to 29 ft. lbs. (40 Nm) 8. Lower the vehicle and fill the

'■►Do not use a pry tool when removing the oil pan. To install:

5. Clean all gasket surfaces of the cylin¬ der block and the oil pan. 6. Apply sealant around the gasket sur¬ faces of the oil pan. 7. Install or connect the following: • Oil pan onto the cylinder block within 15 minutes after applying

Nm). sealant. Tighten to 60 inch lbs. (5 • Bell housing cover • Exhaust pipe to the engine mani¬ fold with new gasket in place. Tighten the exhaust pipe to mani¬ fold flange nuts to 33 ft. lbs. (45 Nm). Install and tighten the support bolt to 18 ft. lbs. (25 Nm). • Oil plug and tighten to 29 ft. lbs. drain (40 Nm)

8. Fill the crankcase to the proper level. 9. Connect the negative battery cable. Start the engine and check for leaks.

Oil Pump

REMOVAL & INSTALLATION 1.5L and 1.8L Engines ^Whenever the oil pump is disassem¬ bled or the cover removed, the gear cavity must be filled with petroleum jelly to seal the pump and act as a prime. Do not use grease.

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Front engine mount bracket and accessory drive belts • Timing belt upper and lower covers • Timing belt and crankshaft sprocket • Oil pan and remove the oil screen • Front cover mounting bolts. Note the lengths of the mounting bolts as they are removed for proper installation. • assemb Front case ly assembly and oil pump • Oil pump cover • Inner and outer gears from the front case To install

6 Nm 4.3 ft. lbs.

3. Remove all gasket material from the mating surfaces and clean all parts. 4. Thoroughly coat both oil pump gears with clean engine oil and install them in the correct direction of rotation. 5. Install the pump cover and tighten the bolts to 84 inch lbs. (10 Nm). 6. Coat the relief valve and spring with clean engine oil. Install them and tighten the plug to 33 ft. lbs. (45 Nm). 7. Install or connect the following: • New front crankshaft seal and coat the lips of the seal with clean

2 7923PG65

Oil pan and related components— Mirage 1.5L (4G15) engine

engine oil • Front case and oil pump assembly

MITSUBISHI DIAMANTE

to the engine block using a new gasket. Tighten the bolts to 10 ft. lbs. (14 Nm). • Oil screen with new gasket. Torque the screen bolts to 14 ft. lbs. (19 Nm). • Oil pan • Crankshaft sprocket and timing belt 8. Fill the crankcase to the proper level. 9. Connect the negative battery cable. 2.0L (4G94) Engine

precaut

Before

ions

in the beginni

ng

• ECLIPSE • GALANT

2. Drain the engine oil. 3. Remove or disconnect the follow¬ er • Negative battery cable •• Oil pressure switch Oil filter • Drain plug and gasket. Discard the • Cover gasket. • Upper oil pan. Remove the 5 in. (127mm) bolt, which is closest to the flywheel/flexplate first, then, the other bolts. • Baffle plate

of this section.

01

• LANCER • MIRAGE

.70 I

I V

• Lower oil pan. Remove the 5 in. (127mm) bolt, which is closest to the flywheel/flexplate first, then, the other bolts. • Oil screen and gasket •• Relief sealplug and spring • Oil O-ring • Front case

• Oil pump case cover ^Matchmark

the installed position of

the pump rotors before removing them.

• Outer and inner oil pump rotors

f APPLY ENGINE OIL TO ALL MOVING

servici

ng the vehicle,

refer to the 14 124 ±9 in-lb

23 ft-lb N-m 39 ± 5 N m 29 ± 3 ft-lb 7 ± 1 N-m 62 ± 8 in-lb

11 ± 1 N-m 98 ± 8 in-lb~

1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Oil pressure switch Oil filter Drain plug Gasket Cover Upper oil pan Baffle plater Lower oil pan Oil screen Oil screen gasket

11. 12. 13. 14 1 5. 16.

Relief plug Relief spring Relief plunger Oil seal Front case O-ring

17. Oil pump case cover 18. Outer rotor 19. Inner rotor 9357QG20

Exploded view of the oil pump and related components— 2. OL (4G94) engine

91 I L.

fl MITSUBISHI .Q OU

DIAMANTE • ECLIPSE • GALANT • LANCER • MIRAGE

To install:

4. Install or connect the following: • Inner up and outer rotors, making sure the alignment marks are matched • Oil pump case cover • 0-ring ^After installation or the front case, wait at least one hour before filling the crankcase with oil or starting the engine.

• Front case. Apply a 0.12 inch (3mm) bead of sealant, then tighten the case bolts to 124 inch lbs. (14 Nm). • Oil seal • Relief plunger, spring and plug • Oil screen gasket and screen • Lower oil pan. Refer to the oil pan procedure for sealant application and torque specifications. • Baffle plate • Upper oil pan. Refer to the oil pan procedure for sealant application and torque specifications. • Cover • Drain plug with a new gasket. Tighten the plug to 29 ft. lbs. (35 Nm). • Oil filter • Oil pressure switch 5. Fill the engine with the correct amount of oil. 6. Connect the negative battery cable. 7. Start the engine and check for leaks. 2.4L (4G64) Engine

Phillips screwdriver

7923PG71

Holding the silent shaft for oil pump gear removal— Eclipse 2.0L (4G63) engine

3. Drain the engine oil. 4. Using the proper equipment, support the weight of the engine. Remove the front engine mount bracket and accessory drive belts. 5. Remove or disconnect the following: • Timing belt upper and lower covers • Timing belt and crankshaft sprocket • Electrical connector from the oil pressure sending unit • Oil pressure sensor • Oil filter and the oil filter bracket

• Oil pan, oil screen and gasket 6. Using special tool MD998162, remove the plug cap in the engine front cover. 7. Remove or disconnect the following: • Plug on the side of the engine block. Insert a steel rod with a shank diameter of 0.32 in. (8mm) into the plug hole. This will hold the silent shaft. • Driven gear bolt that secures the oil pump driven gear to the silent shaft

^►Whenever the oil pump is disassem¬ bled or the cover removed, the gear cavity must be filled with petroleum jelly to seal the pump and act as a prime. Do not use grease.

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. Rotate the engine so No. 1 cylinder is on Top Dead Center (TDC) of its compres¬ sion stroke.

Make sure to the install the new drain plug gasket as shown, or leaks will occur

Use the special socket and holder to remove the balance shatt plug— Eclipse 2.0 (4G63) engine

MITSUBISHI 0-1 CM

DIAMANTE

• ECLIPSE • GALANT • LANCER • MIRAGE

Li

Ul

.

• Front cover mounting bolts. Note the lengths of the mounting bolts as they are removed for proper installation. • Front case cover and oil pump assembly. If necessary, the silent shaft can come out with the cover assembly. • Oil pump cover, located on the back of the engine front cover. Remove the oil pump drive and dri¬ ven gears. 8. After disassembling the oil pump, clean all components and remove gasket material from mating surfaces. 9. Assemble the oil pump gears into the front case and rotate it to ensure smooth rotation and no looseness. Be sure there is no ridge wear on the contact surface between the front case and the gear surface of the oil pump front cover. To install

10. Align the timing mark on the oil pump drive gear with that on the driven gear and install them into the engine front case. Apply engine oil to the gears. 11. Install the oil pump cover and tighten the retainer bolts to 13 ft. lbs. (18 Nm) on Eclipse models and 17 ft. lbs. (24 Nm) on Galant models. 12. Using the appropriate driver, install a new crankshaft seal into the front case. 13. Position new front case gasket in place. Set seal guide tool MD998285 on the front end of the crankshaft to protect the seal from damage. Apply a thin coat of oil to the outer circumference of the seal pilot tool. 14. Install the front case assembly

19. Install or connect the following: • Oil pan to the engine and secure with the retainers. Tighten bolts to 60 inch lbs. (7 Nm). • Oil pressure gauge unit and the oil

s¬ pre oil t rec cor ify Ver . ks lea. iner eng fo the ect p rt ns sta I d e. an sur

^After applying sealant to the oil pan, do not exceed 15 minutes before installing the oil pan.

3.0L Engines

Co

nn

abl ercy

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. e

pressure switch • Electrical harness connector • Oil cooler. Oil cooler bolt to 31 ft. lbs. (43 Nm). the crankcase. Install new oil filter. Refill 20.

ver the oil pump is disassem¬ ^Whene bled or the cover removed, the gear cavity must be filled with petroleum jelly to seal the pump and act as a prime. Do not use grease.

t beat tiv

ega

n the

ec

• Oil screen in position with new gasket in place 18. Clean both mating surfaces of the oil pan and the cylinder block. Apply sealant in the groove in the oil pan flange.

7923 PG74

Front case bolt identification — Eclipse 2.0L (4G63) and 2.4L (4G64) engines

21

through a new front case gasket and tem¬ porarily tighten the flange bolts. 15. Mount the oil filter on the bracket with new oil filter bracket gasket in place. Install the bolts with washers and tighten to 14 ft. lbs. (19 Nm). 16. Insert a Phillips screwdriver into the hole in the left side of the engine block to lock the silent shaft in place. 17. Install or connect the following: • Oil pump drive gear onto the left silent shaft. Tighten the driven gear bolt to 27 ft. lbs. (37 Nm). • New O-ring to the groove in the front case and install the plug cap. Tighten the cap to 17 ft. lbs. (24 Nm).

SUBISHI 9 MIT 91 -8 UL DIAMANTE • ECLIPSE

C. I

» GALANT • LANCER • MIRAGE

3. Drain the engine oil. 4. Remove or disconnect the following: • Front engine mount bracket and accessory drive belts • Timing belt upper and lower covers • Timing belt and crankshaft sprocket • Oil pan • Oil screen and gasket • Front cover mounting bolts. Note the lengths of the mounting bolts as they are removed for proper installation. • Front case cover and oil pump assembly To install:

5. Thoroughly clean all gasket material from all mounting surfaces. 6. Apply engine oil to the entire surface of the gears or rotors. 7. Assemble the front case cover and oil pump assembly to the engine block. 8. Install or connect the following: • Oil screen with new gasket • Oil pan • Crankshaft sprocket and timing belt • Timing belt covers • Drive belts and the front engine mount bracket

• Negative battery cable, refill the crankcase and check for adequate oil pressure 3.5L Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Negative battery cable • Timing belt 3. Drain the engine oil. 4. Remove or disconnect the following: • Splash shield from the wheel well • Oil filter adapter • Lower and upper oil pans • Lower baffle, oil pump pick-up and upper baffle • Oil pump case mounting bolts and the oil pump case • Oil pump gear cover 5. Make matchmarks on the oil pump rotors before removing them. • Crankshaft seal from the oil pump case To install:

6. Install or connect the following: • New crankshaft seal in the oil pump cover 7. Apply engine oil to the rotors, then align the matchmarks and install the rotors in the oil pump case. • Rotor cover and tighten the bolts to 84 inch lbs. (10 Nm)

13 Nm 10 ft.lbs.

30 ft.lbs. 41 Nm

3

9.8 Nm 7 ft.lbs.

5.9 Nm 4 ft.lbs.

parts with engine oil during reassembly. 11 Nm 8 ft.lbs.

Removal 1. 2. 3. 4. 5.

6. 7. 8. 9. 10. 11.

steps

Oil pressure gauge unit Oil filter Oil filter bracket Oil filter Drain plugbracket gasket

Drain plug gasket Oil pan, lower Cover Oil pan, upper Baffle plate Oil screen

14. Plug 16

12. Oil screen gasket 13. Baffle plate

15, Relief spring

Relief plunger Crankshaft oil seal 17 18. Oil pump case 19. O-ring 20. Oil pump cover 21 . Oil pump outer rotor 22. Oil pump inner rotor 7923PG77

Exploded view of the oil pump mounting— 3. 5L engine

MITSUBISHI DIAMANTE

sealant to the back of the oil pump case. Install the case on the engine and tighten 9 the bolts to 10 ft. lbs. (13 Nm). . 8. Ap • plUpper plate and oil pump y a 0.baffle 113 in. (3mm) pick-up using a new bead of gasket— Tighten the baffle bolts to 84 inch lbs. (10 Nm) and the pick¬ up bolts to 13 ft. lbs. (18 Nm). • Lower baffle in the upper oil pan. Tighten the bolts to 96 inch lbs. (11 Nm). • Oil pans . • Oil filter adapter using a new gas¬ ket. Tighten the larger bolt to 30 ft.

• ECLIPSE • GALANT

lbs. (41 Nm) and the smaller bolt to 17 ft. lbs. (23 Nm).

91

• LANCER • MIRAGE

■

09 UU

ing: 2. Remove or disconnect the follow¬ • Transaxle

• Timing belt and remaining compo¬ nents

• Flywheel or flexplate from the crankshaft

amount of oil. 10. Connect the negative battery cable. 1 1Fi.ll Start engine and check for leaks. the enthe gine w ith Rear Main Seal the correct

3. Carefully pry the seal out of the oil seal case without damaging the sealing sur¬ face of the crankshaft.

REMOVAL & INSTALLATION

the proper size seal driver. 5. Install or connect the following: •• Transaxle Flywheel or flexplate

preca

To install:

4. Apply engine oil to the lip of the new seal and install the seal in the case using

in the begi o t s nnin f his ection. g s

ution

1 B efore servi cing the v ehicl e, re fer t o the

98 ±5 N-m 73 ± 3 ft-lb

98 ± 5 N m 73 ± 3 ft-lb

1 . FLYWHEEL BOLT 2. ADAPTER PLATE 3. FLYWHEEL ASSEMBLY 4. ADAPTER PLATE 5. DRIVE PLATE BOLT 6. ADAPTER PLATE 7. DRIVE PLATE 8. CRANKSHAFT REAR OIL SEAL 9357QG16

Exploded view of a typical rear main seal

SUBISHI 8/1 MIT DIAMANTE

91I OH L.

• ECLIPSE • GALANT • LANCER • MIRAGE

Timing Belt

Timing mark

REMOVAL & INSTALLATION 1.5L and 1.8L Engines

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Electrical connectors, tag before disconnecting • Timing belt upper and lower covers 3. Make a mark on the back of the tim¬ ing belt indicating the direction of rotation so it may be reassembled in the same direc¬ tion if it is to be reused. Loosen the timing belt tensioner and move the tensioner to provide slack to the timing belt. Tighten the tensioner in this position. • Timing belt

i: WARNING Coolant and engine oil will damage the rubber in the timing belt, drasti¬ cally reducing its life. Do not allow engine oil or coolant to contact the timing belt, the sprockets or ten¬ sioner assembly.

4. If defective, replace the tensioner spacer, tensioner spring and tensioner assembly.

79235G56

Timing mark locations with engine at Top Dead Center (TDC) ot compression stroke — Mit¬ subishi 1.5L (4G15) engine

Timing mark

To install:

5. Position the tensioner, tensioner spring and tensioner spacer on engine block. 6. Align the timing marks on the camshaft sprocket and crankshaft sprocket. This will position No. 1 piston on Top Dead Center (TDC) on the compression stroke. 7. Position the timing belt on the crankshaft sprocket and keeping the tension side of the belt tight, set it on the camshaft sprocket, then the tensioner. 8. Apply slight counterclockwise force to the camshaft sprocket to give tension to the belt and be sure all timing marks are aligned. 9. Loosen the pivot side tensioner bolt and the slot side bolt. Allow the spring to remove the slack. 10. Tighten the slot side tensioner bolt, then the pivot side bolt. If the pivot side bolt is tightened first, the tensioner could turn with bolt, causing over tension. 11. For 1.5L engines, turn the crankshaft clockwise. Loosen the pivot side tensioner bolt, then the slot side bolt to allow the spring to take up any remaining slack.

Camshaft sprocket

Timing belt tensioner A

Belt tension side Water pump sprocket

Timing marks

Belt tension side

Crankshaft sprocket

79235G57

Timing mark locations with engine at Top Dead Center (TDC) ot compression stroke— Mit¬ subishi 1.8L (4G93) engine

MITSUBISHI DIAMANTE

OH

• ECLIPSE • GALANT • LANCER • MIRAGE

Tighten the slot bolt, then the pivot side bolt to 17 ft. lbs. (24 Nm). 12. For 1.8L engines, turn the crankshaft clockwise two rotations and tighten the adjuster bolt to 18 ft. lbs. (24 Nm) and the pivot (spring) bolt to 35 ft. lbs. (45 Nm). 13. Install the timing belt covers and tighten the cover bolts to 84-96 inch lbs. (10-11 Nm). 14. Install the remaining components in the reverse order of removal.

■

OE UU

Camshaft

2.0L Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Front timing belt cover *»-lf the timing belt is going to be reused, mark the direction of rotation on the belt with an arrow. Install the belt in the same direction.

3. Rotate the crankshaft sprocket clock¬ wise until the timing marks are aligned. 4. Place 8mm Allen wrench into the belt tensioner, then using the long end of a Va in. (3mm) Allen wrench, rotate the ten¬

sioner counterclockwise until it slides into the locking hole. 5. Remove the belt.

Do not rotate the crankshaft or the camshafts while the belt is removed. To install:

6. Using a vise, slowly compress the plunger into the body of the tensioner and install a pin through the body of the ten¬ sioner to retain the plunger. 7. Be sure the timing marks are still aligned, if not, align the camshaft sprocket timing marks facing each other. Align the crankshaft sprocket timing mark with the mark on the oil pump housing, then turn the crankshaft sprocket backward Vz notch. 8. Install the timing belt, starting at the crankshaft, then around the water pump sprocket, idler pulley, camshaft sprockets and the tensioner pulley. 9. Turn the crankshaft sprocket Vz notch to Top Dead Center (TDC) to take up the slack in the belt. 10. Install the tensioner on the engine, but do not tighten the bolts. 11. Place a torque wrench on the tenS sioner pulley and apply 21 ft. lbs. (28 Nm) of torque in the direction of the water pump, s Push the tensioner up against the tensioner pulley and tighten the mounting bolts to 23 ft. lbs. (31 Nm).

Timing belt sprocket mark alignment for belt service — Mitsubishi 2.0L non-turbo engines

12. Pull the pin out of the tensioner. Belt tension is correct when the pin can be removed and installed. 13. Rotate the crankshaft two revolutions and check the timing marks for alignment. Repeat the previous steps, if necessary. 14. Install the timing belt cover and all other applicable components.

2.4L Engine

1 . Before servicing the vehicle, refer to the tion.precautions in the beginning of this sec¬ 2. Position the engine so that the No. 1 piston is at Top Dead Center (TDC). 3. Remove the timing belt covers.

Counterbalance shaft sprocket Belt tension side Timing

Timing \ marks

marks

Crankshaft sprocket B 79235G61

Timing belt “B” installation mark alignment— 2. 4L engines

MITSUBISH•IECLIPSE • GALANT • LANCER £91 I -fl uufi DIAMANTE • MIRAGE •►If the timing belts are going to be reused, mark the direction of rotation on the belt. This will ensure the belt is reinstalled in same direction, extend¬ ing belt life.

Timing marks

4. To loosen the timing (outer) belt ten¬ sioner, install Mitsubishi Special tool MD998738 to the slot and screw inward to move the tensioner toward the water pump. Once the tension has been relieved, remove the outer timing belt. 5. If tensioner replacement is required, align the pin hole in the tensioner rod to the hole in the tensioner cylinder. Insert a 0.055 in. (1.4mm) wire in the hole and remove the special tool from the slot. With the cylinder 5 tension relieved, remove the auto-tensioner cylinder assembly two mounting bolts. 6. Remove the outer crankshaft sprocket and flange. 7. Loosen the silent shaft (inner) belt tensioner and remove the belt. To install: .

: WARNING Do not spray or Immerse the sprock¬ ets or tensioners in cleaning solvent. The sprocket may absorb the solvent and transfer it to the belt. The ten¬ sioners are internally lubricated and the solvent will dilute or dissolve the lubricant.

8. Align the timing marks of the silent shaft sprockets and the crankshaft sprocket with the timing marks on the front case. Route the timing belt around the sprockets so there is no slack in the upper span of the belt and the timing marks are still aligned. 9. Install the tensioner pulley and move the pulley by hand so the long side of the belt deflects approximately 14 in. (6mm). 10. Hold the pulley tightly so the pulley cannot rotate when the bolt is tightened. Tighten the bolt to 14 ft. lbs. (19 Nm) and recheck the deflection. 11. Align the timing marks of the camshaft, crankshaft and oil pump sprock¬ ets with their corresponding marks on the front case or rear cover. ’■•There is a possibility to align all tim¬ ing marks and have the oil pump sprocket and silent shaft out of time, causing an engine vibration during operation. If the following step is not followed exactly, there is a 50 percent chance that the silent shaft alignment will be 180 degrees (V2 turn) off.

12. Before installing the timing belt, ensure that the left side (rear) silent shaft

sprocket

79235G62

Proper alignment of the timing belt sprocket marks for belt service— 2.4L engines

sprocket, oil pump sprocket, then camshaft (oil pump sprocket) is in the correct posi¬ tion as follows: sprocket, in that order. While doing so, be sure there is no slack between the sprocket a. Remove the plug from the rear side of the block and insert a tool with shaft except where the tensioner is installed. diameter of 0.31 in. (8mm) into the hole. for the fol ste b. With the timing marks still aligned, ps: low m i ng crankshaft the shaft of the tool must be able to go in a. Turn the 14 turn coun¬ terclockwise, then turn it clockwise to at least 2 V2 in. (63.5mm). If the tool can move No. 1 cylinder to TDCL only go in approximately 1 in. (25mm), b. Loosen the center bolt. Using tool the shaft is not in the correct orientation MD998752 and a torque wrench, apply a and will cause a vibration during engine To adj operation. Remove the tool from the hole torque of 2.6 ft. lbs. (3.6 Nm) to the ten¬ ust and turn the oil pump sprocket one com¬ the t sioner. Tighten the center bolt. imi c. Screw the special tool into the plete revolution. Realign the timing ng( out left support bracket until its end marks and insert the tool. The shaft of engine er makes)belcontact with the tensioner arm. At the tool must go in at least 2 14 in. t pe r (63.5mm). this point, screw the special tool in some more and remove the set wire attached to c. Recheck and realign the timing marks. the auto-tensioner, if the wire was not d. Leave the tool in place to hold the previously removed. Then, remove the silent shaft while continuing. special tool. 13. If the camshaft belt tensioner was d. Rotate the crankshaft two complete removed, use a vise to carefully push the turns clockwise and let it sit for approxi¬ auto-tensioner rod in until the set hole in mately 15 minutes. Then, measure the auto-tensioner protrusion (the distance the rod is aligned with the hole in the cylin¬ der. Place a wire into the hole to retain the between the tensioner arm and auto-ten¬ rod. Mount the tensioner to the engine sioner body) to ensure that it is within block and tighten the mounting bolt to 17 ft. 0.15-0.18 in. (3.8-4.5mm). If out of lbs. (23 Nm). specification, repeat substeps a through 14. Install the belt to the crankshaft d until the specified value is obtained.

MITSUBISHI

9

DIAMANTE

.

f»Do not manually overtighten the belt or it will howl.

16. Install the upper and lower timing belt covers. 3.0L (6G72) SOHC Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Position the engine so the No. 1 cylinder is at Top Dead Center (TDC) of its compression stroke.

CAUTION Wait at least 90 seconds after the negative battery cable is discon¬ nected to prevent possible deploy¬ ment of the air bag.

3. Remove all necessary components for access to the timing belt covers, then remove the covers from the engine. 4. If the same timing belt will be reused, mark the direction of the timing belt’s rotation for installation in the same direction. Be sure the engine is positioned so the No. 1 cylinder is at the TDC of its compression stroke and the timing marks are aligned with the engine’s timing mark indicators.

• ECLIPSE • GALANT • LANCER

5. Loosen the timing belt tensioner bolt and remove the belt. It the tensioner is not being removed, position it as far away from the center of the engine as possible and tighten the bolt. 6. If the tensioner is being removed, mark the outside of the spring to ensure that it is not installed backwards. Unbolt the ten¬ sioner and remove it along with the spring.

Do not rotate the camshafts when the timing belt is removed from the engine. Turning the camshaft when the timing belt is removed could cause the valves to interfere with the pistons thus causing severe internal engine damage. To install:

7. Install the tensioner, if removed, and hook the upper end of the spring to the water pump pin and the lower end to the tensioner in exactly the same position as originally installed. 8. Ensure both camshafts are still posi¬ tioned so the timing marks align with those on the rear timing covers. Rotate the crank¬ shaft so the timing mark aligns with the mark on the front cover.

O-i

• MIRAGE

07

U I

while keeping the belt shaft spInrostck alet l than e dtimi ng be tight on the tension side, ltinstonall ththe e crbeanltk¬on the front (left) camshaft sprocket. 10. Install the belt on the water pump

pulley, then the rear (right) camshaft sprocket and the tensioner. 1 1 . Loosen the bolt that secures the adjustment of the tensioner and lightly press the tensioner against the timing belt. 12. Check that the timing marks are in alignment. 13. Rotate the crankshaft 2 full turns in the clockwise direction only, then realign the timing marks. 14. to Tighten sioner 19 ft. the lbs. bolt (26 that Nm).secures the ten¬ 15. Install the lower and the upper tim¬ ing belt covers, along with all other applica¬ ble components. 3.0L (6G72) DOHC Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Position the engine so the No. 1 cylinder is at Top Dead Center (TDC) of its compression stroke. 3. Remove ail necessary components for access to the timing belt covers, then remove the covers from the engine.

Timing mark (on belt cover)

r

sprocket

3.0L (6G72) SOHC engine Align the sprockets properly before removing or installing the timing belt — Diamante with

79235G64

Q 91.QUU

fc. 1

MITSUBISHI DIAMANTE

• ECLIPSE • GALANT • LANCER

• MIRAGE

To install:

CAUTION Be sure to disconnect the negative battery cable. Wait at least 90 sec¬ onds after the negative battery cable is disconnected to prevent possible deployment of the air bag.

4. If the same timing belt will be reused, mark the direction of the timing belt’s rotation for installation in the same direction. Be sure the engine is positioned so the No. 1 cylinder is at the TDC of its compression stroke and the timing marks

are aligned with the engine's timing mark 0 indicators on the rear timing covers. 5. Remove the timing belt. . i: WARNING Turning the camshaft sprocket when the timing belt is removed could cause the valves to contact with the pistons, resulting in severe engine damage.

aut to the eng b a ine lock nd remo-te the ten sio ove nsi ner one . r

'■•The auto-tensioner assembly must be reset to correctly adjust belt ten¬ sion.

7. Loosen the center bolt of tensioner pulley to provide timing belt slack. Remove the timing belt assembly. 8. Position the auto-tensioner into a vise with soft jaws. The plug at the rear of tensioner protrudes, be sure to use a washer as a spacer to protect the plug from contacting vise jaws. 9. Slowly push the rod into the ten¬ sioner until the set hole in rod is aligned with set hole in the auto-tensioner. the ten Unc set hol the alig sion fnreodm the visees. and linasmtap it on th¬e er ll bolt to mou tens Tigh engi nti s i n t 17 fte..lbs. (24en Nm) oner ng .

K WARNING DO NOT rotate or turn the camshafts Inse when removing the sprockets or rt a 0.05 severe 5 in engine damage will result . (1 from internal .4m component interfer¬ m) w ence. i

re i nto

Timing marks (on right

e

Sprocket alignment for timing belt installation— Diamante with the 3.0L (6G72) DOHC engine

11. Align the mark on the crankshaft sprocket with the mark on the front case. Then, move the crankshaft sprocket 1 tooth counterclockwise. 12. Align the timing marks of the camshafts with the marks on the rear cov¬ ers. 13. Using large paper clips to secure the timing belt to the sprockets, install the tim¬ ing belt in the following order. Be sure camshafts-to-cylinder heads and crankshaft-to-front cover timing marks are aligned. Install the timing belt around the pulleys bank).in the following order: a. Exhaust camshaft sprocket (front

bank). b. Intake camshaft sprocket (front c. Water pump pulley. d. Intake camshaft sprocket (rear bank). bank). e. Exhaust camshaft sprocket (rear f. Tensioner pulley. g. Crankshaft pulley. h. Idler pulley. '••Since the camshaft sprockets turn easily, secure them with box wrenches when installing the timing belt.

MITSUBISHI DIAMANTE

14. Align all timing mark on the crank¬ shaft and raise tensioner pulley against belt to remove slack, snug tensioner bolt. 15. Check the alignment of all the timing marks and remove the clips that secure the timing belt to the camshaft sprockets. 16. Rotate the engine Va turn counter¬ clockwise, then rotate the engine clockwise to align the timing marks. Check that all the timing marks are in alignment. 17. Loosen the center bolt on the ten¬ sioner pulley. Using tool MD998752 and a torque wrench, apply 84 inch lbs. (10 Nm) to the tool on the tensioner. Tighten the ten¬ sioner bolt to 35 ft. lbs. (49 Nm) and be sure the tensioner does not rotate with the bolt. 18. Rotate the crankshaft two complete turns clockwise and let it sit for approxi¬ mately five minutes. Then, check that the set pin can easily be inserted and removed from the hole in the auto-tensioner. 19. Remove the set wire attached to the auto-tensioner. 20. Measure the auto-tensioner protru¬ sion (the distance between the tensioner arm and auto-tensioner body) to ensure

• ECLIPSE • GALANT • LANCER • MIRAGE

that it is within 0.15-0.18 in. (3.8-4. 5mm) If out of specification, repeat adjustment procedure until the specified value is obtained. 21 . Check again that the timing marks on all sprockets are in proper alignment. 22. Install the timing belt covers and all other applicable components. 3.5L (6G74) SOHC Engine

91 -flQ ^

4. If the same timing belt will be reused, mark the direction of the timing belt’s rotation for installation in the same direction. Be sure the engine is positioned so the No. 1 cylinder is at the TDC of its compression stroke and the timing marks are aligned onwith indicators thethe rearengine's timing timing covers. mark 5. Remove the timing belt.

WARNING

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Position the engine so the No. 1 cylinder is at Top Dead Center (TDC) of its compression stroke. 3. Remove all necessary components for access to the timing belt covers, then remove the covers from the engine.

** CAUTION Be sure to disconnect the negative battery cable. Wait at least 90 sec¬ onds after the negative battery cable is disconnected to prevent possible deployment of the air bag.

RIGHT BANK

TIMING MARK

SOHC engine Sprocket alignment for timing belt installation — Diamante with 3.5L (6G74)

Turning the camshaft sprocket when the timing belt is removed could cause the valves to contact with the pistons, resulting in severe engine damage.

6. Remove the bolts that secure the auto-tensioner to the engine block and remove the tensioner. To install: ^The auto-tensioner assembly must be reset to correctly adjust belt ten¬ sion.

7. Loosen the center bolt of tensioner pulley to provide timing belt slack. Remove the timing belt tensioner assembly.

LEFT BANK

MITSUBISH•IECLIPSE Qfl DIAMANTE 91I 3u

t

• GALANT

• LANCER

• MIRAGE

camshafts with the marks on the rear cov¬ ers. 13. Realign the crankshaft pulley with timing mark on the housing. ^Be sure camshafts-to-cylinder heads and crankshaft-to-front cover timing marks are aligned.

14. Install the timing belt around the pulleys in the following order: a. Crankshaft pulley. b. Idler pulley. c. Left camshaft sprocket. d. Water pump pulley. e. Right camshaft sprocket. f. Tensioner pulley. •-►Since the camshaft sprockets turn easily because of spring action, be careful not to get your fingers caught.

15. Align all timing mark on the crank¬ shaft and raise tensioner pulley against belt to remove slack, snug tensioner ing. bolt. 16. Check the alignment of all the tim¬

9301 5G29

Measuring the standard value ot the timing belt tensioner— Diamante with 3.5L (6G74) SOHC engine

8. Position the auto-tensioner into a vise with soft jaws. The plug at the rear of tensioner protrudes, be sure to use a washer as a spacer to protect the plug from contacting vise jaws. 9. Slowly push the rod into the ten¬ sioner until the set hole in rod is aligned with set hole in the auto-tensioner. the ten Un se ho the ali i o t¬ sio gnfero thte vilses. an clians e d mtpal t n he ner d m bol to mo l ten Tig eng un ts 17 infet.. lbs h(t2en Nm sion t in . 4 ). er g

* WARNING DO NOT rotate or turn the camshafts when removing the sprockets or severe engine damage will result from internal component interfer¬ ence.

1 1 . Align the mark on the crankshaft sprocket with the mark on the front case. Then, move the crankshaft sprocket 3 teeth counterclockwise. 12. Align the timing marks of the

17. Using special tool MD998769, rotate the crankshaft 14 turn counterclockwise, then rotate the crankshaft clockwise to align the timing marks. Check that all the timing marks are in alignment. 18. Loosen the center bolt on the ten¬ sioner pulley. Using tool MD998767 and a torque wrench, apply 3.3 ft. lbs. (4.4 Nm) to the tool on the tensioner. Tighten the ten¬ sioner bolt to 33 ft. lbs. (44 Nm) and be sure the tensioner does not rotate with the bolt. 19. Rotate the crankshaft two complete turns clockwise and let it sit for approxi¬ mately five minutes. Then, check that the set pin can easily be inserted and removed from the hole in the auto-tensioner. 20. Remove the set wire attached to the auto-tensioner. 21 . Measure the auto-tensioner protru¬ sion (the distance between the tensioner arm and auto-tensioner body) to ensure that it is within 0.150-0.196 in. (3.8-5. Omm). If out of specification, repeat adjustment procedure until the specified value is obtained. 22. Check again that the timing marks on all sprockets are in proper alignment. 23. Install the timing belt covers and all other applicable components.

MITSUBISHI

01

_Q1

DIAMANTE • ECLIPSE • GALANT • LANCER • MIRAGE ^ I 3 1

IDENTIFICATION

MARK

Timing belt

“T"

side

Before removing the caps from the con¬ necting rods, be sure to matchmark them as shown

2.0L engines— compression ring identifi¬ cation mark locations

1.5L, 1.8L. 2.0L and 2.4L engines— piston-to-engine block mark location on the piston face

Side rail

"1 R” identification mark

Spacer 7923AG65

1.5L and 2.4L engines— compression ring identification mark locations

1.8L engine — oil side and spacer ring positioning

3.0L engine — piston-to-engine block mark locations

Front mark Identification mark “T

“74”

and spacer 7923AG62

1.8L engine— compression ring identifica¬

tion mark locations

Piston ring end-gap spacing

3.5L engine — piston and connecting rod assembly positioning

9 U91 I -Q JL

SUBISHI MIT DIAMANTE • ECLIPSE

• GALANT • LANCER • MIRAGE FUEL SYSTEM

4. Remove or disconnect the following: • Air cleaner assembly and intake hoses • Battery and battery tray • Fuel lines from the filter • Mounting bolts and remove the fuel filter from the vehicle

Fuel System Service Precautions Safety is the most important factor when performing not only fuel system mainte¬ nance but any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle’s fuel system components can be accomplished safely and effectively by adhering to the following rules and guide¬ lines. • To avoid the possibility of fire and per¬ sonal injury, always disconnect the negative battery cable unless the repair or test proce¬ dure requires that battery voltage be applied. • Always relieve the fuel system pres¬ sure prior to disconnecting any fuel system component (injector, fuel rail, pressure reg¬ ulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may pene¬ trate the skin or any part of the body that it contacts. • Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suit¬ able waste container. • Always keep a dry chemical (Class B) fire extinguisher near the work area. • Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame.

y fet esra

rop

top

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Turn the ignition to the OFF posi¬ tion.

Fuel Filter .

in els tow hop

ces

Pla

RELIEVING

3. Loosen the fuel filler cap to release fuel tank pressure. 4. For the Lancer, Mirage and Eclipse, remove the rear seat cushion, then remove the service cover and disconnect the fuel pump harness connector. 5. For the Front Wheel Drive (FWD) Galant and Diamante, detach the fuel pump harness connector located near the fuel tank. It may be necessary to raise the vehicle to access the connector. 6. For the All Wheel Drive (AWD) Galant, remove the carpet from the trunk, locate the fuel tank wiring at the pump access cover, then detach the wiring. 7. Start the vehicle and allow it to run until it stalls from lack of fuel. Turn the key to the OFF position. 8. Disconnect the negative battery cable, then reconnect the fuel pump con¬ nector. Install the access cover, cushion or carpet as necessary. 9. Wrap shop towels around the fitting that is being disconnected to absorb resid¬ ual fuel in the lines.

ner

Fuel System Pressure

Location of the fuel pump connector— Lancer shown, other models similar

tai

• Always replace worn fuel fitting Fi¬ rings with new. Do not substitute fuel hose or equivalent, where fuel pipe is installed.

'-►Install new gaskets or O-rings when¬ ever fuel connections have been disas¬ sembled.

con

• Always use a back-up wrench when loosening and tightening fuel line connec¬ tion fittings. This will prevent unnecessary stress and torsion to fuel line piping. Always follow the proper torque specifica¬ tions.

To install:

REMOVAL & INSTALLATION Diamante

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Properly relieve the fuel pressure. 3. Disconnect the negative battery cable. ►•The filter is located in the engine compartment, mounted on the inner fender panel.

5. Install or connect the following: • Filter to its bracket finger-tight • New gaskets and connect the high pressure hose and eye bolt, then the main pipe and eye bolt. Tighten the eye bolts to 22 ft. lbs. (30 Nm). Tighten the flare nut to 25 ft. lbs. (35 Nm). 6. Tighten the mounting bolts fully. 7. Install or connect the following: • Air cleaner assembly • Battery and battery tray • Negative battery cable, install the fuel filler cap, turn the key to the ON position to pressurize the fuel

system and check for leaks. Lancer, Mirage and Galant

'■►The fuel filter is located in the engine compartment.

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Properly relieve the fuel system pres¬ sure. 3. Remove or disconnect the following: • Negative battery cable • Air intake hose and the battery • Fuel lines from the filter • Mounting bolts and the fuel filter from the vehicle To install:

4. If equipped with flare fitting, tighten the fitting by hand before installing the filter to the vehicle. 5. Install or connect the following: • Filter to its bracket finger-tight • New gaskets and connect the high pressure hose and eye bolt, then the main pipe. Tighten the eye bolts to 22 ft. lbs. (30 Nm). Tighten the flare nut to 27 ft. lbs. (37 Nm). 6. Tighten the filter mounting bolts fully. ] 7. Install or connect the following: ,1 • Air intake hose • Negative battery cable, install the

MITSUBISHI DIAMANTE

9 fuel filler cap, turn the key to the

• ECLIPSE • GALANT

• LANCER

ON position to pressurize the fuel

5. Disconnect the center exhaust sys¬ tem from the main muffler. Disconnect the rear exhaust hangers, lower the exhaust and secure aside. 6. Remove the tank drain plug and drain the fuel into an approved container. 7. On models equipped with 4WS, remove the mounting bolts and lower the rear steering gear. 8. Remove or disconnect the following:

no

^

• Fuel return hose, high pressure

2. Properly relieve the fuel system

hose and vent hose from the send¬

pressure. 3. Disconnect the negative battery cable. system and check for leaks. . 4. Remove the left rear wheel well liner, Eclipse if equipped. 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Disconnect the negative battery cable. 4. On models equipped with the 2.4L engine, remove the battery and the air intake hose. 5. Remove the fuel lines from the filter. 6. Remove clamp and the hose from the fuel pressure regulator. 7. Remove or disconnect the following: • Fuel filter mounting bracket bolts and remove the fuel filter • Bracket screw and remove the fuel filter from the mounting bracket 8. On 2.0L non-turbo models, remove the following from the filter: a. The eye bolt and washer. b. The fuel connector and washer with the fuel pressure regulator.

• MIRAGE

91

• Electrical ing unit connector • Filler and vent hoses. Place a sup¬ port under the tank and remove the retaining nuts. 10. Remove the fuel pump retaining nuts Lower the assembly from the tank. and remove th To install:e tank fro m the vefollowing: hicle. 1 1 . Install or connect the • Pump assembly to the tank and tighten the retaining nuts to 24 inch lbs. (3 Nm)

To install:

9. On 2.0L non-turbo models, install the fuel connector with the fuel pressure regulator to the filter with 2 new washers ; and tighten the eye bolt to 22 ft. lbs. (36 Nm).

10. Install or connect the following: • Fuel filter to the mounting bracket with the screw • Fuel filter to the vehicle with the bracket mounting bolts

Proper method of supporting rear exhaust system— Diamante 3.0L engine

• Main fuel pipe to the fuel filter con¬ nector or the filter itself. Torque the flare nut to 27 ft. lbs. (36 Nm). 11. On the 2.0L non-turbo engine mod¬ els reconnect the hose and clamp to the fuel pressure regulator. 12. Reconnect the high pressure fuel hose to the fuel filter. Torque the eye bolt to 22 ft. lbs. (29 Nm). 13. On 2.4L engine models, install the battery and the air intake hose. 14. Reconnect the negative battery cable, start the engine and check for fuel leaks.

Fuel Pump REMOVAL & INSTALLATION Diamante 7923PG80

in the beg

the pre j tion caut . io

in

n

ni

of thi sec s ng

Power cylinder identification— Diamante 3.0L engine

OI.Q/I

L. I

MITSUBISHI

DIAMANTE • ECLIPSE • GALANT • LANCER • MIRAGE

• Fuel tank and connect the filler and vent hoses. Tighten the tank retain¬ ing nuts and bolts to 19 ft. lbs. (26 Nm).

• Return hose, high pressure hose and all other hoses and connectors connected to the pump/sending unit • Power cylinder unit and tighten the mounting bolts to 31 ft. lbs. (43 Nm), if equipped with 4WS • Exhaust pipe and secure the rear hangers • Left rear wheel well liner, if removed 12. Lower the vehicle and return fuel to the gas tank. 13. Connect the negative battery cable and check the entire system for proper operation and leaks. Eclipse

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: • Negative battery cable • Rear seat cushion by pulling the seat stopper near the floor and lift¬ ing the cushion up • Inspection cover on the right side of the vehicle • Harness connector and the fuel lines

Harness •• Fuel lineselectrical connector

• Pump mounting nuts and remove the pump assembly

To install:

4. Install the fuel pump assembly to the tank and tighten the retaining nuts to 22 inch lbs. (2.5 Nm). ^Tilt the float to the left of the vehicle, when installing the pump assembly.

5. Install or connect the following: • High pressure hose, return hose and the fuel tank wiring • Negative battery cable 6. Check the fuel pump for proper pres¬ sure and inspect the entire system for leaks. 7. Apply sealant to the access cover and install the cover. 8. Install the rear seat cushion. Lancer

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Properly relieve the fuel system pres¬ sure. 3. Disconnect the negative battery cable. 4. Remove or disconnect the following: • Rear seat assembly • Retainer screws and service hole cover

• Fuel pump • Fuel pump 5. Disassemble as necessary. Refer

module mounting nuts module the fuel pump module to the accompanying

figure. 6. Installation is the reverse of the removal procedure. Torque the fuel pump module nuts to 23 inch lbs. (2.5 Nm). Mirage

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system

3. Disconnect the negative battery pressure. cable. 4. Raise and safely support the vehicle. 5. Drain the fuel from the fuel tank into an approved container. 6. Disconnect the filler and vent hoses. 7. Support the tank with a transmission jack. Disconnect the retainer straps and lower the tank to gain access to the fitting on top of the tank. 8. Remove or disconnect the following: • Return hose, high pressure hose and vapor hoses from the

pump/sending unit

• Fuel pump assemble from the tank. Remove the locking ring on the All Wheel Drive (AWD) model.

To install:

4. Install or connect the following: • Fuel pump in the tank • Hoses and the harness connector • Inspection cover • Rear seat • Negative battery cable Galant

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Properly relieve the fuel system pres¬ sure. 3. Remove or disconnect the following: • Negative battery cable • Rear seat cushion, by pulling the seat stopper outward and lifting the lower cushion upward • Access cover • Fuel pump wiring • Return hose and the high pressure fuel hose

1. 2. 3. 4.

CAP O-RING PUMP HARNESS FUEL PUMP BRACKET

5. 6. 7. 8.

FUEL PUMP CUSHION FUEL PUMP GROMMET FUEL FILTER ASSEMBLY 9357QG24

Exploded view of the fuel pump module— Lancer

9 . • Electrical connectors at the pump/sending unit • Fuel tank from the vehicle • Access plate to the fuel tank and remove the pump assembly To install:

new packing gasket, and tighten mounting 4nuts. 10. Raise the tank in position under the vehicle. 11. Attach all connections to the top of the tank.

12. Raise the tank completely and posi¬ tion the retainer straps around the fuel tank. . Install new fuel tank self-locking nuts and . Install tofue22 ft. lbs. (31 Nm). tighten l pump to fuel hose 13. Connect the inreturn tank, and with high pressure hoses. 14. Install the vapor hose and the filler hose. Install the filler hose retainer screws to the fender, if removed. 15. Lower the vehicle and pour the drained fuel into the gas tank. 16. Connect the negative battery cable. Check the fuel pump for proper pressure and inspect the entire system for leaks.

Fuel Injector REMOVAL & INSTALLATION 1.5L & 1.8L Engines 1. Relieve the fuel system pressure as described in this section. 2. Remove or disconnect the following: • Positive Crankcase Ventilation (PCV) hose from the valve cover • Breather hose at the opposite end of the valve cover • High pressure fuel line

CAUTION Observe all applicable safety precau¬ tions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a con¬ tainer specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibil¬ ity of fire or explosion. • Vacuum hose from the fuel pres¬ sure regulator

MITSUBISHI

O-f

DIAMANTE • ECLIPSE • GALANT • LANCER • MIRAGE • Fuel return hose from the pressure regulator • Electrical connector from each injector. Label for reference • Bolt(s) holding the fuel rail to the manifold. Carefully lift the rail up and remove it with the injectors attached. Take great care not to drop an injector. Place the rail and injectors in a safe location on the workbench; protect the tips of the injectors from dirt and/or impact. • Injector insulators from the intake manifold, discard. The insulators are not reusable. • Injectors from the fuel rail by pulling gently in a straight outward motion. Make certain the grommet

I

nc

3U

• PCV hose and the breather hose • Negative battery cable

inspecPtrealsslurcioznenecthtio for leaks. e fnusel sys tem and 2.0L Engine 1 . Relieve the fuel system pressure as described in this section. 2. Disconnect the negative battery cable. 3. Wrap the connection with a shop towel and disconnect the high pressure fuel line at the fuel rail.

:: CAUTION Observe all applicable safety precau¬ tions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or

and O-ring come off with the injec¬ tor. To install: vapors to come in contact with a spark or open flame. Keep a dry 4. Install a new insulator in each injector chemical fire extinguisher near the port in the manifold. work area. Always keep fuel in a con¬ 5. Remove the old grommet and O-ring tainer specifically designed for fuel from each injector. Install a new grommet storage; also, always properly seal and O-ring; coat the O-ring lightly with fuel containers to avoid the possibil¬ clean, thin oil. 6. If the fuel pressure regulator was ity of fire or explosion. removed, replace the O-ring with a new one and coat it lightly with clean, thin oil. Insert • Positive Crankcase Ventilation the regulator straight into the rail, then check that it can be rotated freely. If it does not • (PCV) Exhausthose Gas Recirculation (EGR) rotate smoothly, remove it and inspect the solenoid valve connector O-ring for deformation or jamming. When • Manifold Differential Pressure R properly installed, align the mounting holes emov eo (MDP) sensor connector and tighten the retaining bolts to 84 inch r di sco • Purge control solenoid valve con¬ nne nector procedure must be fol¬ Nm). ifThis lbs. (9 even ctt lowed the fuel rail was not removed. he f ol Position (TP) sensor con¬ • Throttle 7. Install or connect the following: nectorlowing : • Injector into the fuel rail, constantly • Idle Air Control (IAC) motor con¬ turning the injector left and right nector during installation. When fully • Electrical connector from each installed, the injector should still injector, label for reference turn freely in the rail. If it does not, • High pressure fuel hose remove the injector and inspect the • Fuel return hose • Vacuum hose(s) O-ring for deformation or damage. • Delivery pipe and injectors to the regulator • Fuel pressure hose engine. Make certain that each • Fuel return pipe injector fits correctly into its port and that the rubber insulators for • Bolt(s) holding the fuel rail to the the fuel rail mounts are in position. manifold. Carefully lift the rail up • Fuel rail retaining bolts and tighten and remove it with the injectors them to 108 inch lbs. (12 Nm) attached. Take great care not to • Wiring harnesses to the appropriate drop an injector. Place the rail and injector injectors in a safe location on the • Fuel return hose to the pressure workbench; protect the tips of the then connect the vacuum regulator, hose injectors from dirt and/or impact. • Injector insulators from the intake 8. Replace the O-ring on the high pres¬ manifold, discard. The insulators sure fuel line, coat the O-ring lightly with are not reusable. clean, thin oil and install the line to the fuel • Injectors from the fuel rail by rail. Tighten the mounting bolts.

MITSUBISHI 91-Qfi JU DIAMANTE • ECLIPSE

c. \

• GALANT • LANCER • MIRAGE

9 pulling gently in a straight outward motion. Make certain the grommet 8 and O-ring come off with the injec¬ tor. . . To install:

holes and tighten the retaining bolts to 84 inch lbs. (9 Nm). This procedure must be followed even if the fuel rail was not removed.

5. Install a new insulator in each injector port in the manifold. 6. Remove the old grommet and 0-ring from each injector. Install a new grommet and 0-ring; coat the O-ring lightly with clean, thin oil. 7. If the fuel pressure regulator was removed, replace the O-ring with a new one and coat it lightly with clean, thin oil. Insert the regulator straight into the rail, then check that it can be rotated freely. If it does not rotate smoothly, remove it and inspect the O-ring for deformation or jamming. When properly installed, align the mounting

• High pressure fuel line to the fuel rail • Fuel injector connectors • IAC motor connector • TP sensor connector

• Injector into the fuel rail, constantly turning the injector left and right Install during installation. When fully or con the injector should still installed, nect t turn freely inhethefolrail. lowinIfg it does not, : inspect the remove the injector and O-ring for deformation or damage. • Fuel rail and injectors to the engine. Make certain that each injector fits correctly into its port and that the rubber insulators for the fuel rail mounts are in position. • Fuel return pipe and fuel hose • Fuel return hose to the fuel rail

• • • • •

Purge control solenoid connector MDP sensor connector EGR solenoid valve connector PCV hose connector Negative battery cable

inspe

a c for leaks. ct ll onnectio ns 2.4LPresEngine suriz e the el sysystem pressure as 1. Relieve thefufuel ste described in this section. m and 2. Label and disconnect the spark plug wires. Position the wires aside. 3. Remove or disconnect the following:

9tt 14 5.0 ±1.0 N m

1744

± 9 in-lb

F

T*>

8,11 ft

3

O-RING

18 O

9.0 ± 2.0 N-m 80 ± 17 in-lb

O-RING

17

ENGINE OIL

1. 2. 3.

PCV HOSE CONNECTION EGR SOLENOID VALVE CONNECTOR MANIFOLD DIFFERENTIAL PRESSURESENSOR CONNECTOR

4.

5. 6. 7.

PURGE CONTROL SOLENOID VALVE CONNECTOR THROTTLE POSITION SENSOR CONNECTOR IDLE AIR CONTROL MOTOR CONNECTOR INJECTOR CONNECTOR 9357QG25

Exploded view of the fuel rail and injectors— 2. OL engine

MITSUBISHI

^ • Positive Crankcase Ventilation (PCV) hose from the valve cover • High pressure fuel line to the fuel rail and disconnect the line. Be prepared to contain fuel spillage; plug the line to keep out dirt and debris.

:: CAUTION Observe all applicable safety precau¬ tions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a con¬ tainer specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibil¬ ity offireorexplosiom

4. Remove or disconnect the follow' ing: • Vacuum hose from the fuel pres¬ sure regulator • Fuel return hose from the pressure regulator • Electrical connector from each injector, label for reference • Bolt(s) holding the fuel rail to the manifold. Carefully lift the rail up and remove it with the injectors attached. Take great care not to drop an injector. Place the rail and injectors in a safe location on the workbench; protect the tips of the injectors from dirt and/or impact. • Injector insulators from the intake manifold, discard. The insulators are not reusable. • Injectors from the fuel rail by pulling gently in a straight outward motion. Make certain the grommet and O-ring come off with the injec¬ tor. To install: 5. Install a new insulator in each injector port in the manifold. 6. Remove the old grommet and O-ring from each injector. Install a new grommet and O-ring; coat the O-ring lightly with * clean, thin oil. 7. If the fuel pressure regulator was

replace the O-ring with a new one removed, \ and coat it lightly with clean, thin oil. Insert

N the regulator straight into the rail, then . check that it can be rotated freely. If it does I not rotate smoothly, remove it and inspect

91.Q7

* DIAMANTE • ECLIPS |: CAUTION CER • MIRAGE the O-ring for deformation or jamming.E • GALANT • LAN * When properly installed, align the mounting holes and tighten the retaining bolts to 84 Observe all applicable safety precau¬ tions when working around fuel. inch lbs. (9 Nm). This procedure must be followed even if the fuel rail was not Whenever servicing the fuel system, removed. always work in a well ventilated area. Do not allow fuel spray or 8. Install or connect the following: • Injector into the fuel rail, constantly vapors to come in contact with a spark or open flame. Keep a dry turning the injector left and right during installation. When fully chemical fire extinguisher near the installed, the injector should still work area. Always keep fuel in a con¬ turn freely in the rail. If it does not, tainer specifically designed for fuel ring remove the injector and inspect the storage; also, always properly seal O-ring for deformation or damage. fuel containers to avoid the possibil• Delivery pipe and injectors to the ity of fire or explosion. engine. Make certain that each 6. Remove or disconnect the following: injector fits correctly into its port and that the rubber insulators for • Fuel return hose and remove the 0the fuel rail mounts are in position. • Fuel rail retaining bolts and tighten • Vacuum hose from the fuel pres¬ sure regulator them to 108 inch lbs. (12 Nm) • Electrical connectors from each • Wiring harnesses to the appropriate injector • Fuel return hose to the pressure regulator, then connect the vacuum hose • O-ring on the high pressure fuel line, coat the O-ring lightly with clean, thin oil and install the line to the fuel rail. Tighten the mounting bolts to 48 inch lbs. (6 Nm). • PCV hose and spark plug wires • Negative battery cable 9. Pressurize the fuel system and inspect all connections for leaks. 3.0L and 3.5L Engines 1. Relieve the fuel system pressure. 2. Disconnect the negative battery cable.

Work MUST NOT be started until at least 90 seconds after the ignition switch is turned to the LOCK position and the negative battery cable is dis¬ connected from the battery. This will allow time for the air bag system backup power supply to deplete its stored energy preventing accidental air bag deployment which could result in unnecessary air bag system repairs and/or personal injury. 3. Drain the cooling system. 4. Disconnect all components from the air intake plenum and remove the plenum from the intake manifold. 5. Wrap the connection with a shop towel and disconnect the high pressure fuel line at the fuel rail.

injector • Fuel pipe connecting the fuel rails • Injector rail retaining bolts. Make sure the rubber mounting bushings do not get lost. 7. Lift the rail assemblies up and away from the engine. 8. Remove the injectors from the rail by pulling gently. Discard the lower insulator. To install: ^Some of the vehicles may have a clip that secures the injector to the fuel rail. Be sure to remove or install the injector clip where necessary. 9. Install or connect the following: • New grommet and O-ring to the injector. Coat the O-ring with light oil. • Injector to the fuel rail

10. Replace the seats in the intake mani¬ fold. Install the fuel rails and injectors to the manifold. Make sure the rubber bushings are in place before tightening the mounting bolts. 11. Tighten the retaining bolts to 84-108 inch lbs. (10-13 Nm). Install the fuel pipe with new gasket. 12. Install or connect the following: • Electrical connectors to the injec¬ • tors Fuel return hose

• O-ring, lightly lubricate it and con¬ nect the high pressure fuel line • Intake plenum and all related items, using new gaskets 13. Fill the cooling system. 14. Connect the negative battery cable and check the entire system for proper operation and leaks.

21-98

MITSUBISHI DIAMANTE • ECLIPSE

GALANT • LANCER • MIRAGE

DRIVE TRAIN

Transaxle assembly REMOVAL & INSTALLATION Manual ECLIPSE

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Battery and the air intake hoses • Battery tray and support • Auto-cruise actuator and bracket, if equipped with cruise control • Charcoal canister and bracket • Shift and select cables from the transaxle • Back-up light switch and the Vehicle Speed Sensor (VSS) con¬ nectors • Starter assembly • Engine support fixture to the engine and remove the transaxle mounting bolts 3. Remove or disconnect the following: • Rear roll stopper bracket mounting bolts • Transaxle mounting bracket mount¬ ing nuts • Engine undercovers • Transfer case assembly, if equipped with All Wheel Drive (AWD) • Axle shafts

• Slave cylinder from the bell hous¬ ing without disconnecting the fluid line. Position it out of the way. • Bell housing cover and the righthand center member stay (support) • Center member 4. Place a transmission jack under the transaxle and remove the transaxle mount¬ ing bolt. 5. Remove the transaxle mounting and lower the transaxle. To install: 6. Raise the transaxle into position and install the transaxle mounting. Torque the through-bolt to 50 ft. lbs. (69 Nm). 7. Install or connect the following: • Transaxle assembly mounting bolt. Torque the bolt to 22-25 ft. lbs. (30-34 Nm). • Center member assembly and the right-hand stay • Bell housing cover and the slave cylinder • Axle shafts. Be sure to install the washer in the proper direction. • Engine undercovers and lower the vehicle

• Transfer case assembly, if removed • Transaxle mounting bracket mount¬ ing nuts • Rear roll stopper bracket mounting bolts

• Transaxle assembly mounting bolts. Torque the mounting bolts to 35 ft. lbs. (48 Nm).

MZ203827

8. Remove theblyengine support fixture. 9. Install or connect the following: • Starter assembly • tors VSS and the back-up light connec¬ • Cruise control actuator if removed • Battery tray support and the tray • Charcoal canister bracket and the canister • Air duct and the air cleaner assem¬ GALANT

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec tion. 2. Remove or disconnect the following: Negative battery cable Air cleaner and intake hoses Cotter pins and clips securing the select and shift cables and remove the cable ends from the transaxle Air compressor, if equipped with Active Electronic Control Suspen¬ sion (Active-ECS) Back-up light switch harness and position aside Speedometer electrical connector from the transaxle assembly Starter motor and position aside 3. Support the engine assembly. Rear roll stopper mounting bracket Transaxle mount bracket Upper transaxle mounting bolts Front wheel assemblies Right-hand undercover Cotter pin and disconnect the tie rod end, from the steering knuckle Stabilizer bar link from the damper fork Damper fork from the lateral lower control arm Lateralinglower arm and the compres¬ sion arm lower ball joints from the steering knuckle Halfshafts from the transaxle, and secure aside Clutch release cylinder without dis connecting the hydraulic line and secure aside Cover from the transaxle bell hous¬ Engine front roll stopper throughbolt • Crossmember and the triangular right-hand stay

Proper method of supporting the engine assembly for transaxle removal

4. Support the transaxle with a transmis¬ sion jack and remove the transaxle lower coupling bolt.

MITSUBISHI

01 .00

DIAMANTE • ECLIPSE • GALANT • LANCER • MIRAGE

*

33

Removal

steps

1. Air cleaner cover and air intake hose assembly 2. Air cleaner element 3. Air hose C 4. Air hose A 5. Battery tray 6. Battery tray stay 7. Shift cable and select cable connection

8. 9. 10. 11. 12.

Backup light switch connector Vehicle speed sensor connector Starter motor Transaxle assembly mounting bolts Rear roll stopper bracket mounting bolts

13. Transaxle mounting bracket mount¬ ing nuts • Supporting engine assembly

7923PG86

Exploded view of the manual transaxle mounting (1 of 2)— FWD Eclipse with 2.4L engine

^The coupling bolt threads from the engine side into the transaxle and is located just above the halfshaft open¬ ing.

5. Slide the transaxle rearward and care¬ fully lower it from the vehicle. To install: 6. Install or connect the following: • Transaxle to the engine and install the mounting bolts. Tighten to 35 ft. lbs. (48 Nm). Install the transaxle lower coupling bolt and tighten to 22-25 ft. lbs. (30-34 Nm).

• Cover to the transaxle bell housing and tighten the mounting bolts to 84 inch lbs. (9 Nm) • Crossmember and tighten the front mounting bolts to 65 ft. lbs. (88 Nm) and the rear bolt to 54 ft. lbs. (73 Nm). Install the front engine roll stopper through-bolt and lightly tighten. Once the full weight of the engine is on the mounts, Nm). the bolt to 42 ft. lbs. (57 tighten Nm) • Triangular stay bracket and tighten the mounting bolts to 65 ft. lbs. (88

• Clutch release cylinder • Halfshafts, using new circlips on the axle ends

• Tie rod and ball joints to the steer¬ ing knuckle. Tighten the ball joint self-locking nuts to 48 ft. lbs. (65 Nm). Tighten the tie rod end nut to 21 ft. lbs. (28 Nm) and secure with a new cotter pin. • Damper fork to the lower control the through-bolt to arm ft.and 65 lbs.tighten (88 Nm) • Stabilizer link to the damper fork and theNm) self-locking nut to 29 ft.tighten lbs. (39

M,TSUBE,SHI» ECLIPSE 21-100 DIAMANT

• GALANT • LANCER • MIRAGE

Lifiting up of the vehicle 16. Tie rod end ball joint and kunckle connection 17. Stabilizer link connection 18. Damper fork 19. Lateral lower arm ball joint and kunckle connection 20. Compr ession lower arm ball joint and kunckle connection 21 Drive shaft connection 22 Clutch release cylinder connection 23. Bell housing cover 24. Stay (R.H.) 25. Center member assembly 26. Transaxle assembly mounting bolt

27. Transaxle mounting 28. Transaxle assembly

Caution *im-

Indicates

parts

which

temporarily tightened, and then fully tightbe ened with the *2. vehicle on the ground in the unladen condition. For tightening locations indicated by the symbol, first tighten temporarily, and then make the final tightening with the entire weight of the engine applied to the vehicle body. should

7923PG87

Exploded view of the manual transaxle mounting (2 of 2)— FWD Eclipse with 2.4L engine

MITSUBISHI

01

DIAMANTE • ECLIPSE • GALANT • LANCER • MIRAGE • Underpan • Wheels and lower vehicle • Transaxle mount bracket to the transaxle and tighten the mounting nuts to 32 ft. lbs. (43 Nm) • Rear roll stopper mounting bracket 7. Remove the engine support. Tighten the transaxle mount through-bolt to 51 ft. lbs. (69 Nm) and tighten the front engine roll stopper through-bolt. • Upper transaxle mounting bolts and tighten to 35 ft. lbs. (48 Nm) • Starter motor • Back-up light switch and the speedometer connector • Air compressor, if equipped with Active Electronic Control Suspen¬ sion (Active-ECS) • Select and shift cables and install new cotter pins • Air cleaner and the air intake hose • Negative battery cable 8. Check the transaxle for proper operaLANCER 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the transaxle fluid. 3. Remove or disconnect the following: • Negative battery cable • Engine undercover • Evaporative canister • Positive battery cable, battery and battery tray • Shifter cables • Back-up light switch and Vehicle Speed Sensor (VSS) connector • Starter motor • Clutch hose • Upper engine-to-transaxle bolts • Transaxle mount • Transaxle mount stopper 4. Install a suitable engine support assembly, then raise and safely support the vehicle. • Stabilizer bar • Wheel Speed Sensor (WSS) con¬ nector, if equipped with Anti-lock Brakes (ABS) • Brake hose clamp • Tie rod end • Lower control arm • Centermember • Halfshafts by inserting a prybar between the transaxle case and the driveshaft and prying the shaft from the transaxle. Do not pull on the driveshaft. • Bell housing lower cover Transaxle to engine bolts and lower the transaxle from the vehicle

To install: 5. Install or connect the following: • Transaxle to the engine and install the lower mounting bolts • Bell housing cover ^When installing the halfshafts, use new circlips on the axle ends. 6. Install or connect the following: • Halfshafts into the transaxle • Centermember • Lower control arm • Tie rod end • Brake hose clamp • WSS connector, if equipped • Stabilizer bar 7. Lower the vehicle, then remove the engine support. • Transaxle mount bracket. Tighten the nuts to 35 ft. lbs. (47 Nm). • Transaxle mount stopper. Tighten the nuts to 61 ft. lbs. (82 Nm). • Transaxle mount • Upper transaxle-to-engine bolts and torque to 36 ft. lbs. (48 Nm) • Clutch line • Starter motor • VSS connector • Back-up light switch connector • Shifter cables, adjust • Evaporative canister • Battery and battery tray • Engine undercover • Positive and negative battery cables • Transaxle with fluid 8. Bleed the clutch, check and adjust the front wheel alignment, then check the transaxle for proper operation. MIRAGE 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. ing:2. Remove or disconnect the follow¬ • Negative battery cable • Front wheels and the inner wheel • Air cleaner assembly and vacuum hoses panels 3. Note the locations and disconnect the shifter cables. • Back-up lamp switch connector • Speedometer cable and remove the starter motor

• Upper transaxle-to-engine mount¬ ing bolts 4. Remove the undercover and splash 5. Drain the transaxle oil. 6. Support the engine and remove the pan. ember. crossm

.mi I

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»

7. Remove or disconnect the following: • Upper transaxle mounting bolt and bracket • Stabilizer bar, tie rod ends and the lower ball joint connections • Clutch release cylinder and clutch oil line bracket. Disconnect the clutch cable, if equipped with cable controlled clutch system. • Halfshafts by inserting a prybar between the transaxle case and the driveshaft and prying the shaft from the transaxle. Do not pull on the driveshaft. • Bell housing lower cover • Transaxle to engine bolts and lower the transaxle from the vehicle To install: 8. Install or connect the following: • Transaxle to the engine and install the mounting bolts • Bell housing cover ^When installing the halfshafts, use new circlips on the axle ends. 9. Install or connect the following: • Halfshafts into the transaxle • Slave cylinder or connect the clutch cable

tie rodonsends and stabi¬ • Ball lizer joints, bar connecti • Upper transaxle mounting bracket and bolt • Crossmember • Undercover

• Upper transaxle-to-engine mount¬ • ing Starter boltsmotor • Back-up light switch connector and • speedometer Shifter cables,cable adjust • Air cleaner assembly • Front wheels • Negative battery cable and check the transaxle for proper operation Automatic DIAMANTE

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

2. Properly disarm the Supplemental Restraint System (SRS) system. 3. Raise and safely support the vehicle. or disconnect the following: 4.• Remove Front wheels • Engine side cover and undercovers 5. Drain the transaxle assembly.

6. If equipped, remove the front cat¬ alytic converter. 7. Remove or disconnect the following:

H9

91-11 UL. £~\

MITSUBISHI

DIAMANTE • ECLIPSE • GALANT • LANCER • MIRAGE

• Exhaust pipe, main muffler and cat¬ alytic converter • Tie rod end and ball joint from the steering knuckle • Support bearing for the left side halfshaft

• Halfshafts by inserting a prybar between the transaxle case and the driveshaft and prying the shaft from the transaxle • Air cleaner assembly and adjoining ductwork • Engine harness connection • Compressor assembly, if the vehicle is equipped with Active Electronic Controlled Suspension (Active-ECS) — suspend with wire — Do not allow the compressor to hang from the air hose. • Roll stopper stay bracket, if equipped • Speedometer cable from the transaxle • The clip that secures the shifter • Shifter control cable from the transaxle • Plug the oil cooler hoses from the transaxle 8. Disconnect the following: • Park/neutral switch electrical har¬ ness • Kickdown servo switch • Pulse generator • Oil temperature sensor electrical harness • Shift control solenoid valve har¬ ness. 9. Support the transaxle and remove the transaxle mounting bracket. 10. Remove the 3 upper transaxle-toengine mounting bolts. 11. For vehicles with Four Wheel Steer¬ ing (4WS), remove the heat shield for the 4WS oil pump and remove the pump. Do not allow the pump to hang from the oil hoses. 12. For vehicles equipped with ActiveECS, disconnect the height sensor rod from the lower control arm. 13. Remove or disconnect the following: • Bolt that secures the Heated Oxy¬ gen (HO2S) sensor harness to the right side crossmember • Starter assembly • Mounting brackets for access to the bell housing cover bly • Bell housing/oil pan covers assem¬

• Bolts holding the flexplate to the torque converter • Lower transaxle to engine bolts and remove the transaxle assembly

7923PG83

Location of 4-wheel steering oil pump mounting bolts— Diamante with a F4A33 automatic transaxle

To install: 14. Install or connect the following: • Transaxle assembly to the engine block and install the mounting bolts • Bolts that secure the torque con¬ verter to the driveplate. Tighten the bolts to 34-38 ft. lbs. (46-53 Nm). • Bell housing/oil pan covers • Transaxle stay brackets that were removed for access to the bell wiring cover housing • Starter assembly and connect the

16. If removed, install the 4WS oil pump 24 tighten the mounting bolts to 17 ft. lbs. and Nm). 17. If removed, install the 4WS oil pump heat shield and tighten the mounting bolts to 17 ft. lbs. 24 Nm). 18. Install the 3 upper transaxle-toengine mounting bolts. Tighten the mount¬ ing bolts to 54 ft. lbs. (75 Nm).

'■►One of the upper bolts has a ground¬ ing strap to secure under the bolt.

• Bolt that secures the HO2S sensor harness to the right side cross¬ member and tighten the bolt to 84-108 inch lbs. (10-12 Nm) 15. For vehicles equipped with ActiveECS, connect the height sensor rod from the lower control arm. Check the height sensor rod for a length (A) of 10.59-10.63 in. (269-270mm).

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19. Install or connect the following: • Transaxle mounting bracket. Tighten the mounting nut and bolts to 51 ft. lbs. (70 Nm). • Shift control solenoid valve harness • Kickdown servo switch, pulse gen erator and oil temperature sensor electrical harness • Park/neutral switch electrical har¬ ness

B

5 1 7923PGC0

Height sensor rod adjustment— Diamante with a F4A33 automatic transaxle

MITSUBISHI

01

DIAMANTE • ECLIPSE • GALANT • LANCER • MIRAGE • Oil cooler hoses to the transaxle, using new hose clamps • Shifter control cable to the transaxle and secure the cable with clip • Speedometer cable to the transaxle • Roll stopper stay bracket and tighten the one through nut and bolt to 36-43 ft. lbs. (50-60 Nm), if removed. Tighten the 2 mounting bolts to 16 ft. lbs. (22 Nm). • Active-ECS compressor assembly, if removed. Tighten the mounting bolts to 48 inch lbs. (5 Nm) and connect the electrical harness.

• Engine harness connection • Air cleaner assembly and adjoining ductwork • Halfshafts and seat halfshafts into the transaxle, using new circlips • Bolt that secure the left side sup¬ port bearing and tighten the bolts to 33 ft. lbs. (45 Nm) • Ball joint and tie rod end to the steering knuckle. Using new nuts, tighten the ball joint castle nut to 43-52 ft. lbs. (60-72 Nm) and tighten the tie rod castle nut to 22 ft. lbs. (30 Nm). Install new cotter

.1(1? >

1

• • • •

Exhaust system, using new gaskets Front catalytic converter, if removed Engine undercovers Negative battery cable 20. Fill the transaxle to the correct level. 21 . Start the engine and check for leaks. ECLIPSE 1. Before servicing the vehicle, refer to the precautions tion. 2. Remove • Battery • Battery

in the beginning of this sec¬ or disconnect the following: and the air intake hoses tray and support

pins.

Removal 1. 2. 3. 4. 5. 6. 7. 8. 9.

steps

Transaxle control cable connection Transaxle oil cooler hoses connection PNP switch connector A/T control solenoid valve connector Input shaft speed sensor connector Output shaft speed sensor connector Vehicle speed sensor connector Split pin Connection of the tie rod end

11. Connection for the lower arm ball 12. Drive shaft and inner shaft assembly (RH) and the drive shaft (LH) Caution

joint

Mounting locations marked by * should be provisionally tightened, and then fully tightened when the body is supporting the full weight of the engine. 7923PG84

euft Drsihvan

Transaxle removal — Diamante with F4A51 transaxle 1 of 2

! MITSUBISHI 01. in/ I

L. I

U4

DIAMANTE * ECLIPSE • GALANT • LANCER • MIRAGE

Auto-cruise actuator and bracket, if equipped with cruise control Charcoal canister and bracket Shift and select cables from the transaxle Back-up light switch and the vehicle speed sensor connectors

• • • • • • •

Dipstick and tube assembly Starter assembly Park/neutral switch Oil temperature sensor Kick down servo switch Solenoid valve Pulse generator

• Speedometer connections 3. Attach an engine support fixture to the engine and remove the transaxle mount¬

bolts. ing 4. Remove or disconnect the following: • Rear roll stopper bracket mounting bolts

Lifting up of the vehicle

13. 14. 15. 16. 17. 18. •

Starter motor Center member assembly Rear roll stopper bracket Transaxle upper portion fixing bolt Transaxle mounting bracket Transaxle mount stopper Support the engine and transaxle assembly 19. Bell housing cover Transaxle removal— Diamante with F4A51 transaxle 2 ot 2

20. Drive plate attaching bolt 21. Transaxle lower portion fixing bolt 22. Transaxle assembly Caution

Mounting locations marked by * should be provisionally tightened, and then fully tightened when the body is supporting the full weight of the engine. 7923PG85

bly

MITSUBISHI Ol.lflR

DIAMANTE • ECLIPSE • GALANT • LANCER • MIRAGE

• Transaxle mounting bracket mount¬ ing nuts 5. Raise the vehicle and remove the 1 2 engine undercovers. . 6. Remove or disconnect the following: • Front exhaust pipe • Transfer case assembly, if equipped with All Wheel Drive (AWD) • Axle shafts

• Slave cylinder from the bell hous¬ ing without disconnecting the fluid line. Position it out of the way. • Bell housing cover and the righthand center member stay (support) • Center member • Drive plate connecting bolts 7. Place a transmission jack under the transaxle and remove the transaxle mount¬ ing bolt. 8. Lower the transaxle. To install: 9. Raise the transaxle into position and install the transaxle mounting bracket. Torque the through-bolt to 51 ft. lbs. (69 Nm). 10. Install or connect the following: • Transaxle assembly mounting bolt. Torque the bolt to 22-25 ft. lbs. (29-34 Nm). • Drive plate connecting bolts. Torque the bolts to 33-38 ft. lbs. (45-52 Nm). • Center member assembly and the right-hand stay • Bell housing cover and the slave cylinder • Axle shafts. • Front exhaust pipe • Transfer case assembly if removed • Engine undercovers and lower the vehicle • Transaxle mounting bracket mount¬ ing nuts • Rear roll stopper bracket mounting bolts • Transaxle assembly mounting bolts. Torque the bolts to 35 ft. lbs. (48 Nm). 1 1 . Remove the engine support fixture. • Park/neutral switch • Oil temperature sensor • Kick down servo switch • Solenoid valve • Pulse generator • Speedometer connections • Starter assembly • Dipstick and tube assembly • Vehicle speed sensor and the back¬ up light connectors • Cruise control actuator if removed • Battery tray support and the tray • Charcoal canister bracket and the canister

• Air duct and the air cleaner assem¬ case, if equipped, with the proper fluid.

GALANT Refill the tservicing ransaxle the vehicle, refer to 1. Before and the t ransfer the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Air cleaner and intake hoses 3. Drain the transaxle into a suitable waste container. • Nut securing the shifter lever to the transaxle • Cable retaining clip and remove the cable from the transaxle • Shifter cable mounting bracket • Electrical connectors for the speedometer, neutral safety switch (inhibitor switch), the pulse genera¬ tor, kickdown servo switch, and the oil temperature sensor • Oil cooler lines, at the transaxle • Dipstick and tube from the transaxle • Starter motor and position it aside 4. Support the engine assembly. • Rear roll stopper mounting bracket • Transaxle mount bracket • Upper transaxle mounting bolts 5. Raise and safely support the vehicle. 6. Remove or disconnect the following: • Front wheel assemblies • Right-hand undercover • Tie rod end from the steering knuckle • Stabilizer bar link from the damper fork • Damper fork from the lateral lower control arm • Later lower arm and the compres¬ sion arm lower ball joints, from the ing steering knuckle • Halfshafts from the transaxle and secure aside • Cover from the transaxle bell hous¬ • Engine front roll stopper throughbolt • Crossmember and the triangular right-hand stay • Bolts holding the flexplate to the torque converter 7. Support the transaxle using a trans¬ mission jack, and remove the transaxle lower coupling bolt.

~The coupling bolt threads from the engine side into the transaxle and is ing. located just above the halfshaft open¬

8. Slide the transaxle rearward and carefully lower it from the vehicle. To install: 9. After the torque converter has been mounted on the transaxle, install the transaxle assembly to the engine. Install the mounting bolts and tighten to 35 ft. lbs. (48 Nm). Install the transaxle lower coupling bolt and tighten to 21-25 ft. lbs. (29-34 Nm). 10. Install or connect the following: • Torque converter to the flexplate and tighten the bolts to 33-38 ft. lbs. (45-52 Nm) • Cover to the transaxle bell housing and tighten the mounting bolts to 84 inch lbs. (9 Nm) • Crossmember and tighten the front mounting bolts to 65 ft. lbs. (88 Nm) and the rear bolt to 54 ft. lbs. (73 Nm) • Front engine roll stopper throughboltNm) and lightly tighten. Once the full weight of the engine is on the mounts, tighten the bolt to 42 ft. lbs. (57 Nm). • Triangular stay bracket and tighten the mounting bolts to 65 ft. lbs. (88 • Halfshafts, using new circlips on the axle ends • Tie rod and ball joints to the steer¬ ing knuckle. Tighten the ball joint self-locking nuts to 48 ft. lbs. (65 Nm). Tighten the tie rod end nut to 21 ft. lbs. (28 Nm) and secure with a new cotter pin. • Damper fork to the lower control arm the through-bolt to 65 ft.and lbs.tighten (88 Nm) • Stabilizer link to the damper fork, and theNm) self-locking nut to 29 ft.tighten lbs. (39 • Underpan • Wheels and lower the vehicle • Transaxle mount bracket to the transaxle, and tighten the mounting nuts to 32 ft. lbs. (43 Nm) • Rear roll stopper mounting bracket • Engine support. Tighten the transaxle mount through-bolt to 51 ft. lbs. (69 Nm) and tighten the front engine roll stopper throughbolt. • Upper transaxle mounting bolts and tighten to 35 ft. lbs. (48 Nm) • Starter motor • Dipstick tube and the dipstick • Shifter cable mounting bracket

• Shifter lever and tighten the retain¬ ing nut to 14 ft. lbs. (19 Nm) clamps • Oil cooler lines and secure with

21-106

MITSUBISHI DIAMANTE » ECLIPSE * GALANT • LANCER • MIRAGE Nm)

• Electrical connectors for the speedometer, neutral safety switch (inhibitor switch), pulse generator, kickdown servo switch and oil tem¬ perature sensor • Air cleaner and the air intake hose • Negative battery cable 1 1 . Fill the transaxle to the correct level. LANCER

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Install or connect the following: • Negative battery cable • Engine undercover 3. Drain the transaxle oil and engine 0coolant. • Front exhaust pipe • Battery and battery tray . • Air cleaner assembly • Transaxle control cable • Vehicle Speed Sensor (VSS) con¬ nector

• Driveplate bolts: 36 ft. lbs. (49 Nm) • Centermember bolts: 51 ft. lbs. (69

• Hub nut: 181 ft. lbs. (245 Nm) • Transaxle mount bracket nuts: 36 ft. lbs. (49 Nm) • Transaxle mount stopper nuts: 60 ft. lbs. (81 Nm) • Transaxle-to-engine upper mount¬ ing bolts: 36 ft. lbs. (49 Nm) 7. Fill the transaxle and the engine cooling system to the correct level. 8. Check and adjust the front wheel alignment. 9. Check the speedometer and gear selector for proper operation. MIRAGE

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

2. Remove or disconnect the following: • Negative battery cable • Input and output shaft speed sen¬ sor connectors • Battery and battery tray Start • Inhibitor switch sensor connector • Air hose and air cleaner assembly the engi• Under guar d pan • A/C control solenoid valve connec¬ ne a n d tor 3. Drain cthe hecktransaxle oil. for and cooler lines • Starter • Control cable leak s. • Transaxle oil cooler line • Shift control solenoid valve con¬ nector • Upper engine-to-transaxle bolts • Transaxle mount • Inhibitor switch, kickdown servo • Transaxle mount stopper switch, the pulse generator and oil temperature sensor, if equipped 4. Install a suitable engine support • Speedometer cable and remove the assembly, then raise and safely support the vehicle. starter • Transaxle mounting bolts and • Wheel Speed Sensor (WSS) bracket • Brake hose clamp • Stabilizer bar • Stabilizer bar from the lower con¬ trol arm • Lower control arm • Tie rod end • Steering tie rod end and the ball • Lower control arm joint from the steering arm • Halfshafts at the inboard side from • Halfshafts by inserting a prybar between the transaxle case and the the transaxle. Tie the joint assembly aside. driveshaft and prying the shaft from the transaxle. Do not pull on the 4. Support the engine and remove the driveshaft. center member. • Centermember • Bell housing cover and remove the driveplate bolts • Bell housing lower cover • Transaxle to engine bolts and lower • Transaxle assembly lower connect¬ the transaxle from the vehicle located just over the half¬ ing bolt, opening shaft • Front roll stopper installation bolt • Transaxle • Bell housing cover To install: 5. Support the transaxle with a suitable 5. Install or connect the following: jack. • Driveplate bolts • Transaxle assembly on the engine. Tighten the driveplate bolts to • Lower transaxle-to-engine mount¬ ing bolts 33-38 ft. lbs. (46-53 Nm). • Bell housing cover • Transaxle from the vehicle To install: • Centermember 6. Installation is the reverse of the • Halfshafts to the transaxle, using new circlips removal procedure, noting the following:

• Tie rods, ball joints and stabilizer links to the steering arm • Transa bolts xle mounting bracket and • Starter • Speedometer cable • Inhibitor switch, kickdown servo switch, the pulse generator and oil temperature sensor, if disconnected • Shift control solenoid valve con¬ nector

• Control cables and oil cooler lines • Air cleaner assembly • Battery tray and battery. Connect positive, then the negative ter¬ the minal. Fill the transaxle to the correct Start the engine and check for leaks.

Clutch ADJUSTMENT

'••The following adjustment is for cable actuated clutch systems. Hydraulic sys¬ tems Mirageare self-adjusting.

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Measure the clutch pedal height (measurement A). The specification is 6.38-6.50 in. (162-1 65mm).

•►The clutch pedal height is not adjustable. If not within specifications, part replacement is required. B). 3. Depress clutch pedal several times and check the pedal free-play (measurement 4. If measurement is not 0.67-0.87 in (17— 22mm), adjustment is required. 5. To adjust turn the outer cable adjustClutch pedal height

Mirage Clutch pedal height (A) measurement —

MITSUBISHI 91.107 DIAMANTE • ECLIPSE • GALANT • LANCER • MIRAGE

will prevent warping the clutch cover assembly. • Return clip and the pressure plate and recheck measurement. release bearing. Do not use solvent to clean the bearing. REMOVAL & INSTALLATION 3. Inspect the clutch release fork and 1 fulcrum for damage or wear. If necessary, remove the release fork and unthread the Eclipse, Galant and Mirage fulcrum from the transaxle. 6. Depr 0 ess clutch pe 4. Carefully inspect the condition of the 1. Before servicing dal the sevevehicle, ral timesrefer to clutch components and replace any worn or the precautions in the beginning of this sec¬ damaged parts. tion. To install: 2. Remove or disconnect . the following: 5. Inspect the flywheel for heat damage • Negative battery cable or cracks. Resurface or replace the flywheel • Transaxle assembly from the vehicle as required. • Pressure plate attaching bolts, 6. Install the fulcrum and tighten to 25 pressure plate and clutch disc. If ft. lbs. (35 Nm). Install the release fork. the pressure plate is to be reused, loosen the bolts in a diagonal pat¬ Apply a coating of multi-purpose grease to the point of contact with the fulcrum and the tern, 1 or 2 turns at a time. This

ing nut, located at the firewall, until treeplay is within range.

Flywheel

*

1 u *

point of contact with the release bearing. Apply a coating of multi-purpose grease to the end of the release cylinder pushrod and the pushrod hole in the release fork. 7. Apply multi-purpose grease to the clutch release bearing. Pack the bearing inner surface and the groove with grease. Do not apply grease to the resin portion of the bearing. Place the bearing in position and install the return clip. 8. Using the proper alignment tool, install the clutch disc to the flywheel. Install the pressure plate assembly. Install the retainer bolts and tighten a little at a time, in a diagonal sequence. Tighten them to a final torque of 16 ft. lbs. (22 Nm). Remove the aligning tool. 9. Install the transaxle assembly. Lancer 1. Before servicing the vehicle, refer to Chec in the beginning of this sec¬ thek precautions for tion. prop e 2. Remover clor utc disconnect the following: oper cable • Negative hbattery atio • Transaxle assemblyn. from the vehicle • Clutch fluid line bracket, insulator and washer •• Clutch Boot fluid line • Clutch slave (release) cylinder

Clutch disc

• Clutch cover (pressure plate)

This surface has a manufacturers stamped mark

MD998126

as required.

Pressure plate

7923PG88

Use the alignment dowel to center the disc on the flywheel Mirage

attaching bolts, cover plate and clutch disc. If the pressure plate is to be reused, loosen the bolts in a diagonal pattern, 1 or 2 turns at a time. This will prevent warping the clutch cover assembly. 3. Carefully inspect the condition of the clutch components and replace any worn or damaged parts. To install: 4. Inspect the flywheel for heat damage or cracks. Resurface or replace the flywheel

5. Apply multi-purpose grease to the clutch release bearing. Pack the bearing inner surface and the groove with grease. Do not apply grease to the resin portion of the bearing. Place the bearing in position and install the return clip. 6. Using the proper alignment tool, install the clutch disc to the flywheel. Install the clutch cover (pressure plate) assembly. Install the retainer bolts and tighten a little at a time, in a diagonal sequence. Tighten them to a final torque of 14 ft. lbs. (19 Nm). Bootaligning tool. Remove• the 7. Install or connect the following:

fl -lfl 911 luu

MITSUBISHI

DIAMANTE » ECLIPSE * GALANT • LANCER • MIRAGE

19 Nm 14 ft.lbs.

8 9

-tiiSi

1. 2. 3. 4. 5. 6. 7. 8.

Clutch oil tube Union bolt Gasket Union Valve plate Valve plate spring Clutch release cylinder Clutch cover

9. 10. 11. 12. 13. 14. 15.

Clutch disc Return dip Clutch release bearing Release fork Release fork boot Fulcrum Transaxle 7923PG89

Exploded view of clutch assembly— Eclipse shown

AGE0-1■ MIRHI ER * UBIS DIAMANTE • ECLIPSE • GALANT • LANCMITS

1. 2. 3. 4.

CLUTCH FLUID LINE BRACKET INSULATOR WASHER CLUTCH TUBE

5. 6. 7. 8.

Exploded view of the clutch components— Lancer shown

• Clutch line, washer, insulator and bracket • Transaxle assembly 8. Check tor proper clutch operation.

Hydraulic Clutch System BLEEDING 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Fill the reservoir with clean brake fluid meeting DOT 3 specifications.

Bleeding a typical clutch hydraulic system

CLUTCH RELEASE CONCENTRIC CYLINDER BOOT CLUTCH COVER CLUTCH DISC

--

-

MIRAGE

2. 3. Press the clutch pedal to the floor, then open the bleeder screw on the slave cylinder. 4. Tighten the bleed screw and release the clutch pedal. 5. Repeat the procedure until the fluid is free of air bubbles.

Transfer Case Assembly REMOVAL & INSTALLATION Eclipse

precau

tions in the beginning of this section.

ing:

Remove or disconnect the follow-

Engine undercovers • Front exhaust pipe • Transfer case mounting bolts 3. Support the driveshaft with wire or string and remove the transfer case from the transaxle. To install: 4. Slide the driveshaft into the transfer case and install the transfer case to the transaxle. Torque the bolts to 40-44 ft. lbs (54-59 Nm). 5. Install or connect the following: • Front exhaust pipe • Engine undercover

Halfshaft REMOVAL & INSTALLATION

Diamante, Galant, Lancer & Mirage

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Raise the vehicle and support it safely. 3. Remove the cotter pin, halfshaft nut and washer. 4. If equipped with Anti-Lock Brake (ABS), remove the front wheel speed sensor. 5. If equipped with Active Electronic Control Suspension (Active-ECS) perform the following:

25 ± 5 N m 19 ± 3 ft-lb 12 ± 2 Nm 107 ±17 in-lb

ore se rvicin g the vehicl

e, ref er to t he

245 ± 29 N m 181 ± 21 ft-lb

108±10Nm 80 ± 7 ft-lb

1. 2. 3. 4. 5. 6.

7.

DRIVESHAFT NUT WASHER FRONT SPEED SENSOR

BRAKE HOSE CRAMP STABILIZER BAR CONNECTION LOWER ARM BALL JOINT CONNECTION TIE ROD END CONNECTION 93570G27

Exploded view of the halfshaft mounting — Lancer shown, others similar

MITSUBISHI 91.111

1

3

. DIAMANTE • ECLIPSE • GALANT • LANCER • MIRAGE

a. Loosen the nut that secures the air line to the to the top of the strut and dis¬ card the 0-ring.

b. Remove the bolts that secure the actuator to the top of the strut and remove the component. Disconnect the wiring harness. 6. Disconnect the lower ball joint and the tie rod end from the steering knuckle. 7. If removing the left side axle with an inner shaft, remove the center support bear¬ ing bracket bolts and washers. Then, remove the halfshaft by setting up a puller on the outside wheel hub and pushing the halfshaft from the front hub. Tap the shaft union at the joint case with a plastic ham¬ . mer to remove the halfshaft and inner shaft from the transaxle. 8. If removing right side axle shafts without an inner shaft, remove the halfshaft by setting up a puller on the outside wheel hub and pushing the halfshaft from the front hub. After pressing the outer shaft, insert a prybar between the transaxle case and the halfshaft and pry the shaft from the transaxle. ^Do not pull on the shaft; doing so damages the inboard joint. To install:

9. Replace the circlips on the ends of

the halfshafts.

10. Insert the halfshaft into the transaxle. Be sure it is fully seated.

11. Pull the strut assembly out and install the other end to the hub. 12. Install the center bearing bracket bolts and tighten to 33 ft. lbs. (45 Nm). 13. Install the washer so the chamfered edge faces outward. Install the nut and tighten to 145-188 ft. lbs. (200-260 Nm), for all models except Lancer. For Lancer, tighten the nut to 181 ft. lbs. (245 Nm). Secure with a new cotter pin. 14. Connect the ball joint to the steering knuckle. Torque the new retaining nut to 43-52 ft. lbs. (60-72 Nm) and secure with a new cotter pin. 15. Connect the tie rod end to the steer¬ ing knuckle. Torque the retaining nut to 21 ft. lbs. (29 Nm) and secure with a new cotter

1

Eclipse vehicle Intostalthle thfleoowh r. eeTilghan tedn the damper fork nut to 65 ft. lbs. (88 Nm). lower the

FRONT 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Raise and safely support the vehicle. 3. Remove or disconnect the following: • Front wheel • Halfshaft nut and washer • Tie rod end from the knuckle • Stabilizer link from the damper fork • Compression and lateral arm ball joint studs from the knuckle 4. Mount a puller on the wheel studs and push the halfshaft through the hub assembly. 5. Detach the inner halfshaft from the

REAR 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Raise and safely support the vehicle. 3. Remove or disconnect the following: • Rear wheel • Rear wheel speed sensor, if equipped • Caliper and rotor, if equipped with disc brakes • Brake drum and shoes, If equipped with drum brakes • Brake hydraulic line from the wheel

transaxle by carefully prying the CV-joint housing out. 6. Pull the knuckle assembly outward and remove the halfshaft. To install:

• cylinder Parking brake cable from the rear brakes • Lower end of the shock absorber from the knuckle • Trailing and lower arms from the knuckle

7. Place a new circlip on the inner half¬ shaft and install the halfshaft in the transaxle. 8. Push out on the knuckle assembly and install the halfshaft through the hub. 9. Using new nuts, install the lateral and compression arm ball joint studs in the knuckle. Tighten the nuts to 43-52 ft. lbs. (59-71 Nm). Install new cotter pins. 10. Install the damper fork on the knuckle. Do nut tighten the nut at this time. 1 1 . Attach the stabilizer link to the damper fork. Tighten the nut to 29 ft. lbs. (39 Nm). 12. Install the washer and nut on the halfshaft. Prevent the hub from turning and Nm). the nut to 145-188 ft. lbs. (196-255 tighten

• Toe control arm ball joint from the knuckle

4. Prevent the hub assembly from turn¬ ing by using a tool such as MB990767 and remove the halfshaft nut and washer. 5. Remove the differential mount sup¬

i: WARNING Do not pull on the halfshaft to remove port. it from the differential. Dam¬ age to the inner CV-joint will occur.

Pus

and pry the inn hal ou fsh er thetwadrif aft d fer ent ial . ht

he l

owe

rpa r

tof t

he k

nuc

kle

pin. 16. If equipped with ABS, install the front wheel speed sensor. 17. If equipped with Active-ECS, perform the following:

a. Install the air line with anew 0-

ring. b. Install the actuator to the top of the strut. Connect the wiring harness.

18. Install the wheel and lower the vehicle to the floor.

*

or differential Proper method for removing the inner halfshaft from the transaxle

out of

MITSUBISHI

-1I19

91I L.

IL

DIAMANTE « ECLIPSE » GALANT • LANCER • MIRAGE Washer and a new nut on the end of the halfshaft. Tighten the nut Nm). to 145-188 ft. lbs. (196-255

7. Push the outer end of the halfshaft through the hub/knuckle and remove it. To install: 8. Install the outer end of the halfshaft through the hub/knuckle. 9. Place a new circlip on the inner half¬ shaft and install the halfshaft in the differen¬ tial.

Toe control arm to the knuckle. Tighten the new nut to 20 ft. lbs. (28 Nm). Lower and trailing arms to the knuckle. Do not tighten the fasten¬ ers at this time.

• Differential mount support

• Shock absorber. Tighten the bolt to 71 ft. lbs. (98 Nm). 1 1 . Assemble the brake components. 12. Install or connect the following: • Rear wheel speed sensor • Rear wheel and lower the vehicle to the floor. Tighten the lower arm nut to 71 ft. lbs. (98 Nm) and the trail¬ ing arm nut to 85-99 ft. lbs. (118-137 Nm).

STEERING AND SUSPENSION

Air Bag ** CAUTION

All vehicles are equipped with an air . Inbag The system must be dis¬ stall system. o con nect performi abled r before the fol ng service on or lowinnts, around system compone g: steering column, instrument panel compo¬ nents, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary system repairs. PRECAUTIONS Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible per¬ sonal injury. • Never carry the inflator module by the wires or connector on the underside of the module.

4. Wait at least 1 minute before working on the vehicle. The air bag system is designed to retain enough voltage to deploy the air bag for a short period of time after the battery has been disconnected. REARMING

Rack and Pinion Steering Gear

DISARMING

REMOVAL & INSTALLATION

1

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. n the nec

Con

2. Position the front wheels in the

t beat tiv

ega

straight-ahead position and place the key in the LOCK position. Remove the key from the ignition lock cylinder. 3. Disconnect the negative battery cable and insulate the cable end with high-quality electrical tape or similar non-conductive wrapping.

7923PG99

Insulate the negative battery cable to prevent accidental deployment ot the air bag

) RS (Son iti pos t ain ON estr . R ion the rat ope to al nrt tch ompee swi pplpre Su for one ittih ight l ign ck the che g nin n tur and war

• When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed away. • Place the inflator module on a bench or other surface with the bag and trim cover facing up. • With the inflator module on the bench, never place anything on or close to the module which may be thrown in the event of an accidental deployment.

CJT" ^Battery y \

Manual MIRAGE

,

e abl ercy

'■►Prior to removal of the steering rack, center the front wheels and remove the ignition key. Failure to do so may dam¬ age the SRS clockspring and render SRS system inoperative. Be sure to properly disarm the air bag system.

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: •• Wheels Battery negative cable

• Heated Oxygen (HO2S) sensor and remove the front exhaust pipe 3. Properly support the engine. Remove both roll stopper mounting bolts and the 4 center member installation bolts. • Center member

^Matchmark the pinion input shaft of the rack to the lower steering column joint for installation purposes. 4. Remove or disconnect the following: • Pinch bolt holding the lower steer¬ ing column joint to the rack and pinion input shaft • Cotter pins and disconnect the tie rod ends from the steering knuckle • Rack and pinion steering assembly and its rubber mounts from the right side of the vehicle To install: 5. Align the matchmarks of the input shaft and install the rack to the vehicle.

MITSUBISHI OH* -MO ■ IU

DIAMANTE • ECLIPSE • GALANT • LANCER • MIRAGE 6. Secure the rack using the retainer clamps and bolts. Torque the bolts to 51 ft. lbs. (70 Nm). 7. Torque the steering column pinch bolt to 13 ft. lbs. (18 Nm). 8. Install or connect the following: • Center member • Front exhaust pipe • HO2S sensor • Tie rod ends to the steering knuck¬ les and tighten the castle nuts to 25 ft. lbs. (34 Nm). Install new cotter pins. • Wheels and connect the negative battery cable 9. Perform a front end alignment. Power DIAMANTE ^Prior to removal of the steering gear box, center the front wheels and remove the ignition key. Failure to do so may damage the Supplemental Restraint System (SRS) clock spring and render SRS system inoperative. t p tihoen recaut . i

ons

of this sec¬ in the begi nnin g

2. Remove or disconnect the following: • Negative battery cable. • Front exhaust pipe • Transfer case assembly, if equipped with All Wheel Drive (AWD)

• Frame members and tighten the bolts to 43-51 ft. lbs. (60-70 Nm) • Tie rods and install new cotter pins • Transfer case and front exhaust

• Bolt holding the lower steering col¬ umn joint to the rack and pinion inputrodshaft • Tie ends

4. Refill the reservoir and bleed the sys¬ tem. 5. Perform pipe a front end alignment.

• Left and right frame members • Stabilizer bar bracket • Lines going to the rear pump, if equipped with Four Wheel Steering (4WS) • Rack and pinion steering assembly and its rubber mounts. Move the rack to the right to remove it from the crossmember. To install: 3. Install or connect the following: • Rack and install the mounting bolts, tightening bolts to 51 ft. lbs.

ECLIPSE (NON-TURBO) ^Prior to removal ot the steering gear box, center the front wheels and remove the ignition key. Failure to do so may damage the SRS clock spring and render SRS system inoperative. 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Install or connect the following: • Negative battery cable 3. Drain the power steering fluid. • Stabilizer bar • Windshield washer reservoir • Pinch bolt from the joint assembly • Fluid lines from the steering rack • Tie rod ends from the steering knuckles • Left and right stays (supports)

(70 Nm). When installing the rub¬ ber rack mounts, align the projec¬ tion of the mounting rubber with the indentation in the crossmember. Install the pinch bolt. • Pressure and return lines to the rack and to the rear pump, if equipped

2E

refe

r to

1. 2. 3. 4.

Steering shaft assembly and gear box connecting bolt Band Cotter pin Tie-rod end and knuckle connection

Exploded view of the manual steering gear mounting— Mirage

5. 6. 7. 8.

Cylinder clamp Gear housing clamp Gear box assembly Steering cover assembly 7923PG00

21-114

MITSUBISHI DIAMANTE * ECLIPSE • GALANT • LANCER

MIRAGE

35 Nm 25 ft.lbs.

.

0

1. Joint assembly and gear box con¬ necting bolt 2. Cotter pin 3. Tie-rod end and knuckle connecting nut 4. Left member 5. Right member 6. Stabilizer bar bracket

7. Connection of steering gear box 8. with Clamp4WS oil line *2: AWD

9. Gear box assembly 10. Mounting rubber

NOTE FWD

body

7923PGA5

Exploded view of the power steering gear removal— Diamante

7923PG93

Proper tie-rod end removal method

4. Support the engine and remove the center member. • Clamp and the mounting bolts • Left lower compression arm from the body side of the vehicle and support it with wire or string • Steering rack from the joint assem¬ bly and remove the rack from the left side of the vehicle To install: 5. Position the steering rack in the vehicle and install the clamp and the mounting bolts. Be sure the rack is centered before connecting it to the joint assembly. 6. Install or connect the following:

• Left lower compression arm to the

• Center member • Left and right stays and remove the engine support fixture or jack • Tie rods to the steering knuckles • Fluid lines to the steering rack • Pinch bolt in the joint assembly • Stabilizer bar and the windshield washer reservoir 7. Safely lower the vehicle. 8. Connect the negative battery cable. 9. Refill and bleed the power steering

system.

BISHI

MITSU DIAMANTE • ECLIPSE • GALANT • LANCER • MIRAGE ECLIPSE (TURBO)

:: WARNING Prior to removal of the steering gear box, center the front wheels and remove the ignition key. Failure to do so may damage the Supplemental Restraint System (SRS) clock spring and render SRS system inoperative. 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Install or connect the following: • Negative battery cable 3. Drain the power steering fluid. • Stabilizer bar • Fluid level sensor and remove the brake fluid reservoir and position it out of the way. Do not disconnect the brake hose. • Electrical connector from the air conditioning compressor • Air conditioning compressor from the bracket and position it out of

the way. Do not disconnect the hoses. • Pinch bolt from the joint assembly • Fluid lines from the steering rack • Tie rod ends from the steering knuckles • Left and right stays (supports) 4. Support the engine and remove the center member assembly. • Clamp and the mounting bolts • Left lower compression arm from the body side of the vehicle and support it with wire or string 5. Disconnect the steering rack from the joint assembly and remove the rack from the left side of the vehicle. To install: 6. Position the steering rack in the vehicle and install the clamp and the mounting bolts. Be sure the rack is centered before connecting it to the joint assembly. body 7. Install or connect the following: • Left lower compression arm to the • Center member assembly

IIP

• Tie rod ends to the steering knuck¬ les • Fluid lines to the steering rack • Pinch bolt in the joint assembly • Stabilizer bar • Air conditioning compressor and connect the harness connector • Brake fluid reservoir and connect the fluid level sensor • Negative battery cable 8. Refill and bleed the power steering 9. Perform a front end alignment. system. GALANT

U WARNING Prior to removal of the steering gear box, center the front wheels and remove the ignition key. Failure to do so may damage the Supplemental Restraint System (SRS) clock spring and render SRS system inoperative.

1. Brake fluid reservoir assembly 2. A/C compressor 3. Joint assembly and gear box connecting boh 4. Power steering pipe connection 5. Cotter pin 6 Tie-rod end and knuckle connection 7. Stay (L.H.) 8. Stay (R.H.) 28 Nm 9. Centermember assembly 21 tt.lbs 10. Clamp 11. Gear box assembly 12. Return tube 69 Nm 51 ftibs. NOTE

t

ne

gi en e th of

gh

i we

l ta to y. od eb th le ce ic on veh e th ed n nte goh ti d yce lla napl fi e n ar bee ey s th ha

Eclipse

-ME

• Left and right stays

18 Nm 131LRM.

Power steering rack assembly and related components

O-f

^1

7923PGA2

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Install or connect the following: • Negative battery cable • Both front wheel assemblies • Bolt holding lower steering column joint to the rack and pinion input shaft • Stabilizer bar

^^77 L

• Cotter pins and the tie rod ends from the steering knuckle 3. On vehicles equipped with Electronic Control Power steering (EPS), disconnect the wiring harness from the solenoid con¬ nector. 4. Locate the 2 triangular braces near the crossmember and remove both.

7923PGA3

Disconnect the lower compression arm from the body— Eclipse

18 Nm 13 ftlbs. 43 ftlbs.* Nm* 32

24-33 Nm 18-24 ftlbs.

69-78 Nm 51 -58 ftlbs.

1. Joint assembly and gear box con¬ necting bolt 2. Cotter pin 3. Connection for tie rod end and knuckle 4. Stay

5. Center 6. Clamp member 7. Bolt

assembly

Exploded view of the power steering gear removal procedure— Galant

8. Gear box assembly

Caution The fasteners marked * should be temp orarily tightened before they are finally tightene d once the total weight of the engine has been placed

on the vehicle body.

K

7923PGA4

MITSUBISHI

91.117

DIAMANTE • ECLIPSE • GALANT • LANCER • MIRAGE 5. Support the center crossmember. Remove the through-bolt from the front round roll stopper and remove the bolts securing the center crossmember. 6. Remove the center crossmember. 7. Properly support the engine and remove the rear roll stopper through-bolt. 8. Remove or disconnect the following: • Power steering fluid pressure pipe and return hose from the rack fit¬ tings. Plug the fittings to prevent excessive fluid leakage. • Clamp bolts and the 2 bolts secur¬ ing the rack assembly to the chas¬ sis • Rack and pinion steering assembly and its rubber mounts i*»When removing the rack and pinion assembly, tilt the assembly to the vehicle side of the compression lower arm and remove from the left side of the vehicle. To install: 9. Center the rack assembly and insert the pinion into the steering column shaft. • Rack and with the mounting bolts.

Torque the mounting bolts to 51 ft. lbs. (69 Nm). • Pinch bolt and tighten the bolt to 13 ft. lbs. (18 Nm) • Power steering fluid lines to the rack and tighten the pressure hose fitting to 11 ft. lbs. (15 Nm). Secure the return hose with the clamp. 11. Raise the engine into position. Install the rear roll stopper through-bolt and tighten to 32 ft. lbs. (43 Nm). 12. Raise the crossmember into position. Install the center member mounting bolts and tighten the front bolts to 58-65 ft. lbs. (78-88 Nm) and the rear bolt to 51-58 ft. lbs. (69-78 Nm). 13. Install or connect the following: • Front roll stopper bolt and tighten the nut to 32 ft. lbs. (43 Nm) • 2 triangular braces and tighten the mounting bolts to 50-56 ft. lbs. (69-78 Nm) • Stabilizer bar • Tie rod ends and tighten nuts to 20 ft. lbs. (27 Nm) 14. On vehicles equipped with EPS, con¬ nect the wiring harness to the solenoid con¬ nector.

6. 7. 8. 9. 10.

16. Refill the reservoir with power steer¬ ing fluid and bleed the system. 17. Perform a front end alignment. LANCER

& MIRAGE

^Prior to removal of the steering gear box, center the front wheels and remove the ignition key. Failure to do so may damage the Supplemental Restraint System (SRS) clockspring and render SRS system inoperative. 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the power steering system. 3. Remove or disconnect the following: • Battery negative cable. Raise the vehicle and support safely • Pleated Oxygen (HO2S) sensor and remove the front exhaust pipe, if necessary 4. Properly support the engine. • Both roll stopper mounting bolts and the 4 center member installation bolts. Remove the center member. • Center member

Pressure tube connection Cylinder clamp Gear housing clamp Gear box assembly Steering cover assembly 7923PGA1

Exploded view of the power steering gear assembly— Mirage

■ 1 ■

15. Install the wheel assemblies and lower the vehicle.

132

1. Steering shaft assembly and gear box connecting bolt 2. Band 3. Cotter pin 4. Tie-rod end and knuckle connection 5. Return tube connection

■

and its rubber mounts from the right side of the vehicle

^Matchmark the pinion input shaft of the rack to the lower steering column joint for installation purposes.

.

• Pinch bolt holding the lower steer¬ ing column joint to the rack and pinion input shaft • Cotter pins and disconnect the tie rod ends from the steering knuckle r steering fluid pressure pipe Re•movPowe e oretur r disncohose and the rack fit¬ nnect from the follow tings ing: • Rack and pinion steering assembly

To install:

6. Align the matchmarks of the input shaft and install the rack to the vehicle. 7. Secure the rack using the retainer clamps and bolts. Torque the bolts to 52 ft lbs. (70 Nm). 8. Torque the steering column pinch bolt to 13 ft. lbs. (18 Nm). 9. Using new O-rings, connect the power steering fluid lines to the rack fit¬ tings.

10. Install or connect the following: • Center member

• Front exhaust pipe

• HO2S sensor

• Tie rod ends to the steering knuck¬ les and tighten the castle nuts to 25 ft. lbs. (34 Nm). Install new cotter

• Wheels and connect the negative battery cable 11. Refill pins.the reservoir and bleed the

12. . Perform a front end alignment. system

12±2Nm 102 ±22 in 70 ±10 N m 52 ± 7 ft-lb

57 ± 7 N*m 42 ± 5 ft-lb 15 ±3 Nm 11 ±2 ft-lb

12 ± 2 N*m 102 ±22 in-lb

1. 2. 3. 4. 5.

CROSSMEMBER JOINT COVER GROMMET RETURN HOSE RETURN TUBE O-RING

RETURN TUBE EYE BOLT PRESSURE HOSE ASSEMBLY 8. CLAMP 9. 10. STEERING GEAR AND LINKAGE 6. 7.

9357QG28

Exploded view of the power steering gear— Lancer

MITSUBISHI DIAMANTE

Strut and Coil Spring

• ECLIPSE • GALANT

connect with the mounting bolts. Torque the Nm). mounting bolts to 70-76 ft. lbs. (90-105

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable. 3. Raise and safely support the vehicle. 4. Remove the brake hose and the tube bracket. ^Do not pry the brake hose and tube clamp away when removing it.

5. If equipped with Anti-Lock Brake (ABS), disconnect the front speed sensor mounting clamp from the strut. 6. Support the lower arm and remove the strut to knuckle bolts. Use a piece of wire to suspend the knuckle to keep the weight off the brake hose. 7. If equipped with Active Electronic Control Suspension (Active-ECS) perform the following: a. Loosen the nut that secures the air

I * 3

bolts.

ring. a. Install the air line with anew 0-

7. Remove the strut upper mounting bolts. Remove the strut assembly from the vehicle. 8. Compress the coil spring using a spring compressor until the spring just comes away from one ot the seats. 9. Remove or disconnect the following: • Center nut from the strut and remove the upper mounting bracket • and Coil bushings spring

b. Install the actuator to the top of the strut. Connect the wiring harness. 14. Install or connect the following: • Brake hose bracket and the ABS clamp, if equipped • Wheel and tire assembly 15. Perform a front end alignment. LANCER & MIRAGE 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable. 3. Raise and safely support vehicle. 4. Remove the brake hose and tube bracket retainer bolt and bracket from the front strut. Do not pry the brake hose and tube clamp away when removing. 5. If equipped with ABS, disconnect the front speed sensor mounting clamp from the strut. 6. Support the lower arm using floor

line to the to the top of the strut and dis¬ card the O-ring. b. Remove the bolts that secure the actuator to the top of the strut and remove the component. Disconnect the wiring harness.

■

^Before removing the top bolts, make matchmarks on the body and the strut insulator for proper reassembly.

13. If equipped with Active-ECS, perform the following: DIAMANTE

• LANCER • MIRAGE

jack. Remove the lower strut to knuckle

REMOVAL & INSTALLATION Front

91.11Q

To install:

10. InstallNm)or connect the following: • assembly Compressed spring on the strut • Upper bushings and the mounting

bucket

• Nut and tighten it to 43 ft. lbs. (59 • Strut to the vehicle and install the top mounting bolts. Tighten the mounting bolts to 29 ft. lbs. (40 Nm) for Mirage and 33 ft. lbs. (44 Nm) for Lancer.

44 Nm

^Before removing the top bolts, make matchmarks on the body and the strut insulator for proper reassembly.

8. Remove the strut upper nuts and remove the strut assembly from the vehicle. 9. Compress the coil spring using a spring compressor until the spring just comes away from one of the seats. 10. Remove or disconnect the following: • Center nut from the strut and remove the upper mounting bracket and bushings • Coil spring To install:

11. Install or connect the following: • Compressed spring on the strut assembly • Upper bushings and the mounting bracket • Nm) Nut and tighten it to 43 ft. lbs. (59 • Strut to the vehicle and tighten the upper mounting nuts to 33 ft. lbs. (45 Nm) 12. Align the strut to the knuckle and

Removal

steps

1. Brake hose clamp 2. Front speed sensor

3. Bolts 4. Self-locking

For vehicles with ABS, be careful when handling sensor so the pole piece at the tip of the speed other parts. as not to damage it by striking against

nut

5. Strut assembly

Front strut assembly and related parts— Mirage shown, Lancer similar

7923PGA6

MITSUBISHI fc. i

i L. U

DIAMANTE » ECLIPSE • GALANT • LANCER • MIRAGE

1 1 . Position the strut on the knuckle and install the mounting bolts. While holding the head of the lower mounting bolt, tighten the nuts to 80-94 ft. lbs. (110-130 Nm) for Mirage and 123 ft. lbs. (167 Nm) for Lancer. 12. Install or connect the following: • Brake hose bracket and the ABS clamp, if equipped • Wheel and tire assembly 13. Perform a front end alignment.

Shock Absorber and Coil Spring REMOVAL & INSTALLATION Front

ECLIPSE

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Raise and safely support the vehicle. 3. Remove or disconnect the following: • Front wheel • 3 upper shock absorber mounting nuts. Do not remove the larger nut in the center of the strut at this time.

• Stabilizer link from the damper fork • Damper fork mounting bolt • Shock absorber assembly from the vehicle

Damper fork installation bolt

Inside of the body

4. Use a coil spring compressor and compress the coil spring. 5. While holding the piston rod, remove the self-locking nut. 6. Remove or disconnect the follow¬ ing:

• Upper bracket assembly and spring pad • Collar, upper bushing, cup assem¬ bly, bump rubber and dust cover • Coil spring from the shock absorber To install:

7. Align the end of the coil spring with .the stepped part of the spring seat and install the compressed coil spring on the shock. 8. Install the dust cover, bump rubber, cup assembly, upper bushing, collar, upper spring pad and bracket assembly on the strut. 9. Install or connect the following: • Upper bushing and washer on the piston rod • New self-locking nut on the piston rod. Temporarily tighten the nut.

7923PGB2

Upper bracket assembly alignment— Eclipse

f¬ sel the . m) uNe rq To (25 . lb.s ing spr ft. 6 the 1o t m fro nut

r g sso kin pre loc

1 1 . Position the shock absorber assem¬ bly in the damper fork and install the mounting bolt. 12. Pass the studs in the upper bracket assembly through the holes in the inner fender and install the 3 mounting nuts. 13. Connect the stabilizer link to the damper fork. 14. Install the wheel assembly. 15. Safely lower the vehicle to the floor. 16. Check the front wheel alignment and adjust if necessary.

GALANT

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable. 3. Raise and safely support vehicle. 4. Remove or disconnect the following: • Appropriate wheel assembly • Sway bar link from the damper fork • Damper fork lower through-bolt and upper pinch bolt • Damper fork assembly

MITSUBISHI DIAMANTE

91-191

• ECLIPSE • GALANT • LANCER • MIRAGE

*

l £- \

— 7a gA12I0002

Disassembly 1. 2. 3. 4. 5. 6.

steps 7. 8. 9. 10. 11.

Self-locking nut Washer Upper bushing A Upper bracket assembly Upper spring pad Collar

Upper bushing B Cup assembly Bump rubber Dust cover Coil spring

S—

12. Shock

8

absorber assembly 7923PGB3

Exploded view of the coil spring removal procedure— Eclipse

• Shock absorber upper nuts and remove the strut assembly from the vehicle

5. Compress the coil spring with a spe¬ cial compression tool. • Self-locking nut and washer • Upper bushing, upper bracket assembly, the upper spring pad, and the collar • Other upper bushing, cup assem¬ bly, bump rubber, dust cover, and the coil spring. Carefully remove the coil spring compression tool To install:

gnm

i dal nten

o amfr for

Per

6. Install or connect the following: • Compressed coil spring to the shock absorber assembly. Be sure to align the edge of coil spring to the stepped part of the spring seat. Install the dust cover, bump rubber,

.

ent

cup assembly, upper bushing, col¬ lar, and upper spring pad. • Upper bracket assembly and posi¬ tion it so that the 3 bolts are in the correct position • Upper bushing, washer, and lock¬ nut. Torque the locknut to 18 ft. lbs. (24 Nm). • Shock absorber and tighten the upper mounting nuts to 32 ft. lbs. (44 Nm)

7. Align the shock to the damper fork and install the damper fork. Tighten the lower through-bolt/nut to 65 ft. lbs. (88 Nm) Nm).the upper pinch bolt to 76 ft. lbs. (103 and 8. Connect the sway bar link to the damper fork and tighten the link nut to 29 ft. lbs. (39 Nm). 9. Install the wheel and tire assembly. Rear

DIAMANTE 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable. 3. Raise and properly support vehicle. Remove both rear wheels. 4. Support the lower control arm with a 5. Matchmark the positioning of the jack. plate to the vehicle for rein¬ upper spring stallation purposes. 6. If equipped with Active Electronic Control Suspension (Active-ECS), perform the following: a. Loosen the nut that secures the air

line to the to the top of the strut and dis¬ card the 0-ring. b. Remove the bolts that secure the actuator to the top of the strut and remove the component. Disconnect the wiring harness. 7. Remove the shock absorber lower mounting bolt and remove the 2 nuts that secure the shock upper plate to the vehicle. 8. Lower the support jack and remove the shock from the vehicle. To install

9. Position the upper spring plate and install the strut. Use the support jack to assist with installation. 10. Tighten the upper strut mounting nuts to 33 ft. lbs. (45 Nm). 11. Tighten the lower strut mounting bolt to 71 ft. lbs. (98 Nm).

If equippe g: d with Active-ECS perform the 12. followin a. Using a new 0-ring, tighten the nut that secures the air line to the to the top of the strut to 84 inch lbs. (9 Nm). b. Install the actuator to the top of the shock absorber and secure with mount¬ ing bolts. Connect the wiring harness. 13. Remove the support jack, install wheels and lower vehicle. 14. Connect the negative battery cable.

21-122

MITSUBISHI DIAMANTE

• ECLIPSE

GALANT • LANCER • MIRAGE

ECLIPSE

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Service lid in the luggage compart¬ ment • Cap and flange nuts securing the upper mounting bracket to the body of the vehicle 3. Raise and safely support the vehicle. 4. Remove the bolt attaching the lower end of the shock to the knuckle and remove the shock absorber from the vehicle. 5. Use a coil spring compressor and compress the coil spring. 6. While holding the piston rod, remove the self-locking nut. 7. Remove or disconnect the following: • Upper bracket assembly and spring

Correct upper bracket installed position— Eclipse

pad upper bushing, • Collar, cup assem¬ bly, bump rubber and dust cover • Coil spring from the shock absorber To install:

8. Align the end of the coil spring with the stepped part of the spring seat and install the compressed coil spring on the shock absorber. 9. Install or connect the following: • Dust cover, bump rubber, cup assembly, upper bushing, collar, upper spring pad and bracket assembly on the shock absorber • Upper bushing and washer on the piston rod • New self-locking nut on the piston rod. Temporarily tighten the nut. 10. Remove the spring compressor from the spring. Torque the self-locking nut to 16 ft. lbs. (25 Nm). 11. Install the upper bracket of the shock to the vehicle. Torque the mounting nuts to 32 ft. lbs. (44 Nm). 12. Raise the suspension up with a jack or adjustable stand to align the shock absorber lower mounting holes. 13. Install the lower mounting bolt. Torque the bolt to 71 ft. lbs. (96 Nm). 14. Remove the jack or stand and safely lower the vehicle to the floor. 15. Install the cap and service lid. GALANT 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Raise and support the vehicle chas¬ sis.

1. Cap 2. 3. 4. 5. 6.

Self-locking nut Washer Upper bushing A Bracket Spring pad

7. Upper bushing B

9. Cup 8. Collar 10. Dust cover 11. Bump rubber 12. Coil spring 13. Shock absorber assembly 7923PGB4

Exploded view of the rear shock absorber assembly— Galant and Mirage

MITSUBISHI 01.19Q DIAMANTE • ECLIPSE • GALANT • LANCER • MIRAGE 3. Raise and support the lower control arm assembly slightly. 4. In order to gain access to the top mounting nuts, remove the rear seat as fol¬ lows: a. While pulling the rear seat stopper outward, lift the lower cushion upward. Remove the lower cushion. b. Remove the seat back mounting bolts. c. Lift the seat back upward and remove the seat. 5. Remove or disconnect the following: • Shock upper mounting nuts • Shock lower mounting bolt and remove the assembly from the vehicle 6. Use a coil spring compressor and compress the coil spring. 7. Remove the shock cap. 8. While holding the piston rod, remove the self-locking nut. 9. Remove or disconnect the following: • Upper bracket assembly and spring pad upper bushing, cup assem¬ • Collar, bly, bump rubber and dust cover • Coil spring from the shock

To install

10. Align the end of the coil spring with the stepped part of the spring seat and

install the compressed coil spring on the shock. 1 1 . Install or connect the following: • Dust cover, bump rubber, cup assembly, upper bushing, collar, upper spring pad and bracket assembly on the shock • Upper bushing and washer on the piston rod • New self-locking nut on the piston rod. Temporarily tighten the nut. 12. Remove the spring compressor from the spring. Torque the self-locking nut to 16 ft. lbs. (25 Nm). 13. Install the shock cap. 14. Position the shock assembly so that the lower mounting bolt can be installed and lightly tightened. 15. Use a jack to raise or lower the lower control arm, so that the top shock plate studs align through the body. Raise the jack to hold the shock assembly in position. 16. Install the top plate nuts on the studs and tighten the mounting nuts to 32 ft. lbs. (44 Nm). 17. With the vehicle on the ground, tighten the lower mounting bolt to 71 ft. lbs. (98 Nm). 18. Install the rear seat back and cush¬ ion.

LANCER 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Stabilizer link connection 3. Support the lower control arm with a • Lower control arm and trailing arm bolt • Upper shock absorber mounting jack. nut • Shock absorber-to-lower control arm attaching bolt • Shock absorber assembly

To install: 4. Position the shock absorber into the vehicle. Install the spring seat stepped sec¬ tion so that it points toward the rear side of the vehicle. 5. Install or connect the following: • Shock absorber-to-lower control arm bolt and nut. Tighten the nut to 70 ft. lbs. (95 Nm). • Upper shock mounting nut and tighten to 32 ft. lbs. (44 Nm) • Lower control arm and trailing arm • Stabilizer link. Tighten the self¬ locking nuts so that the end of the stabilizer line bolt protrudes 0.24-0.31 in. (6-8mm).

95 ± 15 N-m 70 ±11 ft-lb

95 ± 15 N-m 70 ±11 ft-lb

1. 2.

3.

STABILIZER LINK CONNECTION LOWER ARM AND TRAILING ARM CONNECTION SHOCK ABSORBER MOUNTING NUT

4. 5.

SHOCK ABSORBER ARM CONNECTING SHOCK ABSORBER

AND LOWER BOLT ASSEMBLY

9357QG29

Exploded view of the rear shock absorber mounting — Lancer

9 A MITSUBISHI 91-1Ifc.1* DIAMANTE

L. I

* ECLIPSE • GALANT • LANCER • MIRAGE

MIRAGE

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Trunk interior trim to gain access to the top mounting nuts • Top nuts cap and upper shock mounting 3. Raise and support vehicle chassis. 4. Support the trailing arm assembly with a jack. 5. Matchmark the upper spring plate to the vehicle chassis for reassembly and remove the upper spring plate mounting nuts. 6. Remove the shock lower mounting bolt and remove the assembly from the vehicle. 7. Compress the coil spring using the proper spring compressor. 8. Hold the piston rod with a wrench and remove the self-locking nut. 9. Remove or disconnect the following: • Washer, upper bushing A, bracket, spring pad, upper bushing B, col¬ lar, cup, dust cover and bump rub¬ ber • Coil spring To install

• Coil spring on the shock

• Bump rubber, dust cover, cup, col¬ lar, upper bushing A, spring pad, bracket, upper bushing B and the washer 11. Temporarily install a new self-lock¬ ing nut, carefully release the spring from the compressor and tighten the self-locking nut to specifications. 12. Position the shock assembly so that lower mounting bolt can be installed and lightly tightened. 13. Use jack to raise or lower the axle assembly so that top shock plate studs aligns through body. Raise jack to hold the shock assembly in position. 14. Install the top plate nuts and tighten them to 20 ft. lbs. (28 Nm). 15. Lower the vehicle and tighten the lower Nm). mounting bolt to 65 ft. lbs. (90

Upper Control Arm REMOVAL & INSTALLATION Diamante and Mirage

These vehicles use a strut type front sus¬ pension. No upper control arm is used. Eclipse and Galant

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. ing:2. Raise and safely support the vehicle. 3. Remove or disconnect the follow¬ • Front wheel • Upper arm ball joint from the steer¬ ing knuckle • from Upper shaft mounting nuts thearmbody

16. Install top cap and interior trim.

• Upper arm • Through-bolts that attach the upper arm to the shafts

Upper Ball Joint REMOVAL & INSTALLATION

To install:

The upper ball joints are an integral part of the upper control arm. If the ball joint becomes worn or damaged, the control arm must be replaced.

4. Assembly the upper arm to the shafts at the proper angle. Torque the throughbolts and nuts to 41 ft. lbs. (57 Nm). The proper angle is 84-86°. After the arm and

86 Nm 62 ft lb*.

o' ?rm 2. Self-locking 3. Upper arm 4. Upper arm 5. Dust cover

k®* join* and knuckle connection nut for upper arm installation

assembly shaft assembly

7923PGB7

Upper control arm assembly— Eclipse and Galant

MITSUBISHI 91.19R DIAMANTE

• ECLIPSE • GALANT • LANCER • MIRAGE

6. Install or connect the following: • Control arm to the vehicle and install the through-bolt. Replace the nut and snug temporarily. • Rear mount clamp, bolts and replacement nuts. Torque the bolts Nm). to 72-87 ft. lbs. (100-1 20 Nm). Torque the nuts to 29 ft. lbs. (40

1

0

.

7923PGB5 1° 85° ±

Correct angle of control arm and shafts — Eclipse and Galant

A : 299.9 mm B . 234.0 mm

(11.8 in.) (9.2 in.)

• Ball joint stud to the knuckle • New nut and tighten to 43-52 ft. lbs. (60-72 Nm) • Sway bar and links 7. Lower the vehicle to the floor for the final tightening of the frame mount throughbolt. 8. Once the full weight of the vehicle is on the floor, tighten the frame mount through-bolt nuts to 75-90 ft. lbs. (102-122 Nm). 9. Connect the negative battery cable. adjust if necessary. ECLIPSE AND GALANT Che ckThe lower lateral arm ball joint and the the whe arm ball joint are integral compression el a lig men lateral arm and the com¬ components of nthe t an pression arm respectively. If the ball joints d are to be serviced, the arms must be

Measure the dimensions A and B as shown — Eclipse and Galant

the shafts are connected at the right angle, measure dimensions A and B to insure cor¬ rect assembly. • AO-ring: 11.8 in. (299.9mm) • B O-ring: 9.2 in. (234.0mm) 5. Install or connect the following: • Control arm assembly to the body with new self-locking nuts. Torque the self-locking nuts to 62 ft. lbs. (86 Nm). • Upper arm ball joint to the steering knuckle with a new self-locking nut. Torque the locking nut to 20 ft. lbs. (28 Nm). • Front wheel 6. Check the front wheel alignment and adjust if necessary. 7. Lower the vehicle. Lower Ball Joint REMOVAL & INSTALLATION The lower ball joint is an integral part of the lower control arm assembly, and can not be serviced separately. A worn or damaged ball joint requires replacement of lower con¬ trol arm assembly.

Lower Control Arm REMOVAL & INSTALLATION Front

DIAMANTE 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Raise the vehicle and support safely allowing wheels and suspension to hang freely. 4. Remove or disconnect the following:

Swayarmbar links from the lower con¬ • trol • Ball joint stud from the steering knuckle

• Inner mounting frame through-bolt and nut • Rear mount bolts. Remove the clamp if equipped • Rear rod bushing if servicing To install:

ing. 5. Assemble the control arm and bush¬

replaced. 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. safely. 2. Raise and support the vehicle 3. Disconnect both ball joint studs from the steering knuckle. 4. To remove the lower lateral arm, remove the crossmember brackets. 5. Remove or disconnect the following: • Inner lateral arm mounting bolts and nut • Arm from the vehicle • 2 bolts holding the compression arm • Compression arm To install:

6. Assemble the control arms and bushings. 7. Install or connect the following: • Lateral control arm to the vehicle and install the inner mounting bolts. Install a new nut and snug temporarily. • Compression arm to the vehicle • Ball joint studs to the knuckle • New nuts and tighten to 43-51 ft. lbs. (59-71 Nm) 8. Lower the vehicle to the floor for the final tightening.

9. Once the full weight of the vehicle is

21-126

MITSUBISHI DIAMANTE

• ECLIPSE * GALANT • LANCER • MIRAGE

40 Nm 29 ft.lbs.

100 Nm 72 ft.lbs.

108 Nm* 78 ft.lbs.*

Removal

steps

10. locking Lower arm nut clamp mounting self¬ 11. Lower arm mounting clamp 12. Lower arm 13. Stopper 14. Rod bushing

1. Stabilizer link mounting nut (stabi¬ lizer bar side) 2. Stabilizer link mounting nut (lower arm side) 3. Stabilizer link 4. Self-locking nut connecting lower arm ball joint to knuckle 5. Lower arm mounting nut 6. Lower arm mounting bolt 7. Clamp mounting seif-locking nut 8. Clamp mounting bolt (small) 9. Clamp mounting bolt (large)

Caution

*: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in an unladen condition.

Exploded view of the lower control arm removal proced ure— Diamante is similar

7923PGB9

MITSUBISHI 91.197 DIAMANTE

• ECLIPSE • GALANT

• LANCER • MIRAGE

■

83 Nm 60ftlbs.

98-118 Nm* 71-85 ftlbs*

88 Nm* 64 ftlbs*



69-78 Nm 51 -58 ftlbs.

Compression lower arm assembly removal steps 1. Connection for compression lower arm ball joint and knuckle 2. Compression lower arm mounting bolt 3. Compression lower arm assembly

steps Lateral lower arm assembly removal 4. Stay

5. Shock absorber lower mounting bolt and nut 6. Connection for lateral lower arm

knuckle and arm ball jointlower 7. Lateral mounting bolt and nut 8. Lateral lower arm assembly Caution * • Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground 7923PGB8 in the unladen condition.

Exploded view of the lower control arms — Eclipse and Galant

MITSUBISHI 91-1i98 L.U DIAMANTE • ECLIPSE

L, l

• GALANT • LANCER • MIRAGE

.

1. 2. 3. 4. 5. 6. 7.

SELF-LOCKING NUT STABILIZER RUBBER STABILIZER BAR COLLAR LOWER ARM AND CONNECTION

KNUCCKLE

LOWER ARM AND CROSSMEMBER CONNECTION LOWER ARM ASSEMBLY

9357QG30

Exploded view of the lower control arm mounting— Lancer

in

of thi sec s ¬ g

4. Lift the transaxle with a jack, then remove the front control arm-to-crossmember bolt. • Lower control arm To install:

5. Install or connect the following: • Lower control arm into the vehicle • Lower control arm-to-crossmember

ehi

nn

• Wheel and tire assembly • Stabilizer bar self-locking nut, rub¬ ber bushings, stabilizer bar and collar. Discard the nut. • Lower control arm-to-knuckle bolt and nut

hev

in the be gi

ing:3. Remove or disconnect the follow¬

ert

th p tioe reca uti n. ons

bolts. Torque the bottom bolt to 123 ft. lbs. (167 Nm) and the side bolt snug until the vehicle is low¬ ered. • Lower control arm-to-steering knuckle bolt. Torque to 80 ft. lbs. (108 Nm). • Stabilizer bar collar, stabilizer bar, bushings and new self-locking nut.

Low

'•The suspension components should not be tightened until the vehicle’s weight is resting on its wheels.

2. Raise the vehicle and support safely.

e icl s. veh lbl. rfot the ont c of 137 e sid to ghte t wei th bol the que r hto wit er n s, mb me the wheel ). ss Nm cro othe, els m-t 6 he altl whe on ar (18 ,nst clei

on the suspension, tighten the lateral arm rear bolt to 71-85 ft. lbs. (98-118 Nm) and the front bolt to the damper fork to 64 ft lbs. (88 Nm). 10. Torque the bolts for the compression arm to 60 ft. lbs. (83 Nm). 11. Reinstall the crossmember brackets with their mounting bolts. Torque the mounting bolts to 51-58 ft. lbs. (69-78 Nm). 12. Perform an alignment on the vehicle. LANCER

MIRAGE

'•The suspension components should

not be tightened until the vehicle’s weight is resting on its wheels.

MITSUBISHI DIAMANTE

91.190

• ECLIPSE • GALANT • LANCER • MIRAGE

I

I

J

Removal steps 1. 2. 3. 4. 5 6^

Lower arm ball joint connection Self-locking nut Stabilizer rubber Caution Stabilizer bar *: Indicates collar tightened, ing bush Lower arm front vehicle on connection

7. Support bracket 8. Lower arm assembly parts which should be temporarily and then fully tightened with the the ground in the unladen condition. 7923PGB0

Lower control arm assembly and related components— Mirage

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Raise the vehicle and support safely. 3. Remove or disconnect the following: • Wheel and tire assembly • Stabilizer bar links or mounting nuts and bolts from lower control arm. Remove the joint cups and bushings. • Ball joint stud from the steering knuckle • Inner lower arm mounting bolt and nut • Rear mount bolts from the retaining clamp. Remove the rear retainer clamp if equipped. • Arm from the vehicle

To install:

4. Install or connect the following: • Control arm to the vehicle and install the inner mounting bolt. Install new nut and tighten to 78 ft. lbs. (108 Nm). • Rear mount clamp and bolts. Torque the clamp mounting bolts to 65 ft. lbs. (90 Nm). • Ball joint stud to the knuckle. Install a new nut and tighten to 43-52 ft. lbs. (60-72 Nm). • Sway bar and links 5. Lower the vehicle to the floor for the final tightening of the inner frame mount bolt. 6. Install the wheel and tire assembly.

Wheel Bearings ADJUSTMENT

The front and rear wheel bearings on these vehicles are not adjustable. If the bearings are noisy or become loose, they must be replaced.

REMOVAL & INSTALLATION Front

DIAMANTE AND MIRAGE

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

MITSUBISHI ion DIAMAN 91_ \ SOU TE * ECLIPSE

U

• GALANT • LANCER • MIRAGE To install:

1 1 . Press the wheel bearing into the knuckle. Once the bearing is installed, install the inner race. 12. Install the grease seal. 13. Using a pressing, mount the front hub assembly into the knuckle. Tighten the nut of the pressing tool to 144-188 ft. lbs. bearing. Nm). Rotate the hub to seat the (200-260 1 . Inner oil seal 2. Hub 3. Dust cover 4. Snap ring 5. Wheel bearing 6. Outer oil seal 7. Knuckle

14. Install or connect the following: • Hub and knuckle assembly onto the vehicle. Install the lower ball joint stud into the steering knuckle and install a new nut. Tighten to 52 ft. lbs. (72 Nm). • assembl Halfshafty into the hub/knuckle

7923PGC1

Front wheel bearing assembly exploded view— Mirage and Diamante

• 2 front strut lower mounting bolts and tighten to 80-94 ft. lbs. (110-130 Nm) on Mirage or 65-76 ft. lbs. (90-105 Nm) on Diamante models. • Tie rod end and tighten the nut to 25 ft. lbs. (34 Nm) for Mirage and ft. lbs. (29 Nm) on Diamante 21 models

• Brake disc and caliper assembly 15. If equipped with Active-ECS, connect the height sensor and tighten the mounting bolt to 15 ft. lbs. (20 Nm). 16. Install or connect the following: • Front speed sensor, if removed • Washer and new locknut to the end of the halfshaft. Tighten the locknut

Use ot press tool for hub removal— Mirage and Diamante

snugly to 144-188 ft. lbs. (200-260 Nm). • Tire and wheel assembly onto the vehicle. Lower the vehicle to the ECLIPSEground.

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Front wheel • Axle nut • Wheel speed sensor, vehicles with Anti-Lock Brake (ABS) • Caliper and suspend it out of the • way Brakewith rotorwire or string

Removing inner race from hub— Mirage and Diamante

2. Disconnect the negative battery cable. 3. Raise the vehicle and support safely. Remove the halfshaft nut. 4. If equipped with Anti-Lock Brake (ABS), remove the front wheel speed sensor. 5. If equipped with Active Electronic Control Suspension (Active-ECS), discon¬ nect the height sensor from the lower con¬ trol arm.

6. Remove the caliper assembly and brake pads. Suspend the caliper with a wire. 7. Ball joint and tie rod end from the steering knuckle. 8. Remove the halfshaft from the hub. 9. Unbolt the lower end of the strut and remove the hub and steering knuckle assembly from the vehicle.

• Steering knuckle from the upper arm 3. Pull the knuckle away from the vehicle to access the hub mounting bolts on the inboard side of the hub. Be careful not to damage the ball joint boot or the ABS rotor if equipped. 4. Remove the mounting bolts and the front hub assembly.

e.

ckl knu the m fro

es

rac

g rin

bea the

ove

rem

MITSUBISHI DIAMANTE

• ECLIPSE • GALANT

01.1Q1 I

• LANCER • MIRAGE

88 Nm 65 ft.lbs.

196-255 Nm 145-188 (Libs.

88 Nm 65ftlbs.

1. Cotter pin 2. Drive shaft nut 3. Front speed sensor

4. 5. 6. 7.

Caliper assembly Brake disc Upper arm connection Front hub assembly

Caution The front hub assembly should not be disas¬ sembled. 7923PGC4

Front hub and related components — Eclipse

Removal steps 1. Cotter pin 2. Drive shaft nut 3. Front speed sensor cVehicles with ABS> 4. Caliper assembly Exploded view of the front hub removal — Galant

5. Brake disc 6. Connection for upper arm 7. Front hub assembly Caution

The front hub assembly

.

..

. .

7923PGC5 should not be disassembled.

IUI

^9 91i-1IUL

MITSUBISHI

DIAMANTE » ECLIPSE • GALANT • LANCER • MIRAGE

^•Do not disassemble the hub assem¬ bly. If binding or damaged, it must be replaced as a unit. To install:

• Hub to the knuckle. Torque the mounting bolts to 65 ft. lbs. (88 Nm). • Knuckle to the upper arm • Brake rotor and the caliper • Wheel speed sensor if removed • Axle nut and tighten to 145-188 ft . Install olbs. (196-255 Nm) r conneand • Wheel ct tlower vehicle to the he follthe owing: floor

GALANT

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Raise the vehicle and support safely. 3. Remove or disconnect the following: • Appropriate wheel assembly • Cotter pin, halfshaft nut and washer • Vehicle Speed Sensor (VSS(), if equipped with Anti-Lock Brake (ABS) • Caliper and brake pads. Support the caliper out of the way using wire.

1 . FRONT ABS SPEED SENSOR < VEHICLES WITH ABS> 2. CALIPER ASSEMBLY 3. BRAKE DISC 4. WASHER 5. DRIVESHAFT NUT 6. CONNECTION FOR STABILIZER BAR

• Brake rotor from the hub assembly • Upper ball joint from the steering knuckle and pull the knuckle out¬ ward 4. From the back of the knuckle, remove the 4 bolts securing the hub to the knuckle. 5. Remove the hub and bearing assem¬ bly from the knuckle. ^The hub assembly is not serviceable and should not be disassembled. To install

6. Install or connect the following: • Hub to the steering knuckle and

7. CONNECTION FOR LOWER ARM BALL JOINT 8. CONNECTION FOR TIE ROD END 9. DRIVESHAFT 10. FRONT STRUT TO HUB AND KNUCKLE MOUNTING BOLT AND NUT 11. HUB AND KNUCKLE 9357QG31

Exploded view of the front wheel bearing and related compone nts

MITSUBISHI 01.1QQ DIAMANTE

5 tighten the mounting bolts to 65 ft. lbs. (88 Nm) . • Upper ball joint to the steering knuckle and tighten the self-locking nut to 21 ft. lbs. (28 Nm) • Axle washer and nut. Tighten the nut to 145-188 ft. lbs. (200-260 Nm). 7. Position the rotor on the hub. 8. Install the caliper holder and the brake caliper. 9. If equipped with ABS, install the

vss.

the vehicle 0 . LANCER

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Raise and safely support the vehicle. 3. Remove or disconnect the following: . • Front wheel

• Wheel Speed Sensor (WSS), vehi¬ cles with Anti-Lock Brake (ABS) • Caliper and suspend it out of the way with wire or string • Brake rotor • Axle nut, using special tool . tall the MB990767 to hold the hub secure wheel asseremoving while mbly a the nut. Discard the nd low nut. er • Stabilizer bar from the lower con¬ trol arm • Lower ball joint from the steering knuckle • Tie rod end from the steering knuckle. Do not remove the nut from the tie rod end. Loosen the nut and use special tool MB991113 or MB990635 to avoid damaging the threads. • Halfshaft from the hub and knuckle using the proper puller • Front strut-to-hub and knuckle mounting bolt and nut • Hub and knuckle from the vehicle i— Do not disassemble the hub assem¬ bly. If binding or damaged, it must be replaced as a unit.

• ECLIPSE • GALANT

• Stabilizer bar • New axle nut and washer and tighten to 181 ft. lbs. (245 Nm) • Brake rotor and caliper. Torque the caliper Nm). bolts to 74 ft. lbs. (100 • Front WSS, if equipped • Front wheel

Low Rear e

r th

e ve ECLIPSE hicle

i~The hub and bearing assembly is serviced as a unit.

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Disconnect the negative battery cable. 3. Raise and safely support the vehicle. 4. Remove or disconnect the following: • Wheel and tire assembly • Rear wheel speed sensor if equipped with Anti-Lock Brake (ABS) • Brake drum. Or, if equipped with disc brakes, remove the caliper assembly and rotor. Suspend the caliper out of the way with wire. 5. On vehicles with rear disc brakes, remove the parking brake shoes. 6. On vehicles equipped with All Wheel Drive (AWD), remove the axle shaft locking nut, and using a suitable tool, separate the hub from the axle shaft. 7. Remove the hub mounting bolts from behind the backing plate and remove the hub.

• LANCER • MIRAGE

assembly and tighten the axle shaft locking nut to 145-1 88 ft. lbs. (196-255 Nm). 10. Install or connect the following: • Hub and tighten the mounting bolts to 54-65 ft. lbs. (74-88 Nm) • Parking brake shoes if equipped • Rotor and caliper or drum • Speed sensor if equipped • Wheel and tire assembly 11. Lower the vehicle to the floor. 12. Connect the negative battery cable. GALANT AND DIAMANTE 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Raise the vehicle and support safely. 3. Remove the appropriate wheel assembly. 4. If equipped with Anti-Lock Brake (ABS), remove the Vehicle Speed Sensor (VSS). 5. Remove the brake drum from the hub assembly. 6. From the back of the knuckle, remove the 4 bolts securing the hub to the knuckle. 7. Remove the hub and bearing assem¬ bly from the knuckle. (-►The hub assembly is not serviceable and should not be disassembled.

8. If replacing the hub, use special socket MB991248 and a press, to remove the wheel sensor rotor from the hub. To install

9. Press the wheel sensor rotor onto the hub. • Hub to the knuckle and tighten the

(-►The rotor for the ABS must be removed and installed using a press.

mounting bolts to 54-65 ft. lbs. (74-88 Nm) • Brake drum on the hub

To install:

I 8. Press the rotor (ABS) to the hub. nstall 9. On vehicles with AWD, engage the or con nec tth splines of the axle shaft with the hub e

• VSS, if equipped with ABS • Wheel assembly and lower the vehicle fol

low

ing

:

To install:

4. Install or connect the following: • Hub and knuckle assembly • Front strut-to-hub bolt and nut. Torque to 123 ft. lbs. (167 Nm). • Halfshaft • Tie rod end. Torque the nut to 19 ft. lbs. (25 Nm). • Lower control arm ball joint. Tighten the nut to 19 ft. lbs. (25 Nm).

IIUU

7923PGC7

Use a press to remove the speed sensor rotor from the hub— Galant

-.

- MIRAGE

< Vehicles with drum brake> 74-88 Nm 54-65 fLIbs

74-88 Nm 84—88 tLNM

49-89 36-43 (Lib*

1. 2. 3. 4. 5. 6. 7. 8.

Rear speed sensor cVehicles with A.B.S> Caliper assembly Brake drum Brake disc Clip mounting bolt Shoe and lining assembly Rear hub assembly Rotor 7923PGC8

Exploded view of the rear hub/bearing assembly and related components— Galant

LANCER & MIRAGE i**The wheel bearing is serviced by replacement of the hub.

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. If equipped with Anti-Lock Brake (ABS), remove the wheel speed sensor. 3. Raise and safely support the vehicle. 4. •Remove or disconnect the following: Rear wheel • Caliper and brake disc or brake drum • Dust cap and flange nut • Rear hub assembly To install:

REMOVAL

STEPS

1. 2.

REAR DRUM HUB CAP

3. 4.

SELF-LOCKING NUT REAR HUB ASSEMBLY

5.

ABS

6.

ABS> HUB BOLT

ROTOR

5. Install or connect the following: • Rear hub assembly using a new • flange Dust canut. p Torque the flange nut to 130 ft. lbs. (180 Nm).

The wheel hub bearing assembly is of wire 0 not repairable; it must be replaced • Brake caliper support when defective. . • Disc brake pads To install: • Brake rotor 5 4. If equipped with drum brakes, p»lf the vehicle is equipped with ABS, remove or disconnect the following: the sensor ring must be removed and • Brake drum installed on the new hub. • Brake shoe assembly, if necessary • Grease cap 6. Apply oil to the threaded portion of the and both sides of the plain washer. spindle 5. Remove the cotter pin, wheel bear¬ 7. Install the wheel hub bearing . locknut, washer and the wheel hub ing bearing assembly. A slide hammer may be assembly, the washer and the wheel bear¬

ing locknut. Torque the wheel bearing locknut to 138-188 ft. lbs. (187-255 Nm). 8. Verify that the wheel bearings oper¬ ate smoothly. 9. Install or connect the following: • New cotter pin into the spindle to hold the wheel bearing locknut

wheel hub bearing assembl and check the y axial Inesnd-pla It should be less than 0.0020 l a yd.ial cap in. (0.•0t5almGrease microme m). ter to the reaif • ABS sensor and its wiring, r removed • Brake assembly and the wheels

BRAKES

• Front wheels • Brake fluid hose • Pin bolts

REMOVAL & INSTALLATION

Altima, Maxima and Sentra

• Caliper assembly from the vehicle To install:

FRONT

ttihoen precaut .

ions

• New pads, new shims and pad retainers • Brake caliper and torque the pin bolts to 23 ft. lbs. (31 Nm) • Brake line to the caliper, using new

ing:2. Remove or disconnect the follow¬

Brake Caliper

of this sec¬ in the begi nnin g

copper washers, and torque the connecting bolt to 12-14 ft. lbs. • (17-20 Wheels Nm).

3. Use a large C-clamp to press the caliper piston back into the caliper. 4. Install or connect the following:

the mas c as nec ess ter ylind er ary . Ble

e, r

ed t

efer

he b

rak

e sy

ste

m an

dt

op o

to

® ©

Main pin Pin boot Torque member fixing bolt

©

Torque member

©

© Shim cover' shim" ©© Inner Inner pad

Front brake caliper— Sentra

Bleed valve © Cyli nder body ©

@ ©

Pad retainer Outer pad shigm bolt Outer nectin Con

@

Piston seal

@ ©

Copper washer Main pin bolt

© @

n spring Pad boot Pistonretur

© ©

©

Piston

93016G51

ff

23-96

NISSAN ALTIMA • MAXIMA • SENTRA

REAR

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Rear wheels • Parking brake cable and the lock spring • Brake fluid hose from the caliper • Caliper pin bolts and remove the caliper

To install: 3. Turn the piston clockwise back into the caliper body. Remove some brake fluid from the master cylinder, if neces¬ sary. Take care not to damage the piston boot.

4. Coat the pad contact area on the mount¬ ing support with a silicone based grease. 5. Install or connect the following: • New pads, shims and the pad springs

Caliper body into position and torque the caliper pin bolts to 16-23 ft. lbs. (22-31 Nm) • Brake fluid hose, using new copper washers, and tighten the flare nut to 12-1 4 ft. lbs. (17-20 Nm) • Lock spring and the parking brake cable 6. Bleed the brake system and top off the master cylinder as necessary. 7. Replace the wheels.

25 -29 (2.5 -3.0, 18-22)

S)(®7 -9 (0.7-0.9,61 -78)

DOBa

: N’f1' (kg-m, ft-lb) : N-m (kg-m, in-lb)

(P) : PBC (Poly Butyl Cuprysll) grease or silicone-based grease point R): Rubber grease point

■[0)38-52 (3.9-5.3,28-38)

c g Brake fluid point (T) Cable guide

(D Cylinder body (D Toggle lever

Pin @ Pin (?) boot (?) Torque member (7) Retainer (?) Inner shim (?) Inner pad (10) Pad retainer ©

Outer pad

Rear disc brakes — Sentra shown

©

Outer shim

© ©

ut String O-r

© @ ©

Push rod Key plate Snap ring

© © @ @

Seat Spring Spring cover Snap ring

©

Piston seal

©

Snap ring

© @

e washer Wav Spacer

@ ©

ing Spacer Bear

© @

Adjuster Cup

© Piston boot © Piston © Air bleeder

9301 6G52

NISSAN 0Q.Q7

up

Nm) • SENTRA ALTIMA • MAXIMA

6 Disc Brake Pads . REMOVAL & INSTALLATION Sentra FRONT 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Wheels • Bottom guide pin from the caliper up and swing the caliper cylinder body • Brake pad retainers and the pads To install: 3. Compress the piston of the disc brake caliper. 4. Install or connect the following: • Brake pads, shims, and retainers • Caliper assembly. Torque the guide pinto 23-30 ft. lbs. (31-41 Nm). • Wheels 5. Check the master cylinder and add fluid if necessary. REAR 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Wheels • Parking brake cable bracket bolt • Pin bolts and lift off the caliper body

• Wheels • Bottom guide pin from the caliper and swing the caliper cylinder body • Brake pad retainers and the pads To install: 3. Compress the piston of the disc brake caliper. 4. Install or connect the following: • Brake pads, retainers, and caliper assembly. Torque the guide pin to • 16-23 Wheels ft. lbs. (22-31 Nm). 5. Check the master cylinder and add fluid if necessary. REAR

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Rear wheels body • Parking brake cable bracket bolt • Pin bolts and lift off the caliper • Pad springs by pulling them out Pads and shims To install: 3. Turn the piston clockwise back into the caliper body. Take care not to damage the piston boot. 4. Coat the pad contact area on the mounting support with a silicone based 5. Install or connect the following: grease.

• Pad springs and the pads and shims To install: 3. Turn the piston clockwise back into the caliper body. Take care not to damage the piston boot. 4. Coat the pad contact area on the mounting support with a silicone based grease. 5. Install or connect the following: • Pads, shims and retainer springs • Caliper body into position in the mounting support and tighten the Nm) pin bolts to 28—38 ft. lbs. (38-52 • Wheels and bleed the system if necessary. Altima and Maxima FRONT

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following:

Exploded view of the rear drum brakes— Sentra

C-O

• Pads, shims, and the pad springs • Caliper body into position in the mounting support and tighten the bolts to 16—23 ft. lbs. (22-31 • pin Wheels

fluid if necessa ry. Check the mas Brake Drumster cylinder

and ad d

REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove the wheels. 3. Remove the brake drum from the brake shoes. Two 8mm x 1.25 bolts can be used to press the drum from the hub. To install: 4. Install the drum assembly to the vehicle. 5. Install the wheels. 6. Adjust the rear brakes.

Brake Shoes REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

23-98

NISSAN

ALUM A • MAXIMA • SENTRA 4 3 To install: . •. Brake drum • Parking brake cable • Return springs, adjuster assembly, the hold-down springs In•stalShoes hold-down springs, and brake shoes l or cowith nsprings, nect the by hooking them • Return • Parking brake cable from the toggle following: 2. Remo ve or disconnect into the new shoes lever the following:

(?) Wheel cylinder assembly (2) Boot (5) Piston (5) Cylinder body Rear drum brakes— Altima

• Adjuster assembly • Drums and wheels. Adjust the brakes and bleed the hydraulic sys¬ tem, if necessary.

ment. Check t he parki ng

brake ad just¬

(D Return spring

(5) Adjuster lever © Adjuster spring

(?) Shoe

© ©

(f) Spring

(?) Adjuster

hold-down pin Shoe Retainer

9301 6G55

NISSAN Frontier • Xterra BRAKES . DRIVE TRAIN . ENGINE REPAIR . FUEL SYSTEM . PRECAUTIONS . SPECIFICATION CHARTS . STEERING AND

24-55 24-43 24-15 24-40 24-15 24-2

SUSPENSION . A

24-48

Air Bag . Disarming . Precautions . Alternator . Installation . Removal . Automatic Transmission . Removal & Installation . Axle Shaft, Bearing and Seal . Removal & InstallB ation .

24-48 24-48 24-48 24-16 24-16 24-16 24-44 24-44 24-47 24-47

Brake Caliper . Removal & Installation . Brake Drums . Removal & Installation . Brake Shoes . Removal & InstallCation .

24-55 24-55 24-56 24-56 24-57 24-57

Camshaft and Valve Lifters . Removal & Installation . Clutch . Removal & Installation . CV-Joints . Overhaul . Cylinder Head . Removal & InstallD ation .

24-32 24-32 24-45 24-45 24-46 24-46 24-25 24-25

Disc Brake Pads . Removal & Installation . Distributor . Installation . Removal . E

24-55 24-55 24-16 24-16 24-16

Engine Assembly . Removal & Installation . Exhaust Manifold . Removal & Installation .

24-17 24-17 24-31 24-31

R

F

Front Crankshaft Seal . Removal & Installation . Fuel Filter . Removal & Installation . Fuel Injectors . Removal & Installation . Fuel Pump . Removal & Installation . Fuel System Pressure . Relieving . Fuel System Service Precautions . H

24-32 24-32 24-41 24-41 24-42 24-42 24-41 24-41 24-41 24-41

Halfshaft . Removal & Installation . Heater Core . Removal & Installation . Hydraulic Clutch System . Bleeding .

24-46 24-46 24-19 24-19 24-46 24-46

Ignition Timing . Adjustment . Intake Manifold . Removal & InstallLation .

24-16 24-16 24-29 24-29

Leaf Springs . Removal & Installation . Lower Ball Joint . Removal & Installation . Lower Control Arm . Control Arm Bushing

24-49 24-49 24-50 24-50 24-54

Replacement . M ation . Removal & Install

24-54 24-54

Manual Transmission . 0 ation . Removal & Install

24-43 24-43

Valve Lash . W Adjustment .

24-34 24-34

Oil Pan . Removal & Installation . Oil Pump . Removal & InstalPlation .

24-35 24-35 24-36 24-36

24-47 24-40 24-40

24-24 24-24 24-54 24-54 24-54

Pinion Seal . Piston and Ring . Positioning .

Water Pump . Removal & Installation . Wheel Bearings . Adjustment . Removal & Installation .

24-40

Rear Main Seal . Removal & Installation . Recirculating Ball Power

24-38 24-38

Steering Gear . Removal & Installation . Rocker Arms/Shafts . S tion . Removal & Installa

24-48 24-48 24-29 24-29

Shock Absorber . Removal & Installation . gs . e BearinPacking Spindl Removal, And

24-49 24-49 24-47

Installation . Starter Motor . Removal & Installation . Supercharger . T ion . Removal & Instllat

24-47 24-34 24-34 24-28 24-28

Timing Belt . Removal & Installation . Timing Chain, Sprockets, Front Cover and Seal . Removal & Installation . Torsion Bar . Transfer Case Assembly . Removal & InstallU ation .

24-38 24-38

Upper Ball Joint . Removal & Installation . . ol Arm ContrArm Control Bushing Upper

24-50 24-50 24-50

Replacement . V ation . Removal & Install

24-54 24-50

24-39 24-39 24-49 24-46 24-46

24-2

NISSAN

SPECIFICATION CHARTS ENGINE

IDENTIFICATION

AND VEHICLE

Engine Cyl. Fuel Sys. Engine Typ

Code ©

Liters (cc)

Cu. In.

KA24DE VG33E VG33ER

2.4 (2389) 3.3 (3277) 3.3 (3277)

146

4

MFI

DOHC

199 199

6 6

MFI MFI

SOHC SOHC

Model Year Eng. Mfg. Nissan Nissan Nissan

MFI: Multi-port Fuel Injection SOFIC: Single Overhead Camshaft

Code© Y

Year 2000 2001 2002

1 2 3 4

2003 2004

DOHC: Double Overhead Camshafts © Located on the timing belt cover © 10th digit of the Vehicle Identification Number (VIN)

ENGINE

GENERAL Engine Displacement

Fuel

Engine

System

Year

ivioaei

2000

Frontier Frontier Xterra Frontier

2.4 (2389)

Frontier Xterra

3.3 2.4 3.3 2.4 3.3 3.3 2.4

(3277) (2398) (3277) (2389) (3277) (3277) (2398)

VG33E KA24DE

3.3 3.3 2.4 3.3

(3277) (3277) (2389) (3277)

VG33E VG33ER KA24DE VG33E

3.3 (3277) 2.4 (2398)

VG33ER KA24DE

3.3 (3277) 3.3 (3277)

VG33E

MFI MFI MFI MFI

VG33ER

MFI

2001

2002

Xterra Frontier Frontier Frontier

Xterra Xterra Xterra 2003

Frontier Frontier Frontier Xterra Xterra

Xterra

3.3 (3277) 3.3 (3277) 2.4 (2389)

KA24DE VG33E VG33E KA24DE

VG33E KA24DE VG33E VG33ER KA24DeT

MFI MFI MFI MFI MFI MFI

SPECIFICATIONS

Net Net Horsepower Torque @ rpm

Bore x Stroke

Oil Compression Pressure 60-70@3000

143@5200

1 54@4000

3.50x3.78

170@4800 170@4800 143@5200 170@4800 143@5200

200@2800 200@2800

3.60X3.27

9.2 8.9 8.9

3.60X3.27 3.50x3.78 3.60X3.27 3.50X3.78

9.2 8.9

MFI MFI MFI

170@4800 143@5200 170@4800

MFI MFI MFI MFI

210@4800 143@5200 170@4800 210@4800

MFI

143@5200 170@4800 210@4800 143@5200 170@4800 210@4800

154@4000 200@2800 1 54@4000 200@2800 1 54@4000 - -200@2800 — - -231 @2800 1 54@4000 200@2800 231 @2800 1 54@4000 200@2800 246@2800 1 54@4000 200@2800 231 @2800

3.60X3.27 3.50x3.78 3.60X3.27 3.60X3.27 3.50X3.78 3.60X3.27 3.60X3.27 3.50x3.78 3.60X3.27 3.60X3.27 3.50X3.78 3.60X3.27 3.60X3.27

9.2 8.9 9.2 1 8.9 1 8.3 1 9.2 8.9 1 8.3 1 9.2 1 1 8.9 1 9.2 1 8.3 8.9 1 8.3:1

60-65@2000 60-65@2000 60-70@3000 60-65@2000 60-70@3000 60-65@2000 60-70@3U0U 60-65@2000 60-65@2000 60-70@3000 60-65@2000 60-65@2000 60-70@3000 60-65@2000 60-65@2000 60-70@3000 60-65@2000 60-65@2000

MFI: Multi-port Fuel Injection 42356-FRON-C02

NISSAN

OA-'i

FRONTIER • XTERRA

ENGINE

Year 2000 2001 2002

2003

Engine Displacement Liters (cc) 2.4 3.3 2.4 3.3 2.4 3.3 3.3 2.4 3.3 3.3

(2389) (3277) (2389) (3277) (2389) (3277) (3277) (2389) (3277) (3277)

TUNE-UP

Engine ID KA24DE VG33E KA24DE VG33E KA24DE VG33E VG33ER KA24DE VG33E VG33ER

(in.) 0.039-0.043 0.039-0.043 0.039-0.043 0.039-0.043 0.039-0.043 0.039-0.043 0.043 0.039-0.043 0.039-0.043 0.043

SPECIFICATIONS _

Timing Pump Ignition Fuel (deg.) AT

Gap Spark Plug

MT 18-22B 13-17B 18-22B

13-17B 18-22B 13-17B 10B 18-22B 13-17B 10B

18-22B 13-17B 18-22B 13-17B 18-22B 13-17B 10B 18-22B

(psi) © 34 34 34 34 34 35 34 34

13-17B 10B

34 35

Idle (rpm) Speed

MT 750-850 700-800 750-850 700-800 750-850 700-800 700-800 750-850 700-800 700-800

AT® 750-850 700-800 750-850 700-800 750-850 700-800

Valve Clearance (in.)

In. 0.012-0.015 HYD

Ex. 0.013-0.016

0.012-0.015 HYD 0.012-0.015

700-800 750-850 700-800 700-800

HYD HYD 0.012-0.015 HYD HYD

HYD 0.013-0.016 HYD 0.013-0.016 HYD HYD 0.013-0.016 HYD HYD

during production. The label figures must be used NOTE: The Vehicle Emission Control Information label often reflects specification changes made if they differ from those in this chart. B: Before top dead center HYD: Hydraulic

© System pressure at idle with vacuum hose connected Should increase to 43 psi when disconnected ©Automatic transmission in Neutral

Front of the FRONT

U

Of CAP

Vehicle

79243G05

79243G66

2.4L Engines

3.3L engines

Firing order: 1-3-4-2 Distributor rotation: Counterclockwise

5-6 3-41-2order Firingibuto ion: r :rotat Counterclockwise Distr

24-4

NISSAN FRONTIER • XTERRA

■H

20-25

(2.0 -2.6, 14-19)

Supercharger

Air conditioner compressor pulley

Generator pulley Power steenng ^

: Check point

pump pulley

: N m (kg-m, ft-lb)

Accessory V-belt routing — 3.3L (VG33ER) engine

Crank pulley

n 23 - 29 (2.3 - 3.0, 17 - 22) -

Tighten 42356-FR0N-G08

NISSAN

9A-R U

FRONTIER • XTERRA

CAPACITIES Engine Displacement Liters (cc)

Engine ID

Frontier Frontier Xterra Frontier

2.4 (2389)

KA24DE VG33E VG33E

Frontier Xterra Xterra Frontier Frontier Xterra Xterra Xterra Frontier Frontier Frontier Xterra Xterra Xterra

3.3 2.4 3.3 2.4

Model

Year 2000

2001

2002

2003

NOTE:

3.3 (3277) 3.3 (3277) 2.4 (2389) (3277) (2398) (3277) (2389)

3.3 (3277) 2.4 (2398)

KA24DE VG33E KA24DE VG33E KA24DE VG33E KA24DE

3.3 (3277) 3.3 (3277) 2.4 (2389)

VG33E VG33ER KA24DE

3.3 (3277) 3.3 (3277) 2.4 (2398)

VG33E

3.3 (3277) 3.3 (3277)

VG33ER KA24DE VG33E VG33ER

Engine Oil with Filter

Transmission 5-Spd

T ransfer Case

Front

— (pts.) 4.8

— (Pts.) 2.8

4.8 —

— 2.8

16.8 —

4.8 —

2.8 —

(pts.)Auto. —

(qts.) © © © © ©

4.25

3.75 3.8

8.5 © 4.25

© —

4.8 — 4.8

4.4 —

© 8.5

© —

—

— 5.8

© ©

© © —

3.5 3.5 3.75 3.5 3.5 3.5 3.5 3.5 3.75 3.5 3.5

® © 4.25 ©

4.25 © © 8.5 © ©

16.8 16.8 —

© © — © ©

4.8 — 4.8

Rear © (pts.) © © © © 3.1 4.9 2.4 3.12 5.9 3.1

4.8 4.8 — 4.8

Cooling

Drive Axle

3.1 3.1 — 5.8 5.8 — 3.1

4.8 3.1

5.9 2.4 3.12 3.12 3.1 5.9

Fuel Tank 15.9 19.4 (gai.) 19.4 15.9 19.4 19.4 19.4 15.9 19.4 19.4 19.4 19.4 15.9 19.4 19.4 19.4 19.4

System 7.75 (qts.) © © 7.75 © 7.75 11.25 7.75 11.6 7.75 11.6 11.6 7.75 11.6 11.6 7.75 11.6 11.6

19.4

a proper fluid level is obtained. All capacities are approximate. Add fluid gradually and check to be sure

© 2WD:

3.75 qts.

4WD:

4.125 qts.

©H190A:

3.1 pts.

C200: 2.75 pts. H233B: 5.9 pts. ® 2WD:

4.25 pts.

4WD: © 2WD: ©

10.4 pts. 8.6 qts.; 4WD:

9.5 qts.

MT: 5.8; AT: 10.75

©MT:

17.5; AT: 18 pts. 42356-FR0N-C04

Crankshaft Journal Year 2000

Liters (cc)

ILJ/VIN

2.4 (2389)

KA24DE

3.3 (3277) 2001

2.4 (2389)

VG33E KA24DE

journal uia.

L/ICdl

di iuc

2002

©3 (3277) ©3^3277) 2003

2.4 (2389) 3.3 (3277) 3.3 (3277)

KA24DE

36092. 2.3612

0.0019 00080.

0.0071 00200.

4

1 .9675 1.9672-

0.0014 0.0004-

2.47902.4793

0.0022 00110.

0.0067 00200.

3

1.9675 1 .9967-

0.0021 0.0006-

36092. 2.3612

0.0019 00080.

0.0071 00200.

4

1.9675 1 .9672-

0.0014 0.0004-

47902. 2.4793

0.0022 0.0011-

0.0067 0.0020-

3

1 .9675 1.9967-

0.0021 0.0006-

36092. 2.3612

0.0019 00080.

0.0071 00200.

4

1 .9675 1 .9672-

47902. 2.4793 ©

0.0022 0.0011©

0.0067 0.0020-

4

1 .9675 1 .9967-

0.0021 0.0006-

0.0067 00200.

3

1 .9675 1.9667-

0.0025 0.0009-

4

1 .9675 1 .9672-

4

1 .9675 1.9967-

0.0021 0.0006-

1.9675 1 .9667-

0.0025 0.0009-

VG33E VG33ER KA24DE VG33E ~VG33E R

36092. 2.3612

0.0019 00080.

0.0071 0.0020-

47902. 2.4793 ©

00110. 0.0022 ©

0.0067 0.00200.0067 00200.

© Excep t No. 1 Grade 0: 2.4790-2.4793

©No.

1: 0.0012-0.0019

Side

3

VG33E

" 3.3(3277) 2.4 (2389)

Oil

0.0014 0.0004-

0.0014 0.0004-

0.0160 0.00800.0138

0.00790.0160 0.00800.0138 0.00790.0160 0.00800.0138 0.00790.0138 0.00790.0160

0.00800.0138 0.00790.0138 0.0079-

Nos. 2, 3,4: 0.0015-0.0026

Grade 1 : 2.4787-2,4790 Grade 2: 2 4784-2.4787 No. 1

Grade 3: 2,4683-2.4793 Grade 4: 2 4789-2.4791 Grade 5: 2.4786-2.4789 Grade 6. 2.4784-2.4786 42356- FR0N-C05

NISSAN

9A-7 1

FRONTIER • XTERRA

VALVE

Year 2000

Engine Displacement Liters (cc)

Engine ID

2.4 (2389)

KA24DE

3.3 (3277) 2001

2.4 (2389) 3.3 (3277)

VG33E

Seat Angle (deg.) 45

KA24DE VG33E

45 45

2002

2.4 (2389)

Face Angle (deg.)

Spring Test Pressure

45.5

93.9@1 .15

45 45

KA24DE

46.75 45.2545.5

3.3 (3277) 2003

2.4 (2389) 3.3 (3277) 3.3 (3277)

VG33ER KA24DE

45

VG33E

45

VG33ER

45

93.9@1 .15 ©

46.75 .2545 45.5

93.9@1 .15 ©

VG33E 45

(lbs. @ in.)

©

45 3.3 (3277)

IONS SPECIFICAT Spring

46.75 45.2546.75 45.2545.5

© [email protected] ©

46.75 45.2546.75 45.25-

©

nstalled Height (in.) NA NA NA NA NA

NA NA

Stem-to-Guide Clearance

NA

(in.)

(in.) Exhaust Intake

Intake

Exhaust

0.0021 0.0008-

0.0029 0.0016-

0.2748 0.2742-

0.2740

0.0021 0.0008-

0.0029 0.0016-

0.2748 0.2742-

0.3138 0.3135-

0.0021 0.0008-

0.0029 0.0016-

0.2748 0.2742-

0.2740

0.0021 0.0008-

0.0029 0.0016-

0.2748 0.2742-

0.0021 0.0008-

0.0029 0.0016-

0.2748 0.2742-

0.0021 0.0008-

0.0029 0.0016-

0.2748 0.2742-

0.00210.0008

0.0019 0.0012-

0.2748 0.2742-

0.0021 00080.

0.0029 0.0016-

0.2748 0.2742-

0.0021 0.0008

0.0029 0.0016-

0.2748 0.2742-

0.0021 0.0008-

0.0019 0.0012-

0.2748 0.2742-

NA NA

Stem Diameter

0.2734-

0.27340.3138 0.3135-

0.2740 0.27340.3138 0.31350.3138 0.31350.2740

0.27340.3138 0.31350.3138 0.3135-

NA: Not Available ©Inner: 57.3 @ 0.984 Outer: 1 17.7 @ 1.181 42356-FR0N-C06

24-8

NISSAN FRONTIER • XTERRA Top

PISTON

All measurements are given in inches. _

_

Year

Displacement Liters (cc)

Engine ID

2000

2.4 (2389)

KA24E

3.3 (3277) 2001

2.4 (2389) 3.3 (3277)

2002

KA24E VG33E

2.4 (2389)

KA24E

3.3 (3277)

VG33E

3.3 (3277) 2003

VG33E

2.4 (2389) 3.3 (3277) 3.3 (3277)

‘ Piston Clearance 00080. 0.0016 ©

00080. 0.0016 ©

00080. 0.0016 ©

VG33ER

ANDTopRING SPECIFICATIONS

Comp.

Ring Gap Bottom Comp. Control Oil

VG33ER

0.0053 0.0026-

0.0272 0.0079-

0.0030 0.0009-

0.0028 0.0012-

0.027 0.018-

0.027 0.008-

0.0031 0.0016-

0.0028 0.0012-

0.0073 0.00060.0053

0.0157 00830.

0.0272 01970.

0.0272 0.0079-

0.0030 0.0009-

0.0028 0.0012-

0.021 0.011-

0.027 0.018-

0.027 0.008-

0.0031 0.0016-

0.0028 0.0012-

0.0157 00830.

0.0272 0.0197-

0.0272 0.0079-

0.0030 0.0009-

0.0028 0.0012-

0.0073 0.0006-

00830. 0.0122

0.0236 0.0197-

0.0236 0.0079-

0.0031 0.0016-

0.0028

0.021 0.011-

0.027 0.018-

0.0031 0.0016-

0.0157 00830.

0.02720.0197

0.027 0.0080.0272 0.0079-

0.0028 0.00120.0028 0.0012-

0.0073 0.00060.0053

0.0236 01970.

0.0236 0.0079-

0.0031 0.0016-

0.027 0.008-

00830.0157 0.

0.0272 01970.

0.021 0.011-

© 0.0122 00830.

(D Except cylinders 3 and 4: 0.0010 - 0.0018 in.

Ring Side Clearance Comp. Bottom Control Oil 0.0028 0.0012-

0.027 0.018-

KA24E VG33E

Comp.

0.0031 0.0016-

0.021 0.011-

©

00080. 0.0016 ©

_ _

0.0030 0.0009-

0.0012-

0.0028 0.0012-

0.00260.0073 0.00060.0053 0.0026-

0.00260.0073

0.00060.0073 0.0006-

Cylinders 3 and 4: 0.0006 - 0.0010 in.

© Cylinders 3, 4: 0.0006-0.0010 in. Cylinders 1, 2, 5. 6: 0.0010-0.0018

in. 42356-FR0N-C07

Lug

NISSAN FRONTIER • XTERRA

TORQUE Engine Displacement Liters (cc)

Year 2000

2.4 3.3 2.4 3.3 2.4

2001 2002

(2389) (3277) (2389) (3277) (2389)

3.3 (3277) 3.3 (3277) 2.4 (2389)

2003

3.3 (3277) 3.3 (3277)

Engine ID

Cylinder Head Bolts

KA24DE VG33E

©

KA24DE VG33E KA24DE VG33E

©

VG33ER KA24DE VG33E

©

VG33ER

©

All readings in ft. lbs. Rod Main Bearing Bearing Crankshaft Damper Flywheel Bolts Bolts Bolts Bolts

© © © ©

© ©

34-41 67-74 34-41 67-74 34-41 67-74 67-74 34-41 67-74 67-74

© Step 1 : 22 ft. lbs. Step 2: 59 ft. lbs.

Step 3. Loosen completely then retorque to 22 ft. lbs. Step 4: 18-25 ft. lbs. Step 5: Plus 86-91 degrees ©10-12

24-9

SPECIFICATIONS

ft. lbs. plus 60-65 degrees or 28-33 ft. lbs.

together © The cylinder heads and the lower intake manifold are installed Step 1 : Tighten the cylinder head bolts to 22 ft. lbs.

Step 2: Tighten the cylinder head bolts to 43 ft. lbs. Step 3: Loosen the cylinder head bolts completely Step 4: Tighten the cylinder head bolts to 84 inch lbs.

lbs. Step 5: Tighten the intake manifold fasteners to 35 inch Step 6. Tighten the intake manifold fasteners to 1 3 ft. lbs.

ft. lbs. Step 7: Tighten the intake manifold fasteners to 12-14 y completel fasteners manifold intake Step 8: Loosen all Step 9: Tighten the cylinder head bolts to 22 ft. lbs.

Step 10. Tighten the cylinder head bolts 60-65 degrees inch lbs. Step 11: Tighten the cylinder head sub-bolts to 80-105 lbs. inch Step 12: Tighten the intake manifold fasteners to 35 inch lbs. Step 13: Tighten the intake manifold fasteners to 78 inch lbs. Step 14: Tighten the intake manifold fasteners to 70-84

© © © © ©

105-112 141-156

105-112 61-69

105-112 141-156

105-112 61-69 105-112

105-112 141-156 141-156

© © © © © ©

105-112 141-156

61-69 61-69 105-112 61-69

141-156

61-69

Plugs Manifold Intake Exhaust 27-35 12-14 © 21-25 27-35 12-14 © 21-25 27-35 12-14 © 21-25 © 21-25 27-35 12-14 © 21-25 © 21-25

10-12 ft. lbs . +60-65 degrees

Spark 14-22 14-22 14-22 14-22 14-22 14-22 14-22 14-22 14-22 14-22

Nuts 87-108 87-108 87-108 87-108 87-108 87-108 87-108 87-108 87-108 87-108

24-10

NISSAN FRONTIER • XTERRA

WHEEL

Year

Model

2000

Frontier

2.4L

Xterra

3.3L ALL

Frontier

2.4L

2001

2002

2003

Xterra Frontier

3.3L ALL 2.4L

Xterra Xterra

3.3L 2WD 4WD

Frontier

2.4L

Xterra

3.3L 2WD 4WD

Xterra

ALIGNMENT

Camber Caster Setting Preferred Preferred Range Setting Range (+/-Deg.) (+/-Deg.) +0.42 (Deg.) (Deg.) +0.60 +0.60 0.50 0.50 +2.17 +0.42 0.50 0.50 +0.60 +0.42 0.50 0.75 +0.60 +0.60 0.50 +2.17 0.50 +0.42 0.50 +0.60 0.50 0.50 +0.42 0.75 +0.60 +0.60 0.50 0.50 +2.17 +0.33 0.50 0.50 +2.57 +0.60 0.50 0.50 +2.10 +0.42 0.50 +0.60 0.50 +0.60 0.50 0.50 +2.17 +0.33 0.50 0.50 +2.57 +0.60 +2.10 0.50 0.50 0.50 0.50

Axis Toe-in (in.)

Inclination (Deg.) —

0.12+/-0.04 0.16+/-0.04

—

0.12+/-0.04 0.12+/-0.04

—

0.16+/-0.04 0.12+/-0.04 0.12+/-0.04 0.16+/-0.04 0.16+/-0.04 0.16+/-0.04 0.12+/-0.04 0.16+/-0.04 0.16+/-0.04 0.16+/-0.04

—

—

— —

—

—

—

—

—

—

—

42356-FR0N-C09

NISSAN FRONTIER • XTERRA

TIRE, WHEEL

AND OEM

2000

Model Frontier 2wd 4-Cyl.

BALL JOINT SPECIFICATIONS _

P215/75R15 P235/70R15 ;I" P235/70R15 None

Frontier 4wd SE

P255/65R16

Xterra

P235/70R15

Frontier 2wd 4-Cyl.

P265/70R15

Frontier 2wd 6-Cyl. Frontier 4wd XE

2002

P265/70R15

j

P235/70R15 None

Frontier 4wd SE

P255/65R16

Xterra

P235/70R15

P265/70R15

Frontier 2wd 4-Cyl.

P225/70R15

None

Frontier 4wd 6-Cyl.

P255/65R16

None

Frontier 2wd SC 6-Cyl.

P265/55R17

None

Frontier 4wd SC 6-Cyl

P265/65R17

None

Inspection U: 0.020 in. L:©

30 26

26

7JJ

L:© U: 0.020 in.

26

7JJ

L:© U: 0.020 in.

29

6JJ

L:© U: 0.020 in.

26

7-JJ 6.5JJ/7JJ

L:© U: 0.020 in.

26 26 26

;

U: 0.020 in. L:©

26 30

U: 0.020 in.

;

|

P235/70R15 P215/75R15

Size 6JJ

|

J

P215/65R15

Ball Joint

7-JJ 6.5JJ/7JJ

26

P265/70R15

Wheel

Rear 29

Front 26

Standard_ Optional P215/65R15 1 None

None 2001

Tire Pressures (psi)

Tires

Frontier 2wd 6-Cyl. Frontier 4wd XE

24-11

30

L:© U: 0.020 in.

30

i

;

26

7JJ

L:© U: 0.020 in.

26 26

26

7JJ

L:© U: 0.020 in. L:©

©

©

NA

©

©

NA

©

©

NA

©

©

©

©

NA NA

©

NA

L:© U: 0.020 in.

!

U: 0.020 in. L:© U: 0.020 in. L:© U: 0.020 in. L:© U: 0.020 in. L:© U: 0.020 in.

Frontier 4wd XE 6-cyl.

P265/70R15

None

Frontier

P265/70R15

None

6-Cyl. XE Desert Runner Frontier

P255/65R16

None

©

©

NA

L: © U: 0.020 in.

6-Cyl. SE Desert Runner Frontier SE V6

P265/70R16

None

© j ©

©

NA

L:© U: 0.020 L:© in.

Frontier

P265/55R17

None

©

©

NA

2wd SC V6 Crew Cab Frontier

P265/65R17

None

©

©

NA

4wd SC V6 Crew Cab Xterra SE, SE S/C, and XE S/C

P265/70R16

None

©

©

7JJ

Xterra XE, XE V6

P265/70R15

|

None

1

©

1

U: 0.020 in. L:© U: 0.020 in. L:© © 1

©

1

7JJ

© 42356-FR0N-C10

1 9 NISSAN

OA

LL I" I L FRONTIER • XTERRA ■ ■■ ' — J w OEM Standard P225/70R15

Model

Year 2003

Frontier 2wd 4-Cyl.

Tires Optional None

Tire Pressures (psi) Front Rear © ©

None

©

©

NA NA

Ball Joint Inspection U: 0.020 in. L:© U: 0.020 in. L:©

Frontier 4wd 6-Cyl.

P255/65R16

Frontier 2wd SC 6-Cyl.

P265/55R17

None

©

©

NA

U: 0.020 in.

Frontier 4wd SC 6-Cyl

P265/65R17

None

©

©

NA

L:© U: 0.020 in.

Frontier 4wd XE 6-cyl.

P265/70R15

None

©

©

Frontier

P265/70R15

None

©

©

NA NA

6-Cyl. XE Desert Runner Frontier

P255/65R16

None

©

©

NA

U: 0.020 in.

6-Cyl. SE Desert Runner Frontier SE V6

P265/70R16

None

©

©

NA NA

L:© U: 0.020 in. L:©

P265/55R17

None

©

©

P265/65R17

None

©

©

Xterra SE, SE S/C, and XE S/C

P265/70R16

None

©

©

Xterra XE, XE V6

P265/70R15

None

©

©

Frontier 2wd SC V6 Crew Cab Frontier

Original Equipment

PSI: Pounds

L:© U: 0.020 in. L:© U: 0.020 in. L:©

U: 0.020 in. NA 7JJ

4wd SC V6 Crew Cab

OEM:

Wheel Size

7JJ

L:© U: 0.020 in. L:© ©

©

Manufacturer

Per Square Inch

STD: Standard OPT : Optional L: Lower U: Upper

© Replace if any measurable

movement

is found.

© See placard on vehicle ® Axial play Upper: 0 Lower: 0.008 in. 42356-FR0N-C11

NISSAN

24-13

FRONTIER • XTERRA

BRAKE

Year 2000 2001 2002 2003

Model Frontier Xterra Frontier Xterra Frontier Xterra Frontier Xterra

SPECIFICATIONS

All measurements in inches unless noted Brake Drum Diameter Maximum Brake Disc Max. Original Machine Inside Maximum Minimum Wear Original Limit Runout Diameter Thickness Thickness Diameter NA © © 0.003 © © © © © 0.003 NA NA © © © 0.003 © © © © 0.003 © NA NA © © © © 0.003 NA 11.67 0.003 11.61 1.100 1.024 NA © 0.003 NA © © NA 11.67 0.003 1.024 1.100 11.61

Lining Minimum Thickness Front Rear 0.079 0.059 0.079 0.059 0.079 0.059 0.079 0.059 0.079 0.059 0.079 0.059 0.079 0.059 0.079 0.059

Brake Caliper Bracket Mounting BOltS Bolts (ft. lbs.)

(ft. lbs.)

53-72 53-72 53-72 53-72 53-72

24-31 24-31 24-31

©

©

©

24-31 17-22 © 17-22 ©

NA: Not Available © 2WD: 4WD: ©2WD: 4WD:

0.870 1.020 0.787 0.945

® 2WD: 4WD: ©2WD: 4WD:

10.20

©Torque

member

mounting bolt: 101-130

11.60 10.30 1 1 .67

Main pin bolt: 17-22 ©4-cyl.: 0.945 6-cyl.: 1.024

® 4-cyl.: 10.30 6-cyl.: 11.67 © 4-cyl.: 53-72 ft. lbs. 6-cyl.: 101-130 ft. lbs. 42356-FR0N-C12

0/1 1/1 NISSAN

£.4“

FRONTIER • XTERRA

SCHEDULED

INTERVALS

MAINTENANCE VEHICLE

TYPE OF SERVICE R

TO BE SERVICED Fnnine

nil & filter

Brake lines & cables

S/I

Brake pads, discs, drums & linings

S/I

Driveshaft boots & propeller shaft

S/I

Front wheel bearings (4x2)

S/I

Front wheel bearings (4x4)

S/I

Automatic & manual transmission, transfer & differential gear oil ©

7.5 y

S/I

Air cleaner filter Fngine coolant

PCV filter (KA24E)

30

15 ✓

22.5 ✓

45

60

✓

✓

V

y

y

✓

52.5 ✓

✓

75 (xIOOO)

67.5 ✓

✓

y

82.5

90

y

Z

y

y

y y

✓

✓

y

y

✓

Z

V

y

✓

y

y

✓

R R

y

Z

y

Z

R

y

R

y

z

✓

z y

y

FYhanst

y

S/I

y

S/I

y

svstem

Pi ipI lines

Steering gear (box) & linkage, axle & suspension parts

z z y

✓

S/I

\/annr lines

J

S/I R

Timing belt ©

z

y

✓

97.5

✓

S/I

z

y

S/I: Service or Inspect

oil every 30,000 miles. © Differential (w/limited-slip differential) oil: replace ©Timing belt: replace at 105,000 miles.

FREQUENT

INTERVAL

37.5

Driue helt(s)

R: Replace

MILEAGE

OPEFIATION

MAINTENANCE

(SEVERE

SERVICE)

conditions it is considered severe service: If a vehicle is operated under any of the following - Extremely dusty areas.

. .

.„«c.

tures be ow or higher temperatures, or constant operation in tempera - 50% or more of the vehicle operation is in 32'C (90»F) - Prolonged idling (vehicle operation in stop and go traffic). to normal operating temperatures). - Frequent short running periods (engine does not warm - Police, taxi, delivery usage or trailer towing usage. Oil & oil filter: replace every 3750 miles.

inspect every 7500 miles. Brake pads, discs, drums & linings: service or every 7500 miles. Driveshaft boots & propeller shaft service or inspect miles. Exhaust system: service or inspect every 7500

every 7500 miles. 4x4), axle & suspension parts: service or inspect Steering gear (box) & linkage, (steering dampermiles. ball joints: service or inspect every 7500 Steering linkage ball joints & front suspension 42356-FR0N-C13

NISSAN FRONTIER • XTERRA

24-15

PRECAUTIONS Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle:

• Never open, service or drain the radia¬ tor or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. • Observe all applicable safety precau¬ tions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. • Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. • Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If

eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance. • The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas as soon as possible after expo¬ sure to used engine oil. Soap and water, or waterless hand cleaner should be used. • All new vehicles are now equipped with

proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also,

an air bag system. The system must be dis¬ abled before performing service on or around system components, steering col¬ umn, instrument panel components, wiring and sensors. Failure to follow safety and dis¬ abling procedures could result in accidental air bag deployment, possible personal injury and unnecessary system repairs. • Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed

important! Many models utilize an interfer¬ ence-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing poten¬ tially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of

away from your body. When placing a nondeployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section. • Clean, high quality brake fluid from a sealed container is essential to the safe and

do not allow any brake fluid to come in con¬ tact with a painted surface; it will damage the •paint. Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine damage. • Timing belt maintenance is extremely

this manual for the recommended replace¬ ment interval for the timing belt, and to the timing belt section for belt replacement and inspection. • Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer sys¬ tem^) and may require the computer to undergo a relearning process once the neg¬ ative battery cable is reconnected. • When servicing drum brakes, only dis¬ assemble and assemble one side at a time, leaving the remaining side intact for refer¬ ence.

ENGINE REPAIR ^Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board com¬ puter system. The computer may undergo a relearning process once the negative battery cable is reconnected.

Distributor REMOVAL

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Negative battery cable • Distributor cap • Distributor wiring harness connector 3. Matchmark the rotor to the distributor housing and the distributor housing to the cylinder head. 4. Remove the distributor.

INSTALLATION Timing Not Disturbed 1 . Install or connect the following:

• Distributor by aligning the matchmarks made during removal • Distributor wiring harness connec¬ tor • Distributor cap

3. Check that the distributor rotor is aligned, as shown. 4. •Install or connect Distributor cap the following: • Distributor harness connector 5. Check the ignition timing and adjust, as necessary.

Distributor

• Negative battery cable 2. Check the ignition timing and adjust, as necessary. Timing Disturbed 2.4L ENGINE

1 . Set the engine to Top Dead Center (TDC) of the compression stroke for the No. 1 cylinder. 2. Install the distributor so that the distrib¬ utor shaft engages the oil pump driveshaft.

9308VG01

Distributor rotor alignment with the engine at Top Dead Center (TDC)— 2.4L engine

3.3L ENGINE

1 . Set the engine to Top Dead Center (TDC) of the compression stroke tor the No. 1 cylinder. 2. Align the index mark on the distribu¬ tor shaft with the protrusion on the distribu¬ tor housing.

Rotor head position (No. 1 cylinder at 1DOY

y 9308VG03

Distributor shaft alignment— 3. 3L engine

3. Install the distributor and check that the distributor rotor is aligned. 4. Install or connect the following: • Distributor cap • Distributor harness connector 5. Check the ignition timing and adjust, as necessary. Alternator

REMOVAL 2.4L Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Engine under cover • Right splash shield • Alternator harness connectors • Alternator belt • Alternator

Distributor rotor alignment — 3.3L engine

INSTALLATION 2.4L Engine

1. Install or connect the following: • Alternator

. Alternator belt. Tighten the adjust¬ ment bolt to 12-14 ft. lbs. (16-19 Nm) and the pivot bolt to 32-38 ft. lbs. (44-52 Nm). • Alternator harness connectors • Right splash shield • Engine under cover • Negative battery cable 3.3L Engine

1. Install or connect the following: • Alternator

• Alternator belt. Tighten the adjust¬

3.3L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Alternator harness connectors • Engine under cover • Alternator belt • Alternator Timing indicator— 3.3L engine shown

ment bolt to 12-14 ft. lbs. (16-19 to 16-22 the pivot Nm)lbs.and(22-30 ft. Nm).bolts Engine under cover Alternator harness connectors Negative battery cable Ignition Timing ADJUSTMENT i-Hgnition timing is set with the engine at operating temperature, transmission in Neutral and all electrical acces¬ sories OFF.

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

NISSAN FRONTIER

2. Attach a timing light to the No. 1 spark plug wire. 3. Start the engine and allow it to reach normal operating temperature. 4. Check that the idle speed is less 5 than 1000 rpm. 5. Run the engine at 2000 rpm for 2 minutes. 6. Rev the engine to 3000 rpm 2-3 times and allow it to idle for 1 minute. . 7. Check for the presence of Diagnostic Trouble Codes (DTC) and service as neces¬ sary. 8. Run the engine at 2000 rpm for 2 minutes. 9. Stop the engine and disconnect the Throttle Position (TP) sensor. 10. Start the engine and rev it to 3000 rpm 2-3 times and allow it to idle. 11. Set the base timing to 8-12 degrees Before Top Dead Center (BTDC). 12. Tighten the distributor lockbolt to 83-113 inch lbs. (9-13 Nm). 13. Set the base idle speed to 700-800 rpm. 14. Stop the engine and connect the TP sensor.

24-17

• XTERRA

• Mass Air Flow (MAF) sensor con¬ nector • Brake booster vacuum line • Fuel lines

Engine Assembly REMOVAL & INSTALLATION

• Exhaust Gas Recirculation (EGR) Frontier

• temperature Throttle cablesensor connector

2.4L ENGINE

• Accessory drive belts • Radiator and hoses • Heater hoses

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: • Hood Negative battery cable • Air cleaner assembly • Idle Air Control (IAC) valve and solenoid connectors • Throttle Position (TP) sensor and switch connectors • Engine Coolant Temperature (ECT) sensor connector • Manifold Absolute Pressure (MAP) sensor connector and vacuum line • Evaporative Emissions (EVAP) can¬ ister purge valve connector and vacuum line

• • •

Exhaust manifold heat shield Heated Oxygen (HO2S) sensor con nectors Exhaust front pipe

• • • • • ••

A/C compressor, if equipped Power steering pump, if equipped Crankshaft Position (CKP) sensor Starter motor Transmission Engine Left and right engine mounts

To install:

• Engine. Tighten the engine mount nuts to 30-38 ft. lbs. (41-52 Nm) • Transmission

Inst

all

• Starter motor or c• CKP sensor onn ect the foll owin g:

(4.2 - S J, 30 • 38) - 8.3. 30

[0)41 -52

J(4i-BJ.30

- 38l

{0)41-82

N«n tkg-m.ft-W 7924VG05

Engine and transmission mounts— 2. 4L engine

24-18

NISSAN FRONTIER

• XTERRA

Power steering pump, if equipped A/C compressor, if equipped Exhaust front pipe 6 HO2S sensor connectors Exhaust manifold heat shield Heater hoses Radiator and hoses . Accessory drive belts Throttle cable EGR temperature sensor connector Fuel lines Brake booster vacuum line MAF sensor connector

3. Relieve the fuel system pressure. 4. Recover the A/C refrigerant, if equipped. 5. Remove or disconnect the following: • Hood Negative battery cable

EVAP canister purge valve connec¬ tor and vacuum line MAP sensor connector and vacuum line ECT sensor connector TP sensor and switch connectors IAC valve and solenoid connectors Air cleaner assembly Hood Negative battery cable 6. Fill the cooling system. 7. Start the engine and check for leaks. 3.3L Engine

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system.

(O) : N»m

• Air cleaner assembly • Idle Air Control (IAC) valve and solenoid connectors • Throttle Position (TP) sensor and switch connectors • Engine Coolant Temperature (ECT) sensor connector • Manifold Absolute Pressure (MAP) sensor connector and vacuum line • Evaporative Emissions (EVAP) can¬ ister purge valve connector and vacuum line

• Mass Air Flow (MAF) sensor con¬ nector • Brake booster vacuum line • Fuel lines • Exhaust Gas Recirculation (EGR) • • • • • •

temperature sensor connector Throttle cable Accessory drive belts Cooling fan and shroud Radiator and hoses Engine under cover A/C compressor manifold

• Power steering pump

• Heated Oxygen (HO2S) sensor con¬ nectors

• Exhaust front pipes

• Crankshaft Position (CKP) sensor • Starter motor

• Transmission •• Engine Left and right engine mounts ^When removing the engine mounts, do not loosen the 4 mount cover nuts. The mount is fluid filled and will not function if the fluid leaks out. To install:

• Engine. Tighten the engine mount nuts to 43-58 ft. lbs. (59-78 Nm). • Transmission Insta ll•or Starter motor co • CKPnnecsensor t th e fo pipes • Exhaust front llow ing: •• HO2S sensor connectors Power steering pump • A/C compressor manifold • Engine under cover • Radiator and hoses • Cooling fan and shroud • Accessory drive belts • Throttle table

(kg-m, fl-lb) 7924VG1 1

Engine mounts and related components — 3.3L engine

: NISSAN FRONTIER • XTERRA

a . 4. Before disconnecting fuel hose, EGR* temperature sensor connector Fuel lines release fuel pressure from fuel line. 5. Remove radiator with shroud and Brake booster vacuum line MAF sensor connector cooling fan. 6. Remove drive belts. • EVAP canister purge valve connec¬ tor and vacuum line 7. Discharge refrigerant. • MAP sensor connector and vacuum 8. Remove A/C compressor manifold. line 9. Remove power steering oil pump • ECT sensor connector from engine. * 10. Remove front exhaust tubes. • TP sensor and switch connectors • IAC valve and solenoid connectors 1 1 . Remove transmission from vehicle. • Air cleaner assembly 12. Install engine slingers. Tighten the • Flood slinger bolts to 15-20 ft. lbs. (20-26 Nm). 13. Hoist engine with engine slingers • Negative battery cable 7. Fill the cooling system. and remove engine mounting nuts from both sides. 8. Recharge the A/C system, if equipped. 14. Lift and remove engine from leaks. for 9. Start the engine and check vehicle. Xterra 15. Installation is the reverse of removal. • • • •

*>Do not loosen front engine mounting insulator cover securing bolts. When cover is removed, damper oil flows out and mounting insulator will not func¬ tion.

See the accompanying illustration for instal¬ lation torques.

1. Remove engine undercover and hood. 2. Drain coolant from cylinder block and radiator. 3. Remove vacuum hoses, fuel tubes, wires, harnesses and connectors.

REMOVAL & INSTALLATION

Engine mounting — Xterra 3.3L engine

Heater Core

2000-02 Frontier and Xterra 1. Disconnect both the negative (1st) and positive (2nd) battery cables.

24-19

2. Remove the steering wheel by per¬ forming the following procedure:

urn the igni ■:TCAUTION tion switch to the OFF position. Wait 3 minutes after disconnecting the battery cables and turning the ignition switch to the OFF position before servicing the air bag system

b. Remove the lower lid and discon¬ nect the driver’s air bag module connec¬ tor. c. Remove both side lids.

t Torx® d. Using the special remove Resistan T50,Tamper size the Wrench bolts from both sides of the steering wheel and discard them. e. Remove the SRS module from the steering wheel. CA U. up TI ON Always store the SRS module face • Position the steering wheel in the straight-ahead position. g. Disconnect the horn connector and remove the steering wheel nut.

AN 24-20 NISS Side lid RH Special Bolt ®~\

^Jl5-25

ASCD ' storing'

n

Side lid LH

: N-m (kg-m, ft-lb) 93113GC3

ts Exploded view of the steering wheel and SRS module and related componen

2000-02 Frontier

h. Using a steering wheel puller, press the steering wheel from the steer¬ ing column.

3. Remove the passenger’s side air bag by disconnecting or removing the following items: a. Turn the ignition switch to the OFF position. :: CAUTION

Wait 3 minutes after disconnecting the battery cables and turning the ignition switch to the OFF position before servicing the air bag sys¬ tem.

Nut (4) 5.2 - 7.0 (0.53-0.71, 46.0 - 61 .6)

b. Open the glove box door. c. Working inside the glove box, open the lower instrument panel lid.

d. Remove the passenger’s air bag module connector clip from the lid.

ctr. the passenger’s SRS e. Disconne module connecto f. Remove the glove box and the lower passenger’s side instrument panel. g. Using the Tamper Resistant Torx® Wrench size T50, remove the SRS module-to-instrument panel special bolts and discard them. h. Remove the 4 SRS module-toinstrument panel mounting nuts. i. Release the SRS module-to-instrument panel clips and remove the SRS module.

Special bolt © - -

ft-lb) (kg-m, in-lb) N-m (kg-m, FI- : N-m ftfl : Insert front edge first

11-18) (1 .5 - 2.5, [3Jl5-25 93113GC4

Frontier View of the passenger’s side SRS module and related components— 2000-02

NISSAN FRONTIER • XTERRA

1 . Steering column cover 2. Instrument lower panel driver side 3. Cluster lid A 4. Combination meter 5. Glove box assembly 6. Passenger side air bag module 7. Instrument stay cover 8. Cluster lid C 9. Audio and deck pocket

24-21

10. ASCD main switch 11. Meter cover 12. A/C & heater control 13. Front pillar garnish 14. Instrument panel assembly 15. Center console assembly 16. Cup holder assembly 17. M/T boot assembly

93113GC5

ents— 2000-02 Frontier Exploded view of the instrument panel and related compon

2000-02 Frontier Exploded view of the heater housing, air conditioning housing and related components—

NISSAN O A

1

6

. e. Remove the 2 glove box screws ■: CAUTION and the glove box. f. Remove the 2 instrument stay Always store the SRS module face up. cover screws; then, disconnect the elec¬ trical harness connectors and remove the 4. Drain the cooling system into a clean stay cover. container for reuse. “C”rical clusterthe lidelect the 2nnect ve disco g.s;Remo then, screw 5. Working inside the engine compart¬ from ment, disconnect the 2 heater hoses harness connectors and remove the clus¬ the heater core. h. Remove the 4 audio and deck 6. Discharge and recover the air condi¬ lid “C”. ter tioning system refrigerant. then, disconnect the elec¬ screws; connectors pocket 7. Disconnect both refrigerant lines trical harness and remove the audio and deck pocket. from the evaporator core. Plug the lines to i. Disconnect the ASCD main switch prevent moisture from entering the system. connector. 8. Remove the glove box and the mat¬ ing trim. j. Remove the 2 meter cover screws; connec¬ amp then, disconnect the electrical harness 9. Disconnect the thermal tor. connectors and remove the meter cover. 10. Remove the air conditioning housing k. Remove the 4 air conditioningheater control screws; then, disconnect assembly from the vehicle. the control cables and remove the air 1 1 . Remove the instrument panel assem¬ procedure: following the bly by performing conditioning-heater control. a. Remove the 4 steering column l. Remove the front pillar garnish. remove m. Remove the 3 instrument panel and cover screws; then, separate the steering column covers. assembly nuts and 2 bolts; then, remove the instrument panel. b. Remove the 2 driver’s side lower lower 12. Remove the heater housing assembly. the and screws instrument panel instrument panel. 13. Remove the heater core from the c. Remove the 4 cluster cover screws heater housing assembly. and the cluster cover. To install: d. Remove the 6 combination meter 14. Install the heater core to the heater housing assembly. screws; then, disconnect the combination meter electrical connector and remove bly.15. Install the heater housing assem¬ the meter.

FRONTIER • XTERRA

alng l thth procedure: e einfo by perfInorstmi stll ruow mein ntg pa nepanel l asse a. Install the instrument andmbly the 3 instrument panel assembly nuts and 2 bolts. b. Install the front pillar garnish. c. Install the air conditioning-heater control, connect the control cables and install the 4 air conditioning/heater con¬ trol screws. d. Install the meter cover, connect the electrical harness connectors and install the 2 meter cover screws. e. Connect the ASCD main switch connector. f. Install the audio and deck pocket, connect the electrical harness connectors and install the 4 audio and deck pocket screws.

lid “C”, clusterconnect Installl the ors connect and harness the g.electrica lid “C” screws. the 2 cluster install h. Install the stay cover, connect the electrical harness connectors and the 2 instrument stay cover screws. i. Install the glove box and the 2 glove box screws. the com¬ meter, connect j. Install bination metertheelectrical connector and install the 6 combination meter screws. k. Install the cluster cover and the 4 cluster cover screws. l. Install the lower instrument panel and the 2 driver’s side lower instrument panel screws.

View of the heater core and heater housing — 2000-02 Frontier

t.4*

OA OA NISSAN

^L* 1 2 3 4* FRONsteering TIER •column covers m. Install the XTERRA and the 4 steering column cover

screws. 17. Install the air conditioning housing assembly to the vehicle. 18. Connect the thermal amp connec¬ tor. 19. Install the glove box and the mating trim. 20. Connect both refrigerant lines to the evaporator core. 21. Inside the engine compartment, con¬ nect the heater hoses to the heater core. 22. Refill the cooling system. 23. Install the passenger’s side air bag by performing the following procedure: a. Install the SRS module and secure the SRS module-to-instrument panel clips. b. Install the 4 SRS module-to-instrument panel mounting nuts. c. Using the Tamper Resistant Torx® Wrench size T50, install the new spe¬ cial SRS module-to-instrument panel bolts. d. Install the lower passenger’s side instrument panel and the glove box.

Connect the passenger’s SRS mod¬ ule e.connector. f. Install the passenger’s air bag module connector clip to the lid. g. Inside the glove box, close the lower instrument panel lid. h. Close the glove box door. 24. Install the steering wheel by per¬ forming the following procedure: a. Align the spiral cable pin guide and install the steering wheel by pulling the spiral cable connectors through it. b. Connect the horn connector and connect the spiral cable by aligning the pawls in the steering wheel. c. Install the steering wheel nut and torque it to 22-29 ft. lbs. (29-39 Nm). d. Install the SRS module to the steering wheel.

e. Using the Tamper Resistant Torx® Wrench size T50, install the new special bolts to both sides of the steering wheel. f. Install the lower lid and disconnect the driver’s air bag module connector. g. Install both side lids. h. Rotate the steering wheel fully right and left to make sure that the spiral cable is set in the neutral position. 25. Connect both the positive (1st) and negative (2nd) battery cables. 26. Evacuate and charge the air condi¬ tioning system refrigerant. 27. Run the engine to normal operating temperatures; then, check the climate con¬ trol operation and check for leaks.

2003 Frontier and Xterra

OiwwMr

of liquid gadcot:

1. Drain cooling system. 2. Disconnect the two heater hoses from the engine compartment side. 3. Discharge the A/C system. 4. Disconnect the two evaporator core refrigerant lines from the engine compart¬ ment side. Cap the refrigerant lines to pre¬ vent moisture from entering the system. 5. Remove the glove box and mating trim. 6. Disconnect the thermal amp. con¬ nector. 7. Remove the cooling unit. 8. Separate the cooling unit case, and remove the evaporator. 9. Remove the steering column. 10. Remove the heater unit. 11. Remove the heater core. 12. Installation is the reverse of removal. Water Pump REMOVAL & INSTALLATION 2.4L Engine 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Remove or disconnect the following: • Negative battery cable • Accessory drive belts • Cooling fan • Water pump To install: 4. Install or connect the following: • Water pump. Apply sealant and

Liquid gasket application — 2.4L engine

tighten the bolts to 12-15 ft. lbs. • (16-21 Cooling Nm). fan • Accessory drive belts • Negative battery cable 5. Fill the cooling system. 6. Start the engine and check for leaks. 3.3L Engine 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: • Negative battery cable • Accessory drive belts • Radiator hoses • • • ••

Cooling fan and shroud Water pump pulley Front cover Timing beltp Water pum

To install: 4. Install or connect the following: • Water pump. Tighten the bolts to 12-15 ft. lbs. (16-21 Nm).

NISSAN FRONTIER • XTERRA

24-25

Exploded view of the water pump assembly — 3.3L engine

• Timing belt • Front cover • Water pump pulley • Cooling fan and shroud • Radiator hoses • Accessory drive belts • Negative battery cable 5. Fill the cooling system. 6. Start the engine and check for leaks. Cylinder Head REMOVAL & INSTALLATION 2.4L Engine 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Remove or disconnect the follow¬ ing: • Negative battery cable • Air cleaner assembly • Spark plug wires • Radiator hoses • Accessory drive belts • Fuel lines • Intake manifold • Exhaust manifold • Valve cover. Remove the bolts in the sequence shown. • Camshaft sprocket cover • Camshaft sprockets and upper tim¬ ing chain 5. Wedge the lower timing chain in place to prevent the chain tensioner from expanding.

Engine

_

front Use new snaprings and plug seals for assembly.

5. Install or connect the following: • CV-joint boot • CV-joint housing • Spider assembly • Snapring. Pack the joint with grease. • CV-joint boot clamps • Plug seal 6. Install the axle halfshaft to the vehicle.

3

4 FRON * TIER • XTERRA

• Thrust washer • Inner seal • Steering knuckle • Lower ball joint • Upper ball joint or steering knuckle bracket bolts • Outer tie rod ends • Axle halfshaft • Wheel speed sensor, if equipped • Brake caliper and support • Locking hub or drive flange • Front wheel Axle Shaft, Bearing and Seal REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Rear wheel • Wheel speed sensor, if equipped • Brake drum • Brake shoes • Parking brake cable • Brake fluid line • Bearing cage and backing plate bolts • Axle shaft assembly • Axle seal • Wheel speed sensor rotor, if equipped • Lockwasher • Bearing locknut • Flat washer • Wheel bearing • Wheel bearing cage grease seal

Spindle Bearings

REMOVAL, PACKING AND INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Front wheel • Locking hub or drive flange • Brake caliper and support • Wheel speed sensor, if equipped • Axle halfshaft • Outer tie rod ends • Upper ball joint or steering knuckle bracket bolts • Lower ball joint • Steering knuckle • Inner seal • Thrust washer • Spindle bearing To install:

3. Install or connect the following: • Spindle bearing. Coat the bearing with multi-purpose grease.

O4.47

*

Pinion Seal Front

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. •Remove or disconnect the following: Driveshaft • Front wheels • Front brake calipers ^The front brake calipers must be removed so that there is no additional drag when measuring pinion bearing preload.

3. Use an inch lb. torque wrench and measure the amount of torque required to maintain pinion rotation through several revolutions. 4. •Remove disconnect the following: Pinion orflange • Oil seal To install:

5. •Install the following: Pinionor connect seal • Pinion flange 6. Rotate the pinion flange occasionally while tightening the flange nut to make sure the pinion bearings seat correctly. 7. Take frequent bearing preload torque readings. Tighten the flange nut to achieve the preload torque readings originally recorded. Do not exceed 137-180 ft. lbs. (186-245 Nm) torque when tightening the pinion •:flange nut. CAUTION

To install: '»Use new lockwashers, seals and bearings for assembly.

3. Install or connect the following: • Wheel bearing cage grease seal • Wheel bearing • Flat washer • Bearing locknut • Lockwasher • Wheel speed sensor rotor, if • equipped Axle seal • Axle shaft assembly • Bearing cage and backing plate bolts • Brake fluid line • Parking brake cable • Brake shoes • Brake drum • Wheel speed sensor, if equipped • Rear wheel

4. Bleed the rear brakes and check the rear axle lubricant level.

If the bearing preload can not be achieved at the specified torque, remove the pinion bearing and install a new adjustment spacer.

8. Install or connect the following: • Front brake calipers • Front wheels • Driveshaft. Tighten the fasteners to 29-33 ft. lbs. (39-44 Nm). 9. Fill the differential with gear lubricant and check for leaks. Rear

2 WHEEL DRIVE

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. or disconnect the following: 2. •Remove Driveshaft • Rear wheels • Brake drums

•

9 A

AQ

^4-40

NISSAN FRONTIER • XTERRA

:

^The rear brake drums must be removed so that there is no additional pinion bearing drag when measuring * preload. 3. Use an inch lb. torque wrench and measure the amount of torque required to maintain pinion rotation through several revolutions. 4. Remove or disconnect the following: • Pinion flange • Wheel speed sensor and rotor, if equipped • Oil seal • Pinion bearing • Collapsible spacer To install: ^Use a new collapsible spacer and wheel speed sensor rotor for assembly. 5. Install or connect the following: • Collapsible spacer • Pinion bearing • Pinion seal • Pinion flange 6. Rotate the pinion flange occasionally while tightening the flange nut to make sure the pinion bearings seat correctly. 7. Take frequent bearing preload torque readings. Tighten the flange nut to achieve the preload torque readings originally recorded. Do not exceed 137-180 ft. lbs. (186-245 Nm) torque when tightening the pinion flange nut.

CAUTION Never loosen the pinion nut to reduce bearing preload. If it is necessary to reduce bearing preload, install a new collapsible spacer. 8. Install or connect the following: • Brake drums •* Rear wheels • Driveshaft. Tighten the fasteners to 58-65 ft. lbs. (78-88 Nm). 9. Fill the differential with gear lubricant and check for leaks. 4 WHEEL DRIVE 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. ing:2. Remove or disconnect the follow¬ • Driveshaft • Rear wheels • Brake drums i^The rear brake drums must be removed so that there is no additional drag when measuring pinion bearing preload. 3. Use an inch lb. torque wrench and measure the amount of torque required to maintain pinion rotation through several revolutions.

ing: 4. Remove or disconnect the follow¬ • Pinion flange • Oil seal To install: 5. Install or connect the following: • Pinion seal • Pinion flange 6. Rotate the pinion flange occasionally while tightening the flange nut to make sure the pinion bearings seat correctly. 7. Take frequent bearing preload torque readings. Tighten the flange nut to achieve the preload torque readings originally recorded. Do not exceed 137-180 ft. lbs. (186-245 Nm) torque when tightening the pinion flange nut.

CA

UT

IO

If the bearingN preload can not be achieved at the specified torque, remove the pinion bearing and install a new adjustment spacer. 8. •Install connect the following: Brakeor drums • Rear wheels • Driveshaft. Tighten the fasteners to 58-65 ft. lbs. (78-88 Nm). 9. Fill the differential with gear lubricant and check for leaks.

STEERING AND SUSPENSION Air Bag ** CAUTION Some vehicles are equipped with an air bag system. The system must be disarmed before performing service on, or around, system components, the steering column, instrument panel components, wiring and sensors. Failure to follow the safety precau¬ tions and the disarming procedure could result in accidental air bag deployment, possible injury and unnecessary system repairs. PRECAUTIONS Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible per¬ sonal injury. • Never carry the inflator module by the wires or connector on the underside of the module.

• When carrying a live inflator module, hold securely with both hands, and ensure that away.the bag and trim cover are pointed • Place the inflator module on a bench or other surface with the bag and trim cover facing up. • With the inflator module on the bench, never place anything on or close to the module which may be thrown in the event of an accidental deployment. DISARMING To disarm the SRS system turn the ignition switch to the OFF position. Then, disconnect both battery cables starting with the negative cable first and wait at least 3 minutes after the cables are dis¬ connected. To rearm the SRS system, turn the igni¬ tion switch to the OFF position. Connect both battery cables starting with the positive cable first.

Steering Recirculating Power GearBall _ REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. •Remove disconnect the following: Pitman orarm • Steering column intermediate shaft • Power steering hoses • Steering gear To install: 3. Install or connect the following: • Steering gear. Tighten the bolts to 62-71 ft. lbs. (84-96 Nm). • Power steering hoses. Tighten the banjo fittings to 29-38 ft. lbs. (39-51 Nm). • Steering column intermediate shaft. Tighten the pinch bolt to 17-22 ft. lbs. (24-29 Nm). • Pitman arm. Tighten the nut to

NISSAN

3

FRONTIER • XTERRA

.

102-130 ft. lbs. (138-176 Nm) (4cyl.) or 174-195 ft. lbs. (235-265 Nm) (6-cyl.).

adjust, as necessary .

Shock Absorber

REMOVAL & INSTALLATION .C heck the wheel al Front ignment and FRONTIER

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Support the lower control arm. 3. Remove or disconnect the following: • Front wheel • Lower shock absorber mounting bolt • Upper shock absorber mounting nut • Shock absorber To install: 4. Install or connect the following: • Shock absorber • Upper shock absorber mounting nut. Tighten the nut to 12-16 ft. lbs. (16-22 Nm). • Lower shock absorber mounting bolt. Tighten the bolt to 87-106 ft. lbs. (118-147 Nm). • Front wheel XTERRA

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Support the lower control arm. 3. Remove or disconnect the following: • Front wheel • Lower shock absorber mounting bolt • Upper shock absorber mounting nut • Shock absorber To install: 4. Install or connect the following: • Shock absorber . Upper shock absorber mounting nut. Tighten the nut to 12-16 ft. lbs. (16-22 Nm). • Lower shock absorber mounting

24-49

Rear FRONTIER

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Support the rear axle. 3. Remove or disconnect the following: • Lower shock absorber bolt • Upper shock absorber bolt • Shock absorber To install: ©E®

E®(^

W

Brakeeer fluid (g) ::: Brak se tpoint greapoin E l (g) Rubb prpf grease point (kg-m, ft-lb) N-m (kg-m, ra :: Nm in-lb)

2.

Plug

Shoe (leading side)

5.

Air bleeder

Piston cup

8.

Piston

1.

Shoe hold pin

4. 7.

3. 6.

Back plate Spring

9.

Boot

10. Retainer ring

11. Toggle lever

1 2. Wave washer

13. Shoe (trailing side)

14. Adjuster 17. Piston cup

15. Boot

16. Piston 19. Adjuster lever

20. Spring seat

22. Retainer

23. Adjuster spring

o

: Always replace

18. Wheel cylinder 21. Shoe hold spring 24. Return spring (upper)

25. Return spring (lower) 42356-FR0N-G02

Rear drum brake assembly and related components— 2003 6-cyl. Frontier and Xterra

NISSAN Murano 25-50 BRAKES . 25-35 DRIVE TRAIN . 25-7 ENGINE REPAIR . 25-32 FUEL SYSTEM . 25-7 PRECAUTIONS . SPECIFICATION CHARTS . 25-2 STEERING AND 25-45 SUSPENSION . A

Air Bag . Disarming . Precautions . Alternator . Removal & InstallB atoin .

25-45 25-45 25-45 25-7 25-7

Brake Caliper . Removal & InstallC ation .

25-50 25-50

Camshaft and Valve Lifters . Inspection . Installation . Removal . Cylinder Head . Removal & InstallD ation .

25-16 25-16 25-19 25-16 25-11 25-11

Disc Brake Pads . Removal & InstallEation .

25-51 25-51

Engine Assembly . Removal & Installation . Exhaust Manifold . Removal & InstallFation .

25-8 25-8 25-14 25-14

Front Case and Seal, Timing Chain, Sprockets, Rear Case . Removal & Installation . Front Coil Spring . Removal & Installation .

25-26 25-26 25-46 25-46

Front Halfshaft . Removal & Installation . Front Halfshaft CV-Joints . Overhaul . Front Wheel Bearings . Adjustment . Removal & Installation . Fuel Injectors . Removal & Installation . Fuel Pump . Removal & Installation . Fuel System Pressure . Relieving . Fuel System Service Precautions . H

25-38 25-38 25-40 25-40 25-49 25-49 25-49 25-33 25-33 25-33 25-33 25-32 25-32 25-32

Heater Core . Removal & InstallIation .

25-9 25-9

Ignition Timing . Adjustment . Intake Manifold . Removal & Install 0 ation .

25-8 25-8 25-12 25-12

Oil Pan . Removal & Installation . Oil Pump . Removal & InstallP ation .

25-22 25-22 25-25 25-25

Piston and Ring . Positioning . Rack and Pinion Steering

25-32 25-32

Gear . Removal & Installation . Rear Coil Spring and

25-45 25-45

Lower Member . Removal & Installation .

25-46 25-46

Rear Final Drive . Removal & Installation . Rear Final Drive Seals . Removal & Installation . Rear Halfshaft . Removal & Installation . Rear Halfshaft CV-Joints . Assembly . Disassembly . Rear Main Seal . Removal & Installation . Rear Wheel Bearings . Adjustment . S tion . Removal & Installa

25-43 25-43 25-44 25-44 25-39 25-39 25-41 25-42 25-41 25-26 25-26 25-49 25-49 25-49

Shock Absorber . Removal & Installation . Starter Motor . Removal & Installation . Strut . T tion . Removal & Installa

25-46 25-46 25-22 25-22 25-46 25-46

.. Transaxle . Removal & Installation . Transfer Case Assembly . Removal & Installation . Transverse Link and

25-35 25-35 25-38 25-38

Ball Joint . W ation . Removal & Install

25-46 25-46

Water Pump . Removal & Installation .

25-10 25-10

NISSAN

25-2

MURANO

SPECIFICATION

CHARTS

IDENTIFICATION

ENGINE AND VEHICLE

Model Year

Enqine Liters (cc)

Code © VQ35DE

3.5 (3498)

Cu. In. 213

Engine DOHC

Fuel Sys. MFI

Cyl. 6

Eng. Mfg. Nissan

MFI: Multi-port Fuel Injection

Code 3 4

Year 2003 2004

DOHC: Double Overhead Camshafts 42356-MURA-C01

GENERAL Year

Engine Displacement Model Liters (cc)

2003 | Murano I 3.5 (3498)

Engine IDA/IN VQ35DE

NS ENGINE SPECIFICATIO Net

Fuel

Net

! MFI System Type

Horsepower 240@6000 @ rpm

Torque @ rpm (ft. lbs.) i 265@3200

Oil

Bore x Stroke (in.) j 3.76X3.20

Pressure Ratio pression m- [ M Co 0.0:1

MFI: Multi-port Fuel Injection

ooo

CO

@ rpm

SPECIFICATIONS

ENGINE TUNE-UP Gap Spark Plug

Year

Engine Displacement Liters (cc)

Engine ID/VIN

2003

3.5 (3498)

VQ35DE

(in.) 0.043

Valve

Pump

Timing Ignition !

15B

Fuel

51 © (psi)

Idle RPM Speed 600-700

Clearance (in.) i

In. HYD

Ex. HYD

production. The label figures must be used NOTE: The Vehicle Emission Control Information label often reflects specification changes made during if they differ from those in this chart. B. Before top dead center HYD: Hydraulic © At idle

42356-MURA-C03

NISSAN

OE.O

MURANO

L-v

CAPACITIES

Model Year 2003 | Murano

Engine Displacement Liters (cc)

Engine IDA/IN

3.5 (3498)

VQ35DE

Filter Transmission (qts.) 4.25 |

Cooling

Drive

Engine Oil with

T ransfer Case

(pts.)

Fuel

Axle Front Rear

Engine Year

Displacement Liters (cc)

Engine IDA/IN

2003

3.5 (3498)

VQ35DE

©There

AND

CONNECTING

ROD

System 9.75 (qts.)

21.6 (gai.)

obtained. NOTE: All capacities are approximate. Add fluid gradually and check to be sure a proper fluid level is

CRANKSHAFT

Tank

(pts.) 1 (pts.) 1-5 1 0.32 (pts.)

21.5

«

SPECIFICATIONS

All measurements are given in inches. Crankshaft Main Brg. Main Brg. Oil Thrust Shaft End-play on No. Clearance Journal Dia. 4 © 0.0118 00140. 0.0018

Journal Diameter ©

Connecting Rod Oil

Side

Clearance

Clearance

0.0023 0.0013-

0 0138 0.0079-

are 24 different grades, ranging from A (2.3612) to 7 (2.3603)

© Grade 0: 2.0460-2.0462 Grade 1: 2.0457-2.0460 Grade 2: 2.0445-2.0457

VALVE

Year 2003

Seat

Engine Displacement Liters (cc)

Engine IDA/IN

3.5 (3498)

VQ35DE

Angle (deg.) .1545 45.45

Face Angle (deg.) 45

42356-mura-cos

SPECIFICATIONS Spring

Spring Test Pressure (lbs. @ in.) 45.4(3)1 .457

Installed Height (in.)

Stem-to-Guide Clearance (in.) Intake Exhaust

Stem Diameter (in.) Intake

Exhaust

1.457 0.00210.0008

0.0029 0.0016-

0.2354 0.2348-

0.2346 23410. 42356-MURA-C06

25-4

NISSAN MURANO

Top

SPECIFICATIONS TRING op All measurements are given in inches. AND

PISTON

Year 2003

Engine Piston Displacement Engine IDA/IN Clearance Liters (cc) VQ35DE

3.5 (3498)

Ring Side Clearance Ring Gap_ Oil Bottom Comp. Bottom Comp. Comp. Oil Control Control

Comp.

0.00040.0012

0.0236 0.0079-

0.0189 0.0130-

0.0130 00910.

0.0031 0.0016-

0.0028 0.0012-

0.0020 0.0006-Lug 42356-MURA-C07

TORQUE

Year 2003

Engine Displacement Liters (cc)

Engine IDA/IN

3.5 (3498) |VQ35DE

SPECIFICATIONS

All readings in It. lbs. Rod Crankshaft Cylinder Damper Driveplate Head Bearing Bearing Bolts Bolts Bolts Bolts Bolts © © © Main

°-l

© Step 1 : 72 ft. lbs.

Manifold Intake Exhaust ©

14-22 | Plugs

Nuts Spark

1 21-24 |

| 61-69

90

Step 2: Loosen all bolts completely Step 3: 25-33 ft. lbs. Step 4: +90 degrees Step 5: +90 degrees © Step 1: 24-28 ft. lbs. Step 2: +90 degrees © Step 1: 15 ft. lbs. Step 2: +90 degrees © 29-36 ft. lbs. +60-66 degrees © Step 1 : 44-86 inch lbs. Step 2: 20-23 ft. lbs. 42356-MURA-C08

WHEEL

ALIGNMENT

Caster

Camber _ Preferred Preferred

Year 2003

Model Murano

Setting (Deg.)

Range (+/- Deg.) _ 0.75

|

+2.58

|

Range (+/- Deg.) 0.25

|

Kingpin

Inclination Toe-in Setting (Deg.) (in.) (Deg.) 14.33 | 0.02+/-0.04 | 0-33

NISSAN MURANO

TIRE. WHEEL

AND

OEM Year

Tires

Standard Model I P235/65SR18 | Murano

2003

25-5

BALL JOINT SPECIFICATIONS Optional none

Tire Pressures (psi) Front Rear 33 | 33 |

Ball Joint

Wheel Size

JLA

L

Inspection ©

OEM: Original Equipment Manufacturer PSI: Pounds Per Square Inch NA: Not available © Rotating torque: 5-30 inch lbs.

BRAKE

Model

SPECIFICATIONS

_ _ _ Minimum Brake Caliper Mounting Bracket Lining Rear Brake Disc _ Front Brake Disc Bolts Original Minimum Maximum Original Minimum Maximum Thickness Bolts lbs.) (ft. lbs.) (ft. Rear Thickness Thickness Runout Thickness Thickness Runout Front

'

Year

42356-mura-cio

2003 1 Murano |

_ —

1.102

All measurements in inches unless noted '

1 1.024 1 0.0016 I

0.630

| 0.551

| 0.002 | 0.079 | 0.08 | 101-129 | 17-22

25-6

NISSAN

MURANO

SCHEDULED

MAINTENANCE

INTERVALS

2003 Nissan — Murano VEHICLE 7.5

TYPE OF TO BE SERVICED Engine oil & filter Brake lines & cables

SERVICE R

INTERVAL

19

11

22.5

26

34

30

37.5

41

45 ✓

✓

✓

(xIOOO) 49

52.5 ✓

1 ✓

L/l

CVT, transfer case and differential fluid Air cleaner filter

✓

✓

✓

✓

S/I R R R

✓

platinum tipped plugs every 105,000 miles ✓

/

S/I

Steering gear (box) & linkage, axle & suspension

✓

1

parts Vapor lines

S/I S/I: Service or Inspect

>/ L: Lubricate

© First a 60,000, then every 15,000 miles © After 60,000, replace every 30,000

FREQUENT

✓

✓

1

Exhaust system Fuel lines

✓

✓

R

Engine coolant © Spark plugs Cabin air filter

60

✓

1

Drive belt(s) ©

56

✓

S/I

Brake pads, discs, drums & linings Driveshaft boots & propeller shaft

R Replace

3.8

MILEAGE

15

OPERATION

MAINTENANCE

(SEVERE

SERVICE)

If a vehicle is operated under any of the following conditions it is considered severe service: - Extremely dusty areas.

- 50% or more of the vehicle operation is in 32°C (90°F) or higher temperatures, or constant operation in temperatures below 0°C (32°F). - Prolonged idling (vehicle operation in stop and go traffic).

- Frequent short running periods (engine does not warm to normal operating temperatures). - Police, taxi, delivery usage or trailer towing usage. Oil & oil filter: replace every 3750 miles.

Brake pads, discs, drums & linings: service or inspect every 7500 miles. Driveshaft boots & propeller shaft: service or inspect every 7500 miles. Exhaust system: service or inspect every 7500 miles.

Steering gear (box) & linkage, (steering damper-4x4), axle & suspension parts: service or inspect every 7500 miles. Steering linkage ball joints & front suspension ball joints: service or inspect every 7500 miles.

NISSAN

MURANO

25-7

PRECAUTIONS Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle:

• Never open, service or drain the radia¬ tor or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. • Observe all applicable safety precau¬ tions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. • Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. • Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If

eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance. • The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas as soon as possible after expo¬ sure to used engine oil. Soap and water, or waterless hand cleaner should be used. • All new vehicles are now equipped with

proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in con¬ tact with a painted surface; it will damage

an air bag system. The system must be dis¬ abled before performing service on or around system components, steering col¬ umn, instrument panel components, wiring and sensors. Failure to follow safety and dis¬ abling procedures could result in accidental air bag deployment, possible personal injury and unnecessary system repairs. • Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed

important! Many models utilize an interfer¬ ence-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing poten¬ tially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replace¬ ment interval for the timing belt, and to the timing belt section for belt replacement and

away from your body. When placing a nondeployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section. • Clean, high quality brake fluid from a sealed container is essential to the safe and

the paint. • Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine damage. • Timing belt maintenance is extremely

inspection. • Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer sys¬ tem^) and may require the computer to undergo a relearning process once the neg¬ ative battery cable is reconnected. • When servicing drum brakes, only dis¬ assemble and assemble one side at a time, leaving the remaining side intact for refer¬ ence.

ENGINE REPAIR ^►Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board com¬ puter system. The computer may undergo a relearning process once the negative battery cable is reconnected.

Alternator REMOVAL & INSTALLATOIN 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Alternator harness connectors • Engine right side under cover • Radiator • Remove alternator and air condi¬ tioner compressor belt.

88:N 1. Through bolt 4. Alternator

2. Cylinder block 5. B terminal nut

3. Timing chain case 6. Alternator bracket 42356-MURA-G01

Alternator exploded view

NISSAN

25-8

MURANO

• Idler pulley • Alternator To install:

3. Install or connect the following: • Alternator • Idler pulley • Alternator belt. Tighten the through-bolts to 18-23 ft. lbs. (25-31 Nm). • Engine under cover • Radiator • Alternator harness connectors • Negative battery cable Ignition Timing ADJUSTMENT Timing is not adjustable.

2WD

Engine room harness from the ECM side Heater hoses Wheel and tires

Engine Assembly REMOVAL & INSTALLATION 1. 2. splash 3. 4.

A/C compressor with piping con¬ nected, and temporarily secure it aside

Release fuel pressure. Remove the engine cover, and the guards. Drain engine coolant. Remove or disconnect the following: • Battery and tray • Air inlet duct • Air duct and air cleaner case

Fuel hose quick connector at vehicle piping side Transaxle shift control cable. Starter motor Front exhaust tube Reservoir tank for the power steer¬ ing from engine compartment bracket and position it aside. Power steering gear from steering lower joint Steering outer socket from steering knuckle Stabilizer connecting rod Propeller shaft (AWD models)

assembly with mass air (upper) flow sensor • Power brake booster vacuum hose • Drive belts • Radiator assembly, coolant reser¬ voir, and system hoses • RH windshield wiper arm and right font cowl top cover

models (8.2 -7.1,

P3 60 - 70

: N»m (kg-m, ft-lb)

fjjjjj] : N*m (kg-m, in-lb) 1.

Rear engine mounting bracket

4.

Front engine mounting bracket

2. RH engine mounting insulator 5. Stopper

3.

RH engine mounting bracket

6.

Front engine mounting insulator 42356-MURA-G02

Engine mounting— 2wd

AWD

NISSAN

OC. Q

MURANO

£-\J

V

models

|^| : N*m (kg-m, in-lb) 1.

Rear engine mounting bracket

2.

4.

Front engine mounting bracket

7.

LH engine mounting insulator

RH engine mounting insulator

3.

RH engine mounting bracket

5.

Front engine mounting insulator

6.

LH engine mounting bracket

8.

Rear engine mounting insulator 42356-MURA-G03

Engine mounting — AWD

• Left and right front halfshafts • Power steering piping from power steering oil cooler 5. Position a manual lift table caddy under the engine and transaxle assembly. 6. Remove the right engine mounting insulator

7. Remove mounting bolt between trans¬ verse link and front suspension member 8. Carefully lower the Reengine, transaxle, mo vand transfer case (AWD models) ethec front sus¬ ank manual pension member assembly with rthe sha with interference avoiding caddy, table lift fpto sit the vehicle body. ion sen WARNING ¬ Before and during this procedure, always check if any harnesses are left connected. Avoid any damage to, or any oil or grease smearing or onto the engine mounting insu¬ spills lators.

sor (P OS ). t front suspension mount¬ 10. Disconnec ing nuts and bolts to remove engine, transaxle, transfer case (AWD models) and front suspension member assembly as a unit. 1 1 . Separate the engine, transaxle and transfer case (AWD models) assembly and front suspension member. 12. Installation is the reverse order of removal. See the accompanying illustrations for the proper torque values.

Heater Core REMOVAL & INSTALLATION

4. Remove cowl top seal rubber. 5. Remove clips from cowl top cover (right) and remove cowl top cover (right). 6. Remove clips from cowl top cover (left) and remove cowl top cover (left) 7. Remove washer nozzles and hose from cowl top cover. 8. Remove cowl top cover.

9. Disconnect evaporator-side onetouch joints. a. Install a disconnector tool (Highside: 92530-89908, Low pres¬ pressure sure side: 92530-89916) on A/C piping. b. Slide a disconnector toward vehicle front until it clicks. c. Slide A/C piping toward vehicle front and disconnect it. WARNING

1. Use a refrigerant collecting equip¬ ment (for HFC-1 34a) to discharge refriger¬ ant. 2. Drain coolant from cooling system. 3. Remove both right/left wiper arms.

Seal connection opening of piping with a cap or vinyl tape to avoid exposure to atmosphere.

SAN OC 1I Un NIS MURANO 10. Disconnect two heater hoses from heater core. 11. Remove fuse lid. 12. Remove instrument driver lower panel screws. 13. Remove data link connector. 14. Pull to disengage metal clip by removing panel in horizontal direction. 15. Disconnect in-vehicle sensor and each electrical parts. 16. Remove bolts, and remove hood lock opener. 17. Remove tilt lever knob screws. 18. Remove the knob by picking it up and pulling it out. Using a remover, ply and remove tilt lever mask. 19. Remove steering column cover screws. 20. Disengage the tab, and remove steering column cover. After removing com¬ bination meter screws, remove harness con¬ nector. 21. Using a remover, pry and remove side ventilator assembly (left/right). 22. Disconnect aiming switch harness connector and VDC switch harness connec¬ tor only left side. 23. Insert a remover into lower space of instrument side finisher (left/right) and remove by lifting. 24. Remove screws and glove box striker, disconnect connectors, and remove instrument passenger lower panel assembly. 25. Detach the damper from glove box right side. 26. Remove glove box pins, and remove glove box. 27. Insert a remover into lower space of center ventilator and remove by lifting. 28. Insert a remover into upper space of center ventilator and the upper clip is removed. 29. Remove screws. Disconnect harness connector, and remove tweeter with right and left part. 30. Insert a remover into front space of instrument stay cover (left/right) and detach. 31. Disconnect the left side harness con¬ nector only. 32. Remove cluster lid screws. 33. Disconnect A/C and AV harness con¬ nectors, and remove cluster lid C. 34. Remove display unit screws. 35. Disconnect harness connector and remove display. 36. Using a remover and disengage the ignition key finisher metal clips 37. Disconnect harness connector. 38. Using a remover, pry and remove instrument mask. 39. Disconnect harness connector.

40. Remove screw. Disengage the metal clip and remove instrument driver upper 41. Remove bolt and screws Remove panel. front passenger air bag module. 42. Disconnect metal clips, then remove instrument passenger upper panel. 43. Disconnect harness connector. 44. Pull to inside of vehicle, disconnect metal clips and remove front pillar garnish. 45. Remove bolts and screws, and remove instrument panel from passenger door opening portion. 46. Tweeter and sensor harness clip are removed from the duct. 47. Remove instrument panel assembly. 48. Remove ECM with bracket attached. 49. Remove nuts (2), then bolts (2) and screw (1), then remove blower unit. (■►Move blower unit to the right and remove locating pin (1) and joint. Then remove blower unit downward. 50. Disconnect intake door motor con¬ nector and blower fan motor connector. 51. Remove harness clips (2) from blower unit. 52. Remove blower unit. 53. Remove clips from vehicle harness from steering member. 54. Remove instrument stays (driver side and passenger side). 55. Remove rear ventilator ductl and front floor duct. 56. Remove mounting screws from heater & cooling unit. 57. Remove the steering member, and then remove heater & cooling unit. 58. Remove foot duct (right). 59. Remove heater core cover. 60. Remove heater pipe support and heater pipe grommet. 61. Slide heater core to passenger side. 62. Installation is the reverse of removal. Note the following points: • Replace O-rings for A/C piping with new ones, coated with com¬ pressor oil. • Connection point for female-side piping is thin. So, when inserting male-side piping, take care not to deform female-side piping. Slowly insert in axial direction. • Insert one-touch joint connection point securely until it clicks. • After piping has been connected, pull male-side piping by hand to check that piping does not come off. • When recharging refrigerant, check for leaks.

Water Pump REMOVAL & INSTALLATION 1. 2. 3. 4.

Remove drive belts. Remove undercover. Drain engine coolant from radiator. Remove water drain plug on water

pump side of cylinder block. 5. Support lower oil pan bottom with a transmission jack. 6. Remove right engine mounting insu¬ lator and mounting bracket. 7. Remove idler pulley bracket. 8. Remove chain tensioner cover and water pump cover. 9. Remove the chain tensioner assem¬ bly in the following procedure. a. Pull the lever down and release the plunger stopper tab. b. Insert the stopper pin into the ten¬ sioner body hole to hold the lever and keep the stopper tab released. c. Insert the plunger into the ten¬ sioner body by pressing the timing chain slack guide. d. Keep the slack guide pressed and hold the plunger in by pushing the stop¬ per pin deeper through the lever and into the tensioner body hole. e. Turn crankshaft pulley approxi¬ mately 20 degrees clockwise so that the timing chain on the chain tensioner side is loose. 10. Remove chain tensioner. 11. Remove the 3 water pump bolts. Secure a gap between water pump gear and timing chain, by turning crankshaft pulley approximately 20 degrees counterclockwise. 12. Screw M8 bolts, pitch: 1.25mm (0.049in) length: Approx. 50 mm (1.97in) into water pump’s upper and lower mount¬ ing-bolt holes until they reach timing chain case. Then, alternately tighten each bolt for a half turn, and pull out water pump. 13. Pull straight out while preventing vane from contacting socket in installation area. Remove water pump without causing sprocket to contact timing chain. 14. pump. Remove M8 bolts and O-rings from water To install: 15. Install new O-rings to water pump. 16. Apply engine oil and engine coolant to the O-rings as shown. Locate the O-ring with white paint mark to engine front side. 17. Install the water pump. (-►Do not allow cylinder block to nip the O-rings when installing the water pump.

NISSAN

-M

OE

I I

MURANO

(0.86 - 1.10,75 - 95) £H 8 5 10 7

White paint (Black) BO O-ring

Water pump

3 6.9 - 9. jg (0.70 - 0.95, 61 - 82)

O-ring (Black) (Apply engine coolant.)

©

: Always replace after every disassembly.

0

: Lubricate with new engine oil.

|

Exploded view of the oil seal, retainer and gasket 3.3L engine

i^Be careful, there are 2 crankshaft keys. Use care not to loose them. To install: 12. Clean all parts well. If removed, inspect the crankshaft sprocket for warping or abnormal wear. Check the sprocket teeth for wear, deformation, chipping or other damage. Replace as necessary. Clean the

surface to ease installa¬ mounting sprocket tion. Install the key. Slip the sprocket onto

26-24 Sgf" Aligning marks

Aligning

Rear

because the pistons may be hitting the valves.

r marks

Camshaft Camshaft sprocket CRH) Crankshaft timing sprocket Oil pump

sprocket (LH) No. 1 cylinder at TDC in compression Aligning stroke marks 79245G21

Use a shop rag to clean the alignment marks tor the timing belt— 3.3L engines

the crankshaft. Tap it in place with a suit¬ ably-sized socket. 13. If removed, inspect the camshaft sprockets for damage and wear. Replace as required. The sprockets should be marked L3 to designate the front, or left side camshaft and R3 to designate the rear, or right side camshaft. Use care to install the sprockets properly. A special spanner tool is designed to hold the sprocket to keep it from turning while the center bolt is being tightened. Use care if using a substitute. Tighten the camshaft sprocket center bolts to 61 ft. lbs. (83 Nm). Verify that the timing marks on the camshaft sprockets and the timing marks on the rear cover (called the seal plate) are aligned. 14. Use an Allen wrench to turn the tim¬ ing belt tensioner clockwise until the belt tensioner spring is fully extended. Tem¬ porarily tighten the tensioner nut to 32-43 ft. lbs. (43-58 Nm). 15. If a new timing belt is to be installed, look for a printed arrow on the belt. Be sure the arrow is pointing away from the engine. If the original timing belt is to be reused, be sure that the directional arrow that was marked at disassembly is facing the correct direction. 16. A new Original Equipment Manufac¬ ture (OEM) timing belt should have 3 white timing marks on it that indicate the correct timing positions of the camshafts and the crankshaft. These marks are to help ensure that the engine is properly timed. When the engine is properly timed, each white timing mark on the timing belt will be aligned with

the corresponding camshaft and crankshaft timing mark on the sprocket. Because the white timing marks are not evenly spaced, the technician needs to use care in installing the belt. There should be 40 tim¬ ing belt teeth between the timing marks on the front and rear camshaft sprockets and 43 teeth between the timing mark on the front camshaft sprocket and the timing mark on the crankshaft sprocket. 17. Verify that the camshaft timing marks are aligned with the timing marks on the rear cover (seal plate) and that the crank¬ shaft sprocket timing mark is aligned with the timing mark on the oil pump housing. 18. Install the timing belt starting at the crankshaft sprocket and moving around the camshaft sprockets following a counter¬ clockwise path. Do not allow any slack in the timing belt between the sprockets. After all of the timing marks are aligned with the timing belt installed, slip the timing belt onto the belt tensioner.

19. While holding the timing belt ten¬ sioner with an Allen wrench, loosen the ten¬ sioner nut. Allow the tensioner to put pressure on the timing belt. Use an Allen wrench to turn the timing belt tensioner 70-80 degrees clockwise and tighten the timing belt tensioner nut to 32-43 ft. lbs. (43-58 Nm). WARNING

If any binding is felt when adjusting the timing belt tension by turning the crankshaft, STOP turning the engine,

20. Rotate the crankshaft clockwise twice and align the No. 1 piston to TDC on the compression stroke (firing position). 21 . Apply 22 lbs. (10kg) of force on the timing belt between the rear camshaft sprocket and the timing belt tensioner. An assistant may be needed. While holding the timing belt tensioner steady with an Allen wrench, loosen the timing belt tensioner nut. Remove the Allen wrench and adjust the timing belt tensioner using the following

procedua.re:Install a 0.0138 in. (0.35mm) thick and 0.500 in. (12.7mm) wide feeler gauge where the timing belt just starts to go around the tensioner (approximately sioner). 4 o’clock position, looking at the ten¬ the b. Turn the crankshaft sprocket clock¬ wise, which should force the feeler gauge between the timing belt and the ten¬ sioner, up to a position on the tensioner of about 1 o'clock. timing belt tensioner c. Tighten the nut to 61 ft. lbs. (83 Nm). d. Turn the crankshaft clockwise to rotate the feeler gauge out from between the timing belt tensioner and the timing belt. 22. Rotate the crankshaft clockwise twice, and once again align the No. 1 piston to TDC on the compression stroke (firing position). 23. Apply 22 lbs. (10kg) of force on the timing belt between the front and rear camshaft sprockets. Measure the amount of belt deflection. Belt deflection should be between 0.51-0.59 in. (13-15mm). If belt deflection is out of specification, repeat Steps 29 through 33. If the timing belt deflection cannot be adjusted into specifica¬ tion, the timing belt will have to be

. replaced 24. Install or connect the following: • Lower engine front cover and the 5 lower cover bolts. Do not over Tighten to 27-44 inch lbs. tighten. (3-5 Nm). • Outer timing belt guide next to the crankshaft sprocket with the dished side facing away from the cylinder block. Install the crankshaft pulley. Use a strap wrench to keep the crankshaft pulley from turning and tighten the center bolt to 148 ft. lbs. (201 Nm). • Water pump pulley on the pump. Install the 4 bolts. Use a strap wrench to keep the water pump

NISSAN Ofi.OE

pulley from turning and tighten the 4 water pump pulley bolts to 89 inch lbs. (10 Nm). • Right side outer engine and transaxle splash shield, and secure with the 4 bolts and 2 screws • Right side front wheel. Tighten the lug nuts to 72-87 ft. lbs. (98-118 Nm). • Upper engine timing belt front cover, and tighten the 8 bolts to 27-44 inch lbs. (3-5 Nm) • Main wiring harness on the upper engine front cover • Water bypass hose between the thermostat housing and water con¬ nection • Upper radiator hose between the radiator and the water hose con¬ nection. Secure the hoses with clamps. Install the upper radiator hose bracket. Tighten the bracket bolt to 34-58 ft. lbs. (46-65 Nm). • Air conditioning compressor drive belt idler pulley and install the 3 bolts. Tighten to 15 ft. lbs. (21 Nm), if equipped

QUEST m

• Alternator drive belt, the water

C-\J

pump and power steering pump drive belt and the air conditioning compressor drive belt, if equipped. • Negative battery cable 25. Fill the cooling system. 26. Start the engine and allow it to warm to operating temperature. Check and adjust the ignition timing. Road test to verify cor¬ rect engine operation. 3.3L engines piston and connecting rod assembly positioning

Piston and Ring Positioning Oil ring • Top ring • Oil ring

expander

upper rail

Front

Oil ring -S/

lower rail

2nd ring 7924AG83

3.3L engines piston ring end-gap spacing

3.3L engine piston positioning

FUEL SYSTEM

Safety is the most important factor when performing not only fuel system mainte¬ nance but any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of

engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suit¬ able waste container. • Always keep a dry chemical (Class B) fire extinguisher near the work area. • Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame.

the vehicle’s fuel system components can be accomplished safely and effectively by to the following rules and guide¬ adhering lines.

• Always use a back-up wrench when loosening and tightening fuel line connec¬ tion fittings. This will prevent unnecessary stress and torsion to fuel line piping.

• To avoid the possibility of fire and per¬ sonal injury, always disconnect the negative battery cable unless the repair or test proce¬ dure requires that battery voltage be applied. • Always relieve the fuel system pres¬ sure prior to disconnecting any fuel system component (injector, fuel rail, pressure reg¬ ulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be

Always follow the proper torque specifica¬ tions.

Fuel System Service Precautions

advised that fuel under pressure may pene¬ trate the skin or any part of the body that it contacts. • Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from

• Always replace worn fuel fitting Fi¬ rings with new. Do not substitute fuel hose or equivalent, where fuel pipe is installed. Fuel System Pressure RELIEVING

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

2. Remove the left side engine compart¬ ment relay panel cover. 3. Locate and remove the fuel pump relay from the relay panel. 4. Start the engine. 5. Allow the engine to run until it stalls

from fuel starvation. After the engine stalls, crank the engine over 2 more times to ensure all pressure has been released. 6. Turn the ignition switch to the OFF position and install the fuel pump relay. 7. Most service work that follows fuel pressure relief also requires that the nega¬ tive battery cable (ground) be disconnected before service work begins. This also pre¬ vents accidental fuel pump energizing that could pressurize the system. Fuel Filter REMOVAL & INSTALLATION In-Line— Except California 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Relieve the fuel system pressure using the recommended procedure. 3. Disconnect the negative battery cable. 4. Raise and safely support the vehicle. 5. Remove the fuel hose clamps. 6. Disconnect and plug the hoses to prevent leakage. 7. Remove the fuel filter from the bracket.

26-26

NISSAN QUEST

5. Remove the filter splash shield bolts. 6. Disconnect the lines from each end of the filter and plug the hoses to prevent leakage. 7. Loosen the filter bracket nuts. 8. Remove the fuel filter from the bracket.

To install:

8. Install the fuel filter into the bracket with the arrow facing up, in the direction of the fuel travel to the engine. 9. Reconnect the fuel hoses. 10. Install and tighten the hose clamps. Verify that the clamps are properly tight¬ ened. System operating pressure is approxi¬ mately 36 psi (248 kPa) and fuel will leak is connections are not properly made. 11. Lower the vehicle. 12. Reconnect the negative battery cable. 13. Check for leaks.

2. Properly relieve the fuel system

To install:

9. Install the fuel filter into the bracket with the arrow facing forward. Tighten the bracket bolts to 44 inch lbs. (5 Nm). 10. Reconnect the fuel hoses. 11. Lower the vehicle. 12. Reconnect the negative battery cable. 13. Check for leaks.

In-Line— California

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Relieve the fuel system pressure using the recommended procedure. 3. Disconnect the negative battery cable. 4. Raise and safely support the vehicle.

Fuel Pump REMOVAL & INSTALLATION

ttihoen precau . t

ion

in the beg inn ing

s

of this sec¬

3. Disconnect the negative battery pressure. cable. 4. Raise and safely support the vehicle. 5. Remove the fuel tank as follows: a. Drain the fuel from the tank. b. Remove the filler protector. c. Disconnect the filler tube. d. Detach any electrical connectors related to the fuel pump and fuel level sending unit.

e. Detach the fuel line quick connec¬ tors. f. Safely support the fuel tank. g. Remove the tank mounting straps, then lower the tank out of the vehicle. 6. Remove the 6 fuel pump bolts. 7. Lift the fuel pump out of the fuel tank. Use care. The fuel level sensor and fuel pump and bracket must be tipped to remove it from the fuel tank. Do not lift the fuel sensor and pump assembly straight out

(0.20-0.26, 17-23)-

1

Bef

2.5 (yj 2.0 -

ore

ser

vic

ing

the

vehi

cle,

refe

r to

©

O-ring

(DJ 27 - 35 (2.8 - 3.6, 20 - 26) : N m (kg-m, in-lb) Fuel filler protector

'SB 4.2 - 5.6 (0.43 - 0.57, 37 - 49)

h ^

: N m (kg-m, ft-lb) bly.after ssemce disarepla every : Always 9302WG03

Fuel tank and related components

NISSAN OC

97

QUEST

of the fuel tank or damage to the level sen¬ sor may occur. 8. Remove the 2 bolts attaching the level sensor to the fuel pump. 9. Remove the fuel pump level sensor and the gasket. 10. Discard the gasket. 11. Remove the fuel pump from the bracket. To install: 12. Position the fuel level sensor on the fuel pump and bracket and install the 2 bolts. 13. Install a new level sensor gasket. Carefully install the level sensor and pump assembly. 14. Install the 6 fuel pump bolts. Do not over-tighten the bolts. Tighten the bolts to just 17-23 inch lbs. (2-3 Nm). 15. Install the fuel tank in the reverse order of removal, be sure to tighten the tank mounting straps to 20-26 ft. lbs. (27-35 Nm).

16. Lower the vehicle. Refill the fuel tank as required. 17. Connect the negative battery cable. Verify that the fuel pump relay has been properly installed. Start the engine and check for proper operation.

the 5.cap.Remove the injector cap screws and 6. Pull the injector from the fuel rail. 7. Remove and discard the injector 0rings. To install: ^Use new insulators and O-ring seals for assembly.

Fuel Injector

8. Install or connect the following: • Fuel injectors with the rail and

REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. If removing a rear injector, remove the upper intake manifold. 4. Disengage the injector electrical con¬ nection. (■►When removing the fuel injectors, use a screwdriver head socket to remove the injector cap screws.

tighten (11-15 the Nm)fasteners to 8-11 ft. lbs. • Fuel Nm). injector caps. Tighten the screws to 26-33 inch lbs. (3-4 • Injector electrical connections. • Intake manifold, if removed. • Negative battery cable. 9. Start the vehicle and check for leaks.

DRIVE TRAIN Automatic Transaxle Assembly REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Battery and tray • Resonator • Terminal cord assembly harness connector • Vacuum lines • Starter motor • Transaxle fluid from the unit • Halfshafts • Transaxle cooler hose and control cable • Front exhaust manifold

• Crankshaft Position (CKP) sensor • Engine gusset and torque converter undercover • Bolts from the drive plate from the Rotate the crank¬ torque shaft toconverter. access all the bolts. 3. Support the transaxle with a suitable • Front mount jack. • Rear mount • Bolts attaching the transaxle to the engine 4. Carefully separate the transaxle assembly from the engine assembly. Lower the assembly from the vehicle. To install: 5. Be sure that the transaxle is secured firmly to the transaxle jack. 6. Carefully raise the transaxle into the vehicle and align the transaxle to the engine assembly, making sure that the

erly. alignment dowels are positioned prop¬ 7. Install or connect the remaining components in the reverse order of removal. Refer to the accompanying transaxle torque specification illustration for bolt locations and their specifications. 8. Connect the negative battery cable. 9. Fill the transaxle with the correct amount and type of fluid. 10. Start the engine. 1 1 . Check for leaks and proper operation Halfshaft REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Raise and safely support the vehicle.

Tightening torque Bolt No. 1

39 - 49 (4.0 - 5.0, 29 - 36)

60 (2.36)

30 - 40 (3.1 - 4.1, 22 - 30)

25 (0.98)

30 - 40 (3.1 - 4.1, 22 - 30)

25 (0.98)

2

*: TORX

( mm (in)

N-m (kg-m, ft-lb)

bolt 9348WG17

Transaxle torque specification and locations— 3. 3L engine

OC no LU-LO

NISSAN QUEST

3. Remove or disconnect the following: • Wheel • Fender splash shield • Cotter pin, nut retainer, and the hub retainer washers from the front hub assembly • Lower ball joint from the knuckle • Sway bar from the lower control arm at the sway bar link nut • Halfshaft and CV-joint from the wheel hub 4. Position a drain pan under the transaxle since some fluid may run out when the inner joint is disengaged from the transaxle. 5. A prybar is used to separate the inner CV-joint from the transaxle. Use great care that the prybar does not damage the transaxle case, differential oil seal, outer race or boot. If removing the left side half¬ shaft, position prybars on both sides of the outer race, between the outer race and the transaxle case. Gently pry outward to unseat the circlip. 6. When removing the right side half¬ shaft, it is not be necessary to remove the halfshaft bearing retainer bracket from the cylinder block. Remove the 3 bearing retainer bolts and pull the right side half¬ shaft CV-joint with the bearing retainer from the differential side gear. 7. Support the halfshafts and remove them from the vehicle. Use care not to dam¬ age the boots. Place the halfshafts on a flat, protected work area. To install:

^ OUTER

TRANSAXLE

/ RACE

CASE 7924WG18

Removing the left side halfshaft by gently prying with 2 prybars to unseat the circlip

FRONT AXLE BEARING RETAINER-TO-BRACKET

!> CAUTION Do not reuse the circlip used on the left side halfshaft.

8. To prevent over-expanding the cir¬ clip, install the circlip carefully, starting one end in the shaft groove, then working the circlip over the CV-joint splined end. Always use a new circlip. No circlip is used on the right side halfshaft. 9. Inspect the CV-joint boots. If service is required, replace the CV-joint boots. 10. Inspect the differential oil seals. If dam¬ aged, the factory recommends using a hooktype puller and slide hammer arrangement to remove the seals. A seal driver is used to install the replacement differential oil seals. 1 1 . If installing the left side halfshaft and CV-joint assembly, position the CV-joint so the splines are aligned with the differential side gear splines, then push the halfshaft joint into the differential case. As the circlip locks into the differential side gear groove, a click will be felt.

7924WG19

Right side halfshaft bearing retainer bracket

N,aSuSEAsNT 26-29

12. If installing the right side halfshaft and CV-joint assembly, simply push the CV-joint into the differential side gear. Posi¬ tion the bearing retainer onto the bearing retainer bracket that should still be on the cylinder block. Install the 3 bolts and tighten to 8-14 ft. lbs. (13-19 Nm). 13. Install or connect the following: • Halfshaft • Lower ball joint and tighten the lower ball joint stud nut to 52-63 ft. lbs. (71-86 Nm). Secure the nut with a new cotter pin. • Sway bar link to the lower control arm and tighten the link nut to 12-16 ft. lbs. (16-22 Nm). • Wheel outer bearing retainer, washer and axle nut. Tighten the hub nut to 174-231 ft. lbs. (235-314 Nm). Install the nut retainer and secure with a new cot¬ ter pin. • Splash shield • Wheel. Tighten the lug nuts to 72-87 ft. lbs. (98-118 Nm).

14. Lower the vehicle. 15. Check the transaxle fluid level. 16. Road test the vehicle to verify correct operation and no noise or vibration.

5. Thoroughly clean all parts in solvent and dry with compressed air. Check parts essary. for evidence of damage and replace as nec¬ 6. Install the boot and new boot band on the halfshaft. 7. Install a new inner snapring. 8. Install the ball cage, inner race and balls as a unit. Confirm that the matchmarks are aligned. 9. Install a new outer snapring.

CV-Joint OVERHAUL Inner 1. Remove the boot bands. 2. Matchmark the slide joint housing and inner race, prior to separating the joint assembly.

10. Pack the CV-joint with 5.0-6. 0 ounces (165-175 g) of grease. 11. Ensure that the boot is properly installed on the halfshaft groove. 12. Set the boot so that it does not swell or deform when its length is 3.86 in.

3. Pry off the snapring and remove the ball cage, inner race and balls as a unit. 4. Remove the snapring and withdraw the boot. To install:

(98mm). 13. Lock the new boot bands securely. Outer

The joint on the wheel side cannot be disassembled.

i~-Cover the halfshaft serrations with tape, so as not to damage the boot.

1 . Prior to separating the joint assem-

Boot band *

Circular clip:

Wheel

side gear Make sure circular clip is properly meshed with and side), (wheel ly assemb joint and side) xle (transa will not come out.

side (Rzeppa

joint)

- Boot

e protector Be careful not to damage boots. Use suitabl tion. Installa and l remova or cloth during

T Joint assembly Circular clip B o

Dynamic damper (For M/T models installed on right drive shaft)

Boot

Dynamic damper band ©

Snap ring Inner race

Boot band © Ball

[P] 30 - 40 (3.1 - 4.1, 22 - 30) -^25 - 35 (2.6 - 3.6, 19 - 26) Snap ring O 43 - 58 32 - 43) (4.4 - 5.9,

Snap ring B

Side joint housing with extension shaft

- Dust shield

Cage Snap ring C ^

o

Support bearing Slide joint housing

Support bearing retainer Bracket

Dust shield i

^ Circular clip A ^

13 D. 19 (1.3 . i.9> 9 . 14) Snap ring

Left drive shaft

Dust shield ; N.m

Right drive shaft

(kg-m, ft-lb)

Transaxle

side (Double

offset joint) 8961 7G09

Exploded view of the halfshafts and related components

OC on NISSAN

cD“OU

*

QUEST

'

89617G05

Use vinyl tape and wrap the end of the shaft to protect the boot during installation

8961 7G07

The inner CV-joint uses a large C-clip to retain the ball and cage assembly in the outer housing

Use an old nut to protect the threads when tapping the outer CV-joint onto the shaft

*-Cover the halfshaft serrations with tape, so as not to damage the boot. 5. Install the boot and small boot band on the halfshaft.

After the outer housing is removed, the ball and cage assembly can slide from the shaft by removing the C-clip —

—

l»

z

bly, matchmark the halfshaft and joint assembly.

1/ LLi _

JL 89617G02

Make sure to properly position the boot before tightening the boot clamps

ham¬ mer. 2. Separate the joint using a slide 3. Remove the boot bands and the boot. To install: 4. Thoroughly clean all parts in solvent and dry with compressed air. Check parts evidence of damage and replace as nec¬ for essary.

6. Set the joint assembly onto the half¬ shaft and align the matchmarks. 7. Attach the joint assembly to the half¬ shaft by lightly tapping the serrated end with a plastic hammer. musing a metal hammer may damage the threads on the end of the joint. 8. Pack the CV-joint with 4.76-5.11 ounces (135-145 g) of grease. 9. Ensure that the boot is properly installed on the halfshaft groove. 10. Set the boot so that it does not swell or deform when its length is 3.82 in. (97mm). 1 1 . Lock the new boot bands securely.

NISSAN

Ofi.QI

QUEST

O I

STEERING AND SUSPENSION Air Bag PRECAUTIONS

Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible per¬ sonal injury. • Never carry the inflator module by the wires or connector on the underside of the module. • When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed away. • Place the inflator module on a bench or other surface with the bag and trim cover facing up. • With the inflator module on the bench, never place anything on or close to the module which may be thrown in the event of an accidental deployment. DISARMING K CAUTION To avoid rendering the Supplemental Restraint System (SRS) inoperative, which could lead to personal injury or death in the event of a severe frontal collision, extreme caution must be taken when servicing the electrical related systems. f»AII SRS electrical wiring harnesses and connectors are covered with YEL¬ LOW outer insulation. Do not use elec¬ trical test equipment on any circuit related to the SRS (air bag) sensors. When installing SRS components, always install with the arrow marks facing the front of the vehicle. Disarming

To disarm the Supplemental Restraint System (SRS) system turn the ignition switch to the OFF position. Then, discon¬ nect the both battery cables starting with the wait at least 10 min¬ negative cable first and utes after the cables are disconnected. Be sure to insulate the battery terminal ends. Arming

To arm the Supplemental Restraint Sys¬ tem (SRS) system turn the ignition switch to OFF position. Connect the both battery cables starting with the positive cable first.

^The SRS or air bag system is with a self-diagnostic opera¬ equipped tion. After turning the ignition key to the ON or START position, the AIR BAG lamp will illuminate for 7 sec¬ warning onds. After 7 seconds, the AIR BAG lamp will extinguish if no malfunction is detected. If the AIR BAG lamp does not extinguish after 7 seconds, check the SRS self-diagnostic system for a malfunction. Power Rack and Pinion REMOVAL & INSTALLATION

The power steering gear is held in posi¬ gear brackets and insula¬ tion that the housing may move Note2 steering tors. by slightly when the steering wheel is turned. If the housing moves more than 0.080 inch (2mm), replace the steering gear insulators. If one or both of the brackets move, check the torque of the bracket bolts. The correct torque for these bolts is 54-72 ft. lbs. (73-97 Nm). 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Place a drain pan under the steering rack. 3. Remove or disconnect the following: • Brake master cylinder remote reser¬ voir bracket screws. Position the reservoir out of the way and secure with wire.

o m

• Junction block/high pressure line way. the steering rack. Position the from junction block and line out of the • Both front wheels • Front sway bar • Tie rod ends from the steering knuckles • Lower steering column shaft clamp bolt • Power steering fluid return hose and position out of the way. • The steering rack clamp bracket bolts 4. Lower the steering rack from the vehicle. To install: 5. Carefully slide the steering gear rack and pinion assembly in place from the left side of the vehicle. Position the input shaft just below the lower steering column so shaftit isclamp. 6. Raise the steering gear until the plas¬ tic aligning tab on the input shaft enters the the lower column shaft. gaptheon clamp clamp Do not bolt install bolt yet. 7. Examine the steering gear brackets. They should be marked UP with arrows pointing to one end of the bracket. Be sure the brackets are installed correctly. Tighten the steering gear bracket bolts to 54-72 ft. lbs. (73-97Nm) in sequence, working counterclockwise from the number 1 bolt right side). (upper 8. Install or connect the following:

m

t=f-U

1

1

lo

(T>H5M3>K4)^ Temporary tightening

Secure tightening 9348WG18

Tighten the power steering rack mounting bolts in the sequence shown

OC QO CVOl.

NISSAN quest

• Fluid return line to the steering

gear • Steering column shaft clamp bolt. Tighten the bolt to 17-22 ft lbs. (24-29 Nm). Install the dust cover. • Tie rod ends • Stabilizer bar • Wheel. Tighten the lug nuts to 1 72-87 ft. lbs. (98-118 Nm). • Junction .block. Tighten the highpressure line to 11-18 ft. lbs. (15-25 Nm).

2. Disconnect the negative battery

• Brake master cylinder reservoir 9. Check for leaks and proper opera¬ tion.

MacPherson Strut REMOVAL & INSTALLATION

o t s i t b the preca ution n he eginning f his ec¬ tion. s

When installing rubber parts, final tightening must be carried out under unladen condition Before with tires on ground. *: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.

cable.3. Matchmark the front strut upper mounting bracket and the chassis strut tower. 4. Raise and safely support the vehicle. 5. Remove the front wheel. 6. If equipped, remove the 2 front brake anti-lock sensor cable bracket bolts and the way. the anti-lock sensor cable out of position 7. Detach the brake tube from the strut. Strut cap

P2 39 - 54 (4.0 - 5.5, 29 - ‘

servic

ing t he veh icle, refer to

59 - 78 (6 - 8. 43 - 58)

Spacer Strut insulator Strut thrust bearing Dust seal Upper spring seat Bound bumper urethane Dust cover

Stabilizer

►X»E3 137 - 157 (14 - 16, 101 - 116) Knuckle Baffle plate

Plain washer Wheel bearing lock nut n 235 - 314 (24 - 32, 174 - 231) 8-147 87-108) ^11 (12-15,

Cotter pin

Plain washer

£4[DJi28- I57 (13-16,94-116^ Transverse link ' Bushing Washer

2 -2-2.2, (1.6 ►X*ni6

&

Cotter pm fj* 8

^E)71

12-16)

Front

-86 (7.2-8.8,52-64)

Lower ball joint

-

El 74 - 88 (7.5 - 9, 54 - 65)

EJ: N m (kg-m, ft-lb) 9302WG04

Coil spring and strut assembly

8. Support the control arm. 9. Matchmark the knuckle to the strut so it can installed in the same position. This is important for the camber angle of the front wheel. 10. Remove the strut-to-steering knuckle bolts. 11. Support the strut and remove the 3 upper strut-to-chassis nuts. Remove the strut from the vehicle.

WARNING Never loosen the strut center nut until the spring is compressed or serious injury or vehicle damage may occur. 12. Place the strut and coil spring

assembly in a suitable vise and remove the strut nut cover. 13. Slightly loosen, but do not remove the front strut nut. If desired, use the following steps to remove the coil spring from the strut. 14. Using an approved coil spring com¬ pressor, compress the coil spring. 15. Remove the strut assembly top nut. 16. Remove the following components from the strut assembly: • Upper mounting bracket • Strut bearing • The bearing seat.

• Upper coil spring seat and dust boot

• Coil spring 17. Slowly release the tension of the coil spring compressor and remove the coil spring from the compressor tool. 18. Remove the coil spring insulator and slide the jounce bumper off of the strut assembly. To install: 19. Slide the jounce bumper onto the

strut assembly and install the coil spring insulator.

20. Carefully compress the coil spring with an approved coil spring compressor. 21 . Reinstall the following components to the strut assembly: • Coil spring w-lnstall the coil spring to the strut assembly with the end of the spring in the lower coil spring seat indentation.

• Upper coil spring seat and dust boot • Bearing seat and the bearing • Upper mounting bracket 22. Install and tighten the strut assembly nut and tighten the nut to 43-58 ft. lbs. (59-78 Nm). 23. Install the strut assembly onto the vehicle and tighten the following:

7924WG22

Compress the coil spring in an approved spring compressor

26-34

NISSAN QUEST

• Strut-to-body nuts: 29-40 ft. lbs. (39-54 Nm) • Strut-to-knuckle bolts: 101-116 ft. lbs. (137-157 Nm) 24. Reattach the brake tube to the strut assembly. 25. Install and tighten the 2 front brake anti-lock sensor cable bracket bolts. 26. Reinstall the tire and wheel assembly. 27. Connect the negative battery cable and the adjustable strut electrical connec¬ tors, if equipped. 28. Check and/or adjust the wheel align¬ ment.

Shock Absorber REMOVAL & INSTALLATION

Lower ball joint — '

7924WG26

Loosen the nut on the lower ball joint stud

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Raise and safely support the vehicle. 3. Support the rear axle and slightly lower the vehicle enough to lessen tension on the shock absorber. 4. Remove the lower shock absorber retaining nut and washer. 5. Disconnect the lower end of the shock absorber from the mounting stud. 6. Remove the shock absorber upper end retaining nut and washer. 7. Remove the shock absorber from the vehicle. To install: 8. Install the shock absorber onto the upper and lower mounting studs of the vehicle. 9. Install the washers and retaining nuts. Tighten the upper and lower retaining nuts to 22-30 ft. lbs. (30-41 Nm). 10. Lower the vehicle.

Lower Ball Joints REMOVAL & INSTALLATION To check if ball joint replacement is required, raise and safely support the vehicle clear of the floor and try to rock the wheel up and down. If any play is felt, have an assistant rock the wheel while observing the front suspension lower arm ball joint at the bottom of the steering knuckle. If any movement is seen, the ball joint should be replaced. If not, any wheel play indicates wheel bearing wear. 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Raise and safely support the vehicle.

3. Remove the tire and wheel. 4. Remove and discard the ball joint cotter pin. Loosen the ball joint attaching nut from the steering knuckle. Because of tight clearance, the nut likely cannot be removed until the ball joint stud is loosened and lowered slightly. 5. Strike the front knuckle with a hammer while pulling down on the lower control arm. There should now be enough clearance to allow removal of the ball joint stud nut. Sepa¬ rate the ball joint from the steering knuckle. 6. Remove the 3 bolts attaching the ball joint to the control arm. 7. Remove the ball joint from the con¬ trol arm. To install: 8. Install the ball joint to the control arm and install the attaching bolts.

9. Tighten the bolts to 54-65 ft. lbs. (74-88 Nm). 10. Install the ball joint into the steering knuckle, just enough to get the nut started on the stud. Then, push the ball joint stud fully in place. Tighten the nut to 52-63 ft. lbs. (71-86 Nm). Secure the nut with a new cotter pin. 11. Install the tire and wheel. 12. Lower the vehicle.

13. A front end alignment check is rec¬ ommended.

Lower Control Arm REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the wheel. 3. Disconnect the ball joint.

4. Disconnect the stabilizer bar from the control arm. 5. Remove the 2 rear arm bolts and the mounting bracket. 6. Remove the lower arm nut. 7. Pull the rear of the arm down and gen¬ tly pry the arm forward and off the gusset. 8. Installation is the reverse of removal. Observe the following torques:

• Stabilizer bar-to-lower arm: 12-16 ft. lbs. (16-22 Nm) • Lower arm rear bolts: 87-108 ft. lbs. (118-147 Nm) • Lower arm nuts: 94-115 ft. lbs. (128-156 Nm) • Ball stud nut: 56-80 ft. lbs. (76-109 Nm) BUSHING REPLACEMENT The bushings are press-fit types. Support the arm in a press, using the proper adapters. Ford tool numbers are: T93P5493-A, T75L-1165-B and -DA.

Wheel Bearings ADJUSTMENT

The wheel bearings are not adjustable. If the bearings become loose or make noise, they must be replaced using the following procedure. REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

M,ggS 26-35 Spacer (4.0 -5.5. 29 - 40)

Coil spnng

Strut assembly

r Bolt assembly

Knuckle

46~51 34 - 38) (4.7 -5.3.

76-109 56 - 80) (7.8-11.1,

Gusset

Transverse

link

118-147(12-15.

87-108)

Stabilizer bar

n

147 87118-5, (12-1

108)

installing rubber parts, final tightening on' be earned out. under unladen conditi must tires with on ground •: Fuel, radiator coolant and engine oil full.

When

: N m (kg-m, ft-lb)

mats in Spare tire, jack, hand tools and designated positions.

Exploded view of the front suspension and drive axles

7924WG25

OC

QC

£U~00

NISSAN QUEST acts as a front wheel bearing outer bear¬ ing 7. retainer. Disengage the lower ball joint stud from the steering knuckle using the follow¬ ing procedure. a. Remove and discard the cotter pin from the front lower ball joint. b. Loosen the lower ball joint nut until it contacts the front halfshaft joint. c. Strike the front knuckle with a hammer while pulling down on the lower control arm until the ball joint stud sepa¬ rates from the knuckle. d. Remove the ball joint nut. e. Disengage the lower ball joint stud from the steering knuckle. 8. Disengage the outer tie rod end stud from the steering knuckle using the follow¬

1

0

6. Wheel hub 7. Wheel hub bolt 8. Snap ring

1 . Cotter pin 2. Nut retainer 3. Insulator 4. Front axle wheel. hub retainer 5. Front wheel outer bearing retainer washer

9. Front wheel bearing 10. Front disc brake rotor shield 1 1 . Front wheel knuckle

ing procedure. a. Remove and discard the cotter pin from the outer tie rod end stud. b. Remove the outer tie rod end retaining nut. c. Use a tie rod end puller to carefully press the tie rod end from the steering knuckle. 9. Remove the front ABS sensor bolt.

7924WG23

Exploded view of the knuckle, hub and bearing

2. Raise and safely support the vehicle. 3. Remove the wheel and tire. 4. Remove the brake caliper assembly. DO NOT disconnect the brake hose. Hang the caliper on a piece of wire from a near by support such as the strut.

5. Remove the brake rotor. 6. Remove and discard the cotter pin from the end of the outboard CV-joint stub shaft. Remove the hub nut retainer, washer and the hub nut. There should be another washer under the hub nut that

FRONT

Rem

ove

the

2f

ron

t st

rut

-to

-fr

ont

CROSS BAR

HOOK

1 . Knuckle puller 2. Knuckle puller adapter 3. Step plate adapter 4. Front disc brake rotor shield 5. Front wheel knuckle

SHAFT PROTECTOR

NUT/BOLT 7924WG27

Example of a puller set up to bear against the front wheel bearing inner race

NISSAN

OC

07

QUEST

Of

Baffle plate

Wheel hub bearing /— vvneei nui

Wheel nut

/

& Front

Oor

L

iio_/

,C

[CJ]98-118(10-12,72-87)

[U) Wheel bearing lock nut

* 216 - 284, Cotter pin

72 - 83)

(22 - 29,159 - 210)

Hub cap -

" B /A 9302WG05

Rear hub assembly

knuckle nuts and remove the 2 bolts. Dis¬ engage the strut from the steering I knuckle.

11. Use a 2-jaw puller to separate the front halfshaft outboard CV-joint stub shaft from the knuckle/bearing assembly. 12. Remove the front wheel hub, knuckle and wheel bearing assembly from the vehicle. 13. If the knuckle is being replaced with a service part, change over the steering stop bolt and jam nut from the old knuckle to the replacement part. 14. To remove the front wheel bearing, jig up a puller to bear against the front wheel bearing inner race and pull the race from the hub/knuckle assembly.

15. Use a shop press to press out dam¬ aged wheel studs and also to press out the outer bearing race. 16. Use a shop press to press out the inner bearing race. To install: 17. If the front wheel bearings were removed, assemble the ABS sensing ring, if

removed and the disc brake dust shield under the steering knuckle. Use a shop press to push in new front wheel bearing inner and outer races. Support the knuckle and press the front wheel bearing into the knuckle and install the snapring retainer. Support the bearing assemblies and press the hub onto the knuckle and wheel bearing assembly. 18. Install the hub, knuckle and bearings as an assembly. Position the assembly on the halfshaft outer CV-joint stub axle end. Guide the knuckle into the front strut and install the 2 knuckle-to-strut bolts and nuts. Tighten the nuts to 83-91 ft. lbs. (113-123 Nm). 19. Install the ABS sensor bolt. Do not

over-tighten. Tighten to just 16-21 inch lbs. (1 .8-2.4 Nm). 20. Install the outer tie rod end to the steering knuckle. Tighten the nut to 22-29 ft. lbs. (29-39 Nm). If the cotter pin holes do not align, tighten the nut slightly until they do. Never loosen the nut to align the holes. Secure the nut with a new cotter

21. Start the lower ball joint stud to the steering knuckle and partially install the nut, then push the ball joint stud fully in place. Tighten the ball joint stud nut to 52-63 ft. lbs. (71-86 Nm). Secure the nut with a new cotter pin. 22. Install the front wheel outer bearing retaining washer and the hub retainer nut. Tighten to 174-231 ft. lbs. (235-314 Nm). Install the nut retainer, insulator and a new cotter pin. 23. Install the front brake rotor and install the disc brake caliper. 24. If removed, install the steering stop bolt. 25. Install the tire and wheel assembly. 118 Nm). Tighten the lug nuts to 72-87 ft. lbs. (98 to

26. Lower the vehicle. Pump the brake pedal slowly to seat the front brake pads. Do not move the vehicle until a firm pedal is obtained. 27. A front end alignment is recom¬ mended.

OR

QQ

£0-00

NISSAN QUEST

Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 1 2. Raise and safely support the vehicle. 3. Remove the rear wheel(s). 0 4. Remove the brake drum. . 5. Remove the grease cap for the

6. Remove and discard the cotter pin. 7. Remove the wheel bearing nut and washer. 8. Remove the rear wheel hub and bearing assembly. To install: 9. Install the rear wheel hub and bear¬ ing assembly onto the vehicle.

washer and nut and tighten the bearing nut to 159-210 ft. lbs. (216-284 Nm). Install a new cotter pin. 11. Install the wheel hub grease cap. Install the brake drum. 12. Install the rear wheel(s) and lug nuts. Tighten the lug nuts, in a star sequence, to 72-87 ft. lbs. (98-118 Nm). 13. Lower the vehicle.

BRAKES Brake Caliper REMOVAL & INSTALLATION The front disc brake caliper slides on 2 stainless steel locating pins. The front disc brakes use a conventional pin slider-type front disc brake caliper with a 10.875 inch (27.6cm) front disc rotor. The front disc brake caliper is attached to the front sus¬ pension with 2 Torx® head brake caliper bolts. Rubber insulators isolate the stainless steel locating pins from direct contact with the front disc brake caliper. The front disc brake calipers must be removed to replace the front brake pads.

Inst1a. Before servicing the vehicle, refer to ll th e rea r winhe the beginning of this sec¬ precautions the el b tion. eari n 2. Remove or disconnectg the following: • Wheel and tire 'Hf the brake caliper is being removed for brake pad replacement only, DO NOT disconnect the brake hose. • 2 caliper pin bolts. Most applica¬ tions will require a Torx® T-40 bit to remove the 2 brake caliper bolts. 3. If the brake caliper is being removed just for brake service, with the brake hose still attached to the caliper, use a length of wire to support the caliper from the front

shock absorber. Do not let the caliper hang by the brake hose. If the caliper is being completely removed from the vehicle for overhaul, use care not to drip brake fluid on the paint. *Hf both calipers are being completely removed from the vehicle at the same time, mark them Left and Right so the calipers can be reinstalled to their original locations. The reason for this is that the bleeder screws must be positioned on the top of the front disc brake caliper when installed on the vehicle. To install: 4. Clean all parts well. Use a C-clamp and a used brake pad to push the caliper piston fully in the piston bore. Inspect the caliper pins and clean any dirt and debris. 5. Install the caliper onto the rotor. Make sure the inboard and outboard brake

BRAKE CALIPER BOLTS (2 REQ’D)

pads are properly positioned. 6. Lubricate the stainless steel locating pins with a Silicone Dielectric Compound such as Ford DZAZ-19A331-A or equivalent silicone grease. Install the 2 caliper pin Nm). bolts and torque to 18-25 ft. lbs. (24-34 7. If disconnected, install the brake hose using a new replacement copper washer, install the banjo bolt and torque to 12-14 ft. lbs. (17-20 Nm). 8. If the brake hose had been discon¬ nected, bleed the brake system. 9. Install the wheel and tire.

10. Torque the lug nuts to 72-87 ft. lbs. (98-118 Nm). 1 1 . Check the master cylinder reservoir and add fresh DOT 3 brake fluid as

93026G10

Caliper pin bolt removal

required. 12. Lower the vehicle. Pump the brake pedal slowly until a firm brake pedal is obtained, indicating that the brake pads are properly seated, before attempting to move the vehicle. Road-test and check for proper brake operation.

NISSAN

Ofi.QQ

QUEST

^»Do not press the piston into the bore as performed on the front disc brakes. Due to the parking brake mechanism, the caliper piston must be turned into the bore using a special tool.

Disc Brake Pads REMOVAL & INSTALLATION Front

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Wheels • Bottom guide pin from the caliper and swing the caliper cylinder body upward; support the caliper with a wire • Brake pad retainers and the pads To install: 3. Compress the piston of the disc brake caliper. 4. Install or connect the following: • Brake pads and caliper assembly. Torque the guide pin to 23-30 ft. lbs. (31-41 Nm). • Wheels 5. Apply the brakes a few times to seat the pads. Check the master cylinder and add fluid if necessary. Bleed the brakes, if necessary. Rear

p ttihoen recau t .

ion

s

in the begi nni ng

Replacing the disc brake pads

of this sec¬

ing:2. Remove or disconnect the follow¬ • Rear wheels 3. Release the parking brake. body • Parking brake cable bracket bolt • Pin bolts and lift off the caliper • Pad springs • Pads and shims To install: 4. Clean the piston end of the caliper body and the area around the pin holes. Be careful not to get oil on the rotor. 5. Using the proper tool, carefully turn the piston clockwise back into the caliper body. Take care not to damage the piston boot. 6. Coat the pad contact area on the mounting support with a silicone based

grease. 7. Install or connect the following: • Pads, shims, and the pad springs. Always use new shims. • Caliper body in the mounting sup¬ port and tighten the pin bolts to 28-38 • Wheels ft. lbs. (38-52 Nm) 8. Bleed the system if necessary.

Oil

Brake Drums REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. The rear drum brakes used on these vehicles are conventional expanding shoetype with the brake shoe lining applied to the inside of the rotating drum. An incre¬ mental brake adjuster screw is designed to actuate whenever sufficient wear occurs. 2. Remove or disconnect the following: • Wheel and tire • Brake drum by pulling it from the wheel studs 3. If necessary for brake drum removal, pry off the access hole plug from the access hole. Insert a screwdriver and a brake adjustment tool. Press the screwdriver against the adjusting lever to disengage it from the adjuster. Loosen the adjuster using the brake adjusting tool. To install: 4. Clean all parts well. It is good prac¬ tice to inspect the wheel cylinder for leaks anytime the brake drum is removed. If a new replacement brake drum is being installed, inspect it for a protective coating on the machined inside braking surface. Remove

any coating with suitable solvent. 5. Install or connect the following:

26-40 SAN

• Brake drum onto the wheel studs 6. In most all cases, manual brake

BRAKE ADJUSTER BRAKE SHOE SCREW ADJUSTING

adjustment IS NOT recommended. Adjust¬ ment is performed by driving the vehicle and applying the brakes. • Tire and wheel and torque the fasten¬ ers to 72-87 ft. lbs. (98-118 Nm) 7. Adjust the rear brake shoes by sharply applying the brakes several times while driving the vehicle alternately for¬ wards and backwards. Check the brake operation by making several stops while driving forward.

Brake Shoes REMOVAL & INSTALLATION 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

Brake shoe adjustment may need to be loosened to remove the brake drum

1 Rear Wheel Cylinder

13

Rear Brake Backing Plate

2 Dust Boot (2 Req'd) 3 Wheel Cylinder Piston (2

14

Bolts (4 Req'd) Parking Brake Lever Clip

Req'd) 4 Cup (2 Req'd) 5 Wheel Cylinder Piston Cup Spring 6 Wheel Cylinder Housing 7 Brake Shoe Hold-Down

Pin

Lining 15 Spring Washer 16 Secondary Brake Shoe and 17

Brake Shoe Hold-Down Spring

18

Lower Retracting Spring

19

Parking Brake Lever

20 21

Parking Brake Lever Pin Brake Shoe Adjusting Lever

10 Access Hole Plug

22

Adjuster Lever Pin Lining

11 Rear Wheel Cylinder Bolt (2

23

Primary Brake Shoe and

Req’d) 12 Rear Brake Backing Plate

24

Upper Retracting Spring

29

Brake Adjuster Screw

Req'd)Hole 8 (2 Access 9 Rear Brake Bleeder Screw

93026G29

Rear drum brake assembly and related components

NISSAN 4 1 QUEST tU • Parking brake rear cable and con¬ duit from the parking brake lever • 2 brake shoe hold-down springs and the 2 brake shoe hold-down

• Upper retracting spring • Lower retracting spring • Brake adjuster screw • Rear brake shoes and linings from the brake backing plate pins • Parking brake lever clip and washer

• Parking brake lever from the sec¬ ondary brake shoe and lining To install: 3. Clean all parts well. 4. Inspect the wheel cylinder for signs of leaking. Service as required. 5. Inspect the retracting springs for heat damage, bends or damage to the coils or shank or loss of tension. A good retract¬ ing spring will make a full thud when dropped on a concrete floor. A heat-dam¬ aged retracting spring that has lost tension will make a distinctive ringing sound when Remove

the upper retracting spring

The rear drum brakes use an internal rear wheel cylinder with expanding shoes and lining that are applied against a rotating brake drum. An incremental brake adjuster screw is actuated whenever sufficient wear occurs. Brake adjustment takes place in for¬

Re

• Brake drum

LOW RETRACTING

mo

ve or

ward or reverse braking but not with parking brake application. ing : • Wheels

dis

SPRING

con

nec the f

oll

ow¬

dropped on a concrete floor. 6. Check the brake backing plate for signs of scoring. The shoe contact points must be smooth and have a light coating of lithium grease. Verify that the brake lining thickness is between 0.059-0.232 in. (1.5-5.9mm). Failure to replace worn rear brake shoes will result in a scored drum. 7. Inspect the brake drum for scratches, con¬ out-of-round and scores bell mouth scoring, Remove on a brake minor ditions. drum with sandpaper. Do not refinish brake drums to remove scoring marks. A brake drum surface that is highly polished can cause the brakes to lock up. Remove pol¬ ished surfaces with sandpaper or refinish the brake drum. Refinish a brake drum that is out-of-round enough to cause vehicle vibration or noise when braking. Remove to true-up the only enough surface metalmaximum inside brake drum. Brake drum diameter is shown on each drum. If the maximum inside diameter shown on the brake drum is exceeded through wear or refinishing, replace the brake drum. After a brake drum is refinished, wipe the refin¬ ished surface with a cloth soaked in clean denatured alcohol. If one brake drum is refinished, the brake drum on the opposite side of the vehicle should also be refinished to the same diameter. The standard inner brake drum diameter is 9.840 inches (250.0mm). Replace the brake drum if worn beyond 9.900 inches (251.5mm). 8. Install or connect the following:

93026G31

Remove

the lower retracting spring

• Parking brake lever to the sec¬ ondary brake shoe and lining with a new parking brake lever clip

oc

LU

A 9 NISSAN

QUEST

on the primary (front) brake shoe. The slot on the adjuster nut end must fit into the slots in the sec¬ ondary (rear) brake shoe and parking brake lever. 9. Install or connect the following: • Brake shoe adjusting lever on the adjuster lever pin • Upper retracting spring in the slot on the secondary shoe and in the slot on the brake shoe adjusting lever. The brake shoe adjusting lever should contact the brake • adjuster Brake drum screw. Nm). • Tire and wheel and torque the fas¬ teners to 72-87 ft. lbs. (98-118 MAXIMUM BRAKE DRUM DIAMETER

(-►In most all cases, manual brake adjustment IS NOT recommended. Adjustment is performed by driving the vehicle and applying the brakes.

93026G32

Replace These size checks should be made and the retracting springs’ condition checked. questionable parts

Secondary (rear) shoe on the back¬ ing plate and the brake shoe hold¬ down spring and pin Primary (front) shoe on the backing plate and the brake shoe hold¬ down spring and pin Parking brake rear cable and con¬ duit to the parking brake lever Lower retracting spring to the rear brake shoes

Apply a light coat of high-quality grease to the threaded areas of the adjuster nut and adjuster socket. Turn the adjuster nut all the way down on the brake adjuster screw, then loosen the adjuster Vfeturn. Install the adjuster screw in the slots on the rear brake shoes. The wider slot on the socket must fit in the slot

10. The rear brakes do not require adjustment when being serviced to obtain a firm brake pedal feel. To achieve a firm brake pedal after servicing the rear brakes, sharply apply the brake pedal several times while driving the vehicle alternately forwards and backwards. Check the brake operation by making several stops while driving forward. The self-adjusting mech¬ anism will sufficiently adjust the rear brake shoes without any manual tighten¬ ing at the brake shoe adjuster. If the rear brake shoes are manually adjusted, the additional action of the brake shoe adjuster can cause the brakes to become over-tightened and result in binding or overheated rear brakes.

NISSAN AND INFINITI Pathfinder • QX4 27-52 BRAKES . 27-42 DRIVE TRAIN . 27-10 ENGINE REPAIR . 27-40 FUEL SYSTEM . 27-10 PRECAUTIONS . SPECIFICATION CHARTS . 27-2 STEERING AND 27-47 SUSPENSION . A

Air Bag . Disarming . Precautions . Alternator . Removal & Installatoin . Automatic Transmission . Removal & Installation . Axle Shaft, Bearing and Seal . Removal & InstallB ation .

27-47 27-47 27-47 27-11 27-11 27-44 27-44 27-46 27-46

Brake Caliper . Removal & Installation . Brake Drums . Removal & Installation . Brake Shoes . Removal & InstallCation .

27-52 27-52 27-53 27-53 27-54 27-54

Camshaft and Valve Lifters . Removal & Installation . Clutch . Removal & Installation . Coil Spring . Removal & Installation . CV-Joints . Overhaul . Cylinder Head . Removal & InstalDlation .

27-29 27-29 27-44 27-44 27-49 27-49 27-46 27-46 27-20 27-20

Disc Brake Pads . Removal & Installation . Distributor . Installation . Removal . E

27-53 27-53 27-10 27-10 27-10

Engine Assembly . Removal & Installation . Exhaust Manifold . Removal & Installation .

27-11 27-11 27-28 27-28

R

F

Front Crankshaft Seal . Removal & Installation . Fuel Filter . Removal & Installation . Fuel Injectors . Removal & Installation . Fuel Pump . Removal & Installation . Fuel System Pressure . Relieving . Fuel System Service H Precautions .

27-29 27-29 27-40 27-40 27-41 27-41 27-40 27-40 27-40 27-40

Rack and Pinion Steering

27-40

Halfshaft . Removal & Installation . Heater Core . Removal & Installation . Hydraulic Clutch System . Bleeding . . .

27-45 27-45 27-14 27-14 27-45 27-45

Ignition Timing . Adjustment . Intake Manifold . Removal & InstallLation .

27-11 27-11 27-27 27-27

Leaf Springs . Removal & Installation . Lower Ball Joint . Removal & Installation . Control Arm . Lower Control Arm Bushing

27-50 27-50 27-50 27-50 27-50

Replacement . Removal & Install M ation .

27-51 27-50

Manual Transmission . 0 ation . Removal & Install

27-42 27-42

Oil Pan . Removal & Installation . Oil Pump . Removal & InstalPlation .

27-30 27-30 27-32 27-32

Pinion Seal . Piston and Ring . Positioning .

27-46 27-39 27-39

Gear . Removal & Installation . Rear Main Seal . Removal & Installation . Recirculating Ball Power

27-48 27-48 27-34 27-34

Steering Gear . Removal & Installation . Rocker Arms/Shafts . Removal & InstallS ation .

27-47 27-47 27-25 27-25

Shock Absorber . Removal & Installation . ngs . le BeariPacking Spind Removal, And

27-49 27-49 27-46

Installation . Starter Motor . Removal & Installation . Strut . Removal & Installation . Supercharger . Inspection . Installation . Removal & InstallT ation .

27-46 27-30 27-30 27-48 27-48 27-25 27-25 27-27 27-25

Timing Belt . Removal & Installation . Timing Chain, Sprockets, Front Cover and Seal . Removal & Installation . Torsion Bar . Transfer Case Assembly . U ation . Removal & Install

27-34 27-34

. ol Arm r ContrArm UppeControl Bushing

27-50

Replacement . V Removal & Installation .

27-35 27-35 27-50 27-45 27-45

27-50 27-50

Valve Lash . * .

27-30

Adjustment . ^ . Water Pump . Removal & Installation . Wheel Bearings . .. Adjustment . Removal & Installation .

27-30 27-18 27-18 27-51 27-51 27-51

NISSAN AND INFINITI PATHFINDER • QX4

Q 07 L/'L

SPECIFICATION

ENGINE AND VEHICLE Engine Code © VG33E VQ35DE

Liters (cc)

Cu. In.

3.3 (3277) 3.5 (3498)

199.8 213

Cyl. 6 6

Fuel Sys. MFI MFI

CHARTS

IDENTIFICATION Model Year

Engine

Eng. Mfg.

SOHC DOHC

Nissan Nissan

Year 2000

Code© Y 1 2 3 4

MFI: Multi-port Fuel Injection SOHC: Single Overhead Camshaft DOHC: Double Overhead Camshafts

2001 2002 2003 2004

© Located on the timing belt cover of the Vehicle Identification Number (VIN) © 10th digit M

GENERAL i ecu 2000 2001 2002 2003

42356-PATH-C01

ENGINE SPECIFICATIONS

Oil ComBore x Net Net Fuel Engine pressior Pressure Displacemenl Engine System HorsepowerTorque @ rpn Stroke Ratio - @ rpm (in.) (ft, lbs.) @ rpm Type Liters (cc) r VID/VIN Model G33E 60-65@2000 3.60x3.27 VG33E MFI 3.3 (3277) 1 70@4800 QX4 200@2800 8.9:1 MFI 60-65@2000 Pathfinder 3.60X3.27 170@4800 3.3 (3277) 200@2800 8.9:1 60-65@2000 VG33E 3.3 (3277) MFI 3.60x3.27 170@4800 QX4 8.9:1 200@2800 60-65@2000 8.9:1 VG33E 3.60X3.27 3.3 (3277) Pathfinder 170@4800 MFI 200@2800 3.76X3.20 VQ35DE MFI 3.5 (3498) 10.0:1 240@6000 43@2000 265@3200 QX4 MFI 3.76X3.20 10.0:1 Pathfinder 3.5 (3498) 43@2000 VQ35DE 240@6000 265@3200 10.0:1 VQ35DE 3.5 (3498) 3.76X3.20 MFI 240@6000 265@3200 QX4 43@2000 MFI 3 5 (3498) 3.76X3.20 Pathfinder VQ35DE 10.0:1 240@6000 265@3200 43@2000

MFI: Multi-port Fuel Injection 42356-PATH-C02

ENGINE Gap

Year 2000 2001 2002 2003

Engine Displacemenl Liters (cc) 3.3 (3277) 3.3 (3277) 3.5 (3498) 3.5 (3498)

Spark Plug Engine IDA/IN VG33E

SPECIFICATIONS

TUNE-UP

Pump Timing Igniti Fuelon

Idle

(deg.) (in.)

VG33E

0.039-0.043 0.039-0.043

VQ35DE VQ35DE

0.044 0.044

MT MT 13-17B 13-17B 15B 15B

AT 13-17B 13-17B 15B 15B

(psi) © 34 35 35

(rpm) Speed

700-800 700-800 700-800 700-800

Valve Clearance (in.)

AT®

700-800 700-800 700-800 700-800

In. HYD HYD

Ex. HYD HYD

HYD

HYD

HYD

HYD

made during production. The label figures NOTE: The Vehicle Emission Control Information label often reflects specification changes must be used if they differ from those in this chart. B: Before top dead center HYD: Hydraulic

© System pressure at idle with vacuum hose connected Should increase to 43 psi when disconnected ©Automatic transmission in Neutral 42356-PATH-C03

NISSAN AND INFINITI PATHFINDER • QX4

© © ©

07_Q L. I

\J

© © I ®

Front of the Vehicle

/5fX3 @1(2;

79243G66

3.3L engines Firing order: 1-2-3-4-5-6 Distributor rotation: Counterclockwise

Power steering oil pump Fan pulley Crankshaft pulley Air conditioner compressor

F3 26 - 32 (2.6 - 3.3, 19 - 23)

Alternator Idler pulley

▼

: Check point

Cqj ; N*m

(kg-m, ft-lb) 42356-PATH-G01

Accessory V-belt routing — 3.5L engine

NISSAN AND INFINITI

27-4

PATHFINDER • QX4

CAPACITIES

Year 2000

Model QX4 Pathfinder

2001

QX4 Pathfinder

2002

QX4

Pathfinder1 QX4 Pathfinder

2003

3.3 3.3 3.3 3.3 3.5 3.5 3.5 3.5

(3277) (3277) (3277) (3277) (3498) (3498) (3498) (3498)

Engine IDA/IN VG33E VG33E VG33E VG33E VQ35DE VQ35DE VQ35DE VQ35DE

3.8 (qts.) 3.8 3.8 3.8 5.25 5.25 5.25 5.25

5-Spd Auto. (pts.) — 18.0 © —

© 18.0

©

© 18.0

—

— —

—

(pts.) 5.3 4.8 5.3 4.8 5.3 ©

18.0 18.0 18.0

5.3 ©

Cooling

de Drive A) Front

Rear

(pts.) 4.4 4.4 4.4 4.4 3.9

(pts.) 5.9 4.9 5.9 4.9

Fuel Tank

(gal.) 21.1 21.1 21.1 21.1 21.1

5.9 5.9 5.9

3.9 3.9 3.9

21.1 21.1 21.1

System 11.25 11.25 (qts.) 11.25 11.25 9.75 9.75 9.75 9.75

fluid level is obtained. All capacities are approximate. Add fluid gradually and check to be sure a proper

NOTE: ©2WD:

4WD: ©2WD: 4WD: ®

Engine Displacement Liters (cc)

Engine Transfer Oil with Transmission Filter Case

5.125 pts. 10.75 pts. 17.5 pts. 18 pts.

Part time: 2.375; full time: 2.625 pts

CRANKSHAFT

Year 2000 2001 2002 2003

Displacement Liters (cc)

Engine IDA/IN

3.3 (3277)

VG33E

3.3 (3277)

VG33E

3.5 (3498) 3.5 (3498)

VQ35DE VQ35DE

AND

CONNECTING

ROD

SPECIFICATIONS

All measurements are given in inches. Crankshaft Thrust Main Brg. Main Brg. Oil Shaft End-play Clearance on No. Journal Dia. 4 2.47900.0022 00110. 2.4793 0.0067 0.00204 2.47902.4793 0.0022 0.00110.0067 00200. 4 © 0.0118 0.0018 0.00144 © 0.0118 0.0018 00140.

Journal Diameter

Connecting Rod Oil Clearance

11.9675 .9967-

0.0021 0.0006-

1 .9675 1 .9©967-

0.0021 0.0006-

©

0.0023 0.00130.0023 0.0013-

Side Clearance

0.0138 0.00790.0138 0.00790.0138 0.00790.0138 0.0079-

NA - Not Available

© There are 24 different grades, ranging from A (2.3612) to 7 (2.3603) ©

Grade 0: 2.0460-2.0462 Grade 1: 2.0457-2.0460 Grade 2. 2.0445-2.0457 42356-PATH-C05

NISSAN AND INFINITI

L. I

PATHFINDER • QX4

VALVE

Year

Engine Displacement Liters (cc)

Engine ID/VIN

2000

3.3 (3277)

VG33E

2001

VG33E

3.3 (3277)

Seat

Face

Angle (deg.)

Angle (deg.)

45 45

3.5 (3498)

Spring Spring Test Installed Pressure Height (lbs. @ in.) ©

46.75 45.25-

.1545.45 45 2003

3.5 (3498)

(in.) NA NA

©

VQ35DE

45.4@1 .457 [email protected]

45.45 45.15-

Stem Stem-to-Guide Diameter Clearance (in.)

(in.) Exhaust Intake

Intake

Exhaust

0.0021 0.0008-

0.0029 0.0016-

0.2748 0.2742-

0.3138 0.3135-

0.0021 0.0008-

0.0029 0.0016-

0.2748 0.2742-

0.3138 0.3135-

0.0021 0.0008-

0.0029 0.0016-

0.2354 0.2348-

0.2346 0.2341-

0.0021 0.0008-

0.0029 0.0016-

0.2354 0.2348-

0.2346 0.2341-

1.457

45

VQ35DE

\3

SPECIFICATIONS _

46.75 .2545 45 2002

07.1;

1.457

NA: Not Available ©Inner: 57.3 @ 0 984 Outer: 117.7 @ 1.181

42356-PATH-C06

Top

PISTON

Year 2000 2001 2002 2003

AND

TRING op

SPECIFICATIONS

All measurements are given in inches. Ring Side Clearance Ring Gap_ Engine Oil Comp. Bottom Bottom Piston Displacement Comp. Engine Comp. Comp. Oil Control Control ID/VIN Liters (cc) Clearance © VG33E 3.3 (3277) 0.0073 0.00830.0157 0.01970.0272 0.0272 0.0030 0.0028 0.00790.00090.00120.0006© VG33E 3.3 (3277) 0.0030 0.0272 0.00830.0073 0.0272 0.0157 0.0028 0.01970.00790.00090.00120.0006VQ35DE 3.5 (3498) 04 00 0.0020 0.0031 0.0130 0. 0.0189 0.00910.0236 0.0012 0.0028 0.01300.00790.00160.00120.0006VQ35DE 3.5 (3498) 0.00040.0031 0.00910.0236 0.0130 0.0189 0.0012 0.0020 0.01300.0028 0.00790.00160.00120.0006-

© Cylinders 1 , 2, 6: 0.001 0 - 0.001 8 in. Cylinders 3 and 4: 0.0006 - 0 0010 in. Cylinder 5: 0 0012-0.0016

in. 42356-PATH-C07

27-6

NISSAN AND INFINITI PATHFINDER

• QX4

TORQUE

SPECIFICATIONS

All readings in ft. lbs. _ _ Rod Crankshaft Cylinder Main Engine Displacement Engine Head Bearing Bearing Damper Flywheel Manifold Year Liters (cc) IDA/IN Bolts Bolts Bolts Bolts Bolts Intake Exhaust © © 21-25 VG33E 141-156 © 61-69 2000 3.3 (3277) 67-74 © © 21-25 141-156 © VG33E 2001 3.3 (3277) 67-74 61-69 © © © © © 61-69 2002 VQ35DE 3.5 (3498) 21-24 © © © 61-69 © © 2003 VQ35DE 3.5 (3498) 21-24 ® The cylinder heads and the lower intake manifold are installed together

® Step 1 : 72 ft. lbs.

Step 1 : Tighten the cylinder head bolts to 22 ft. lbs

Step 2: Loosen all bolts completely

Step 2: Tighten the cylinder head bolts to 43 ft. lbs

Step 3: 25-33 ft. lbs.

Step 3: Loosen the cylinder head bolts completely

Step 4: +90 degrees

Step 4: Tighten the cylinder head bolts to 84 inch lbs.

Step 5: +90 degrees

Step 5: Tighten the intake manifold fasteners to 35 inch lbs.

Spark Lug Nuts Plugs 87-108 14-22 87-108 14-22 87-108 87-108 14-22 14-22

©Step

Step 6: Tighten the intake manifold fasteners to 13 ft. lbs.

1:24-28 ft. lbs.

Step 2: +90 degrees

Step 7: Tighten the intake manifold fasteners to 12-14 ft. lbs.

© Step 1: 15 ft. lbs.

Step 8: Loosen all intake manifold fasteners completely

Step 2: +90 degrees

Step 9: Tighten the cylinder head bolts to 22 ft. lbs.

© 29-36 ft. lbs. +60-66 degrees

Step 10: Tighten the cylinder head bolts 60-65 degrees

© Step 1: 44-86 inch lbs.

Step 1 1 : Tighten the cylinder head sub-bolts to 80-105 inch lbs.

Step 2: 20-23 ft. lbs.

Step 12: Tighten the intake manifold fasteners to 35 inch lbs. Step 13: Tighten the intake manifold fasteners to 78 inch lbs. Step 14: Tighten the intake manifold fasteners to 70-84 inch lbs. ®io-12

ft. lbs. plus 60-65 degrees or 28-33 ft. lbs. 42356-PATH-C08

WHEEL

Year 2000

Pathfinder

2001

QX4 Pathfinder

2002 2003

Model

QX4 Pathfinder QX4 © Pathfinder QX4 ©

©

ALIGNMENT

Camber Caster Setting Preferred Preferred Range Setting Range (+/-Deg.) +0.17 Toe-in (Deg.) (+/-Deg.) (in.) (Deg.) +3.00 +0.10 0.75 0.75 +3.00 0.08+/-0.04 +0.17 0.75 0.75 +3.00 0.08+/-0.04 +0.10 0.75 0.75 0.08+/-0.04 +3.00 0.75 0.75 +0.17 0.08+/-0.04 +3.00 +0.17 0.75 0.75 0.08+/-0.04 +3.00 +0.17 0.75 0.75 +3.00 0.08+/-0.04 +0.17 0.75 +3.00 0.75 0.08+/-0.04 0.75 0.75 0.08+/-0.04

Axis Inclination (Deg.) — — — — — — — —

Assumes P245/65R1 7 tire 42356- PATH-C09

NISSAN AND INFINITI PATHFINDER

OEM Model Pathfinder

2001

QX4 Pathfinder

2002

2003

OEM:

PSI: Pounds

Optional P265/70R15

P245/70R16

None

P235/70R15

P265/70R15

P245/70R16 P245/65SR17 P255/65SR16

QX4 Pathfinder LE Pathfinder SE

P245/70R16 P245/65SR17 P255/65SR16 P245/65R17

Original Equipment

Tires

Standard P235/70R15

QX4 Pathfinder LE Pathfinder SE

QX4

*

• QX4

*

AND BALL JOINT SPECIFICATIONS _

TIRE, WHEEL Year 2000

07.7

None none None P245/65R17 none None None

Tire Pressures (psi) Front Rear 30 30 35

35 30

30 35

35

©

©

©

©

© © © ©

© © © ©

Wheel Size Std: 7-JJ 6.5-JJ

Ball Joint Inspection U: 0.020 in. L:© ©

Opt: 7-JJ 7-JJ Std: 6.5-JJ Opt:8J7-JJ 7JJ Std: 7J/Opt: 8J 7JJ 8J Std: 7J/Opt: 8J

U: 0.020 in. L:© ©

© © © © © ©

Manufacturer

Per Square Inch

STD: Standard OPT: Optional

L: Lower U: Upper © Replace if any measurable

movement

is found.

@ See placard on vehicle ® Axial play Upper: 0 Lower: 0.008 in.

©

Turning torque: 4.3-43 inch lbs. 42356-PATH-C10

BRAKE

SPECIFICATIONS

All measurements in inches unless noted _ _ _ Brake Caliper Minimum Brake Drum Diameter Bracket Mounting Lining Original Max. Maximum Brake Disc Inside Thickness Maximum Machine Bolts Bolts Minimum Wear Original (ft. lbs.) (ft. lbs.) Runout Diameter Limit Diameter Front Thickness Thickness Rear 11.60 NA 0.059 11.67 1.100 1.024 0.079 24-31 53-72 0.004 16-23 1.100 0.059 0.079 1.024 11.60 0.004 11.67 NA 53-72 0.059 NA 11.60 24-31 11.67 1.100 53-72 0.079 1.024 0.004 NA 0.059 16-23 11.60 1.100 11.67 1.024 0.004 53-72 © © 11.67 NA 0.079 0.059 0.003 11.61 1.100 1.024 © © NA 0.079 0.003 0.059 11.67 1.100 11.61 1.024 ' 9 © 0.07 © 0.059 11.67 1.100 0.079 11.61 0.003 1.024 NA © © 0.059 0.079 0.003 1.100 11.67 11.61 1.024 _

Year 2000 2001

Model QX4 Pathfinder

2002

QX4 Pathfinder Pathfinder

2003

QX4 Pathfinder QX4

NA: Not Available

©Torque

member

mounting bolt: 127-134

Main pin bolt: 24-31 ©2WD: 4WD:

0.870 1.020 42356-PATH-C11

i '

~

07 Ll~

Q 0

NISSAN AND INFINITI PATHFINDER * QX4 MAINTENANCE

SCHEDULED

INTERVALS

2000 Nissan — Pathfinder; Infiniti — QX4 VEHICLE TYPE OF TO BE SERVICED

7.5

15

22.5

30

37.5

MILEAGE 45

INTERVAL

52.5

60

SERVICE R

Engine oil & filter Brake lines & cables

S/I

Brake pads, discs, drums & linings

S/I

Driveshaft boots & propeller shaft

S/I

Front wheel bearings (4x2)

S/I

90

67.5

y

✓

✓

✓

82.5 ✓

97.5 y

✓

✓

V

✓ y y

Automatic & manual

✓

transmission, transfer &

y

y

S/I

differential gear oil © Front wheel bearings (4x4)

y

✓

R

Engine coolant

✓

S/I

Steering gear (box) & linkage, axle & suspension

S/I

parts Vapor lines

v'

y y

S/I S/I

Exhaust system Fuel lines

y y

R

Spark plugs Drive belt(s)

y

✓

S/I R

Air cleaner filter

✓

y

✓

y

y

S/I R

Timing belt © R: Replace

75 (xIOOO)

S/I: Service or Inspect

miles. © Differential (w/limited-slip differential) oil: replace oil every 30,000

©Timing

belt: replace at 105,000 miles.

FREQUENT

OPERATION

MAINTENANCE

(SEVERE

SERVICE)

d severe service. If a vehicle is operated under any of the following conditions it is considere - Extremely dusty areas. es, or constant operation in temperatures below 0°C (32°F). - 50% or more of the vehicle operation is in 32°C (90°F) or higher temperatur traffic). go and stop in operation (vehicle idling • Prolonged temperatures). - Frequent short running periods (engine does not warm to normal operating - Police, taxi, delivery usage or trailer towing usage. Oil & oil filter: replace every 3750 miles.

7500 miles. Brake pads, discs, drums & linings: service or inspect every 7500 miles. Driveshaft boots & propeller shaft: service or inspect every Exhaust system: service or inspect every 7500 miles.

& suspension parts: service or inspect every 7500 miles. Steering gear (box) & linkage, (steering damper-4x4), axle or inspect every 7500 miles. Steering linkage ball joints & front suspension ball joints: service 42356-PATH-C12

NISSAN AND INFINITI MAINTENANCE

V

£. I

PATHFINDER • QX4

SCHEDULED

07. Q

INTERVALS

2001-03 Nissan— Pathfinder; Infiniti — QX4 TYPE OF SERVICE R

TO BE SERVICED Engine oil & filter Brake lines & cables

7.5

✓

11 y

15 /

26

y

41

45

✓

/

49

52.5

✓

✓ 60

y y

y

✓

y

L/l

✓

y

y

✓

✓

y

LSD gear oil Front wheel bearing grease (4x4)

R

Timing belt© Air cleaner filter

R R

Enqine coolant ©

R R

✓ ✓

✓

✓

y y

✓

R

y y

platinum tipped plugs every 105,000 mile ✓

S/I l/R 1 S/I

1 ✓

R ✓

1

R ✓ ✓

1

s

R ✓

1

R

✓

S/I S/I: Service or Inspect

y

✓

1

Vapor lines

56

✓

1

Steering gear (box) & linkage, axle & suspension parts

/

37.5

✓

1

Exhaust system Fuel lines

34

(xIOOO)

1

Front wheel bearings (4x2) Automatic & manual transmission, transfer & differential gear oil ©

Spark plugs Drive belt(s) Cabin air filter

INTERVAL

/

S/I

Brake pads, discs, drums & linings Driveshaft boots & propeller shaft

R: Replace

3.8

VEHICLE MILEAGE 30 19 22.5

L: Lubricate

© Differential (w/limited-slip differential) oil: replace oil every 30,000 miles.

©Timing

belt: replace at 105,000 miles.

® After 60,000, replace every 30,000

FREQUENT

OPERATION

MAINTENANCE

(SEVERE

SERVICE)

severe service: If a vehicle is operated under any of the following conditions it is considered - Extremely dusty areas. constant operation in temperatures below 0“C (32'F). - 50% or more of the vehicle operation is in 32°C (90“F) or higher temperatures, or traffic). go and stop in - Prolonged idling (vehicle operation temperatures). - Frequent short running periods (engine does not warm to normal operating - Police, taxi, delivery usage or trailer towing usage. Oil & oil filter: replace every 3750 miles.

miles. Brake pads, discs, drums & linings: service or inspect every 7500 miles 7500 every Driveshaft boots & propeller shaft: service or inspect Exhaust system: service or inspect every 7500 miles.

& suspension parts: service or inspect every 7500 miles. Steering gear (box) & linkage, (steering damper-4x4), axle or inspect every 7500 miles. Steering linkage ball joints & front suspension ball joints: service 42356-PATH-C13

07 1 n NISSAN AND INFINITI L I “ I U PATHFINDER • 0X4 PRECAUTIONS Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle:

• Never open, service or drain the radia¬ tor or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. • Observe all applicable safety precau¬ tions when working around fuel. When¬ ever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extin¬ guisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibil¬ ity of fire or explosion. Refer to the addi¬ tional fuel system precautions later in this section. • Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. • Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If

eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance. • The EPA warns that prolonged con¬ tact with used engine oil may cause a number of skin disorders, including can¬ cer! You should make every effort to mini¬ mize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas as soon as pos¬ sible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. • All new vehicles are now equipped with an air bag system. The system must be disabled before performing service on or around system components, steering col¬ umn, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in acci¬ dental air bag deployment, possible per¬ sonal injury and unnecessary system repairs. • Always wear safety goggles when working with, or around, the air bag sys¬ tem. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When plac¬ ing a non-deployed air bag on a work sur¬ face, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the addi¬ tional air bag system precautions later in this section. • Clean, high quality brake fluid from a

sealed container is essential to the safe and proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in con¬ tact with a painted surface; it will damage the paint. • Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine damage. • Timing belt maintenance is extremely important! Many models utilize an interfer¬ ence-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing poten¬ tially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this section for the recommended replace¬ ment interval for the timing belt, and to the timing belt section for belt replacement and inspection. • Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer system(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected. • When servicing drum brakes, only dis¬ assemble and assemble one side at a time, leaving the remaining side intact for refer¬ ence.

ENGINE REPAIR (■►Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer system. The computer may undergo a relearning process once the negative battery cable is recon¬ nected.

Distributor REMOVAL 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Distributor cap

• Distributor wiring harness connector 3. Matchmark the rotor to the distributor housing and the distributor housing to the cylinder head. 4. Remove the distributor. INSTALLATION

Timing Disturbed 3.3L ENGINE

1 . Set the engine to Top Dead Center (TDC) of the compression stroke for the No. 1 cylinder.

Timing Not Disturbed 1 . Install or connect the following: • Distributor by aligning the matchmarks made during removal • Distributor wiring harness connec¬ • tor Distributor cap • Negative battery cable 2. Check the ignition timing and adjust, as necessary. Distributor shaft alignment — 3.3L engine

INF

INI

TI

* NISSAN AND

*)1

PATHFINDER • QX4

*

I 1■

3. Start the engine and allow it to reach normal operating temperature. 4. Check that the idle speed is less than 1000 rpm. 5. Run the engine at 2000 rpm for 2 minutes. 6. Rev the engine to 3000 rpm 2-3 times and allow it to idle for 1 minute. 7. Check for the presence of Diagnostic sary. Trouble Codes (DTC) and service as neces¬ 8. Run the engine at 2000 rpm for 2 minutes. 9. Stop the engine and disconnect the Throttle Position (TP) sensor. 10. Start the engine and rev it to 3000 rpm 2-3 times and allow it to idle. 11. Set the base timing to 8-12 degrees Before Top Dead Center (BTDC) for 3.3L

Rotor head position (No. 1 cylinder at TDCr

J 9308VG03

Distributor rotor alignment— 3. 3L engine

2. Align the index mark on the distribu¬ tor shaft with the protrusion on the distribu¬ tor housing. 3. Install the distributor and check that the distributor rotor is aligned. 4. Install or connect the following: • Distributor cap • Distributor harness connector 5. Check the ignition timing and adjust, as necessary.

Alternator REMOVAL & INSTALLATOIN

engines. 12. Tighten the distributor lockbolt to 83-113 inch lbs. (9-13 Nm). 13. Set the base idle speed to 700-800

Ignition Timing ADJUSTMENT ^Ignition timing is set with the engine at operating temperature, transmission in Neutral and all electrical acces¬ sories OFF. 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Attach a timing light to the No. 1 spark plug wire.

14. Stop the engine and connect the TP rpm. sensor.

Engine Assembly REMOVAL & INSTALLATION 3.3L Engine 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system.

3.3L and 3.5L Engines 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the follow¬ ing: • Negative battery cable • Alternator harness connectors • Engine under cover • Alternator belt • Alternator To install: 3. Install or connect the following: • Alternator • Alternator belt. Tighten the adjust¬ ment bolt to 12-14 ft. lbs. (16-19 Nm) and the pivot bolts to 16-22 ft. lbs. (22-30 Nm). • Engine under cover • Alternator harness connectors • Negative battery cable

7924VG04

27-12

NISSAN AND INFINITI PATHFINDER • QX4 • • • • •

3. Relieve the fuel system pressure. 4. Recover the A/C refrigerant, if equipped. 5. Remove or disconnect the following: • Negative battery cable • Hood • Air cleaner assembly • Idle Air Control (IAC) valve and solenoid connectors • Throttle Position (TP) sensor and switch connectors • Engine Coolant Temperature (ECT) sensor connector • Manifold Absolute Pressure (MAP) . sensor connector and vacuum line

Cooling fan and shroud Radiator and hoses Engine under cover A/C compressor manifold Power steering pump

• Heated Oxygen (HO2S) sensor con¬ nectors • Exhaust front pipes • Crankshaft Position (CKP) sensor • Starter motor • Transmission •• Left and right engine mounts Engine (■••When removing the engine mounts, do not loosen the 4 mount cover nuts. The mount is fluid filled and will not function if the fluid leaks out.

• Evaporative Emissions (EVAP) can¬ ister purge valve connector and vacuum line

To install:

• Mass Air Flow (MAF) sensor con¬ nector • Brake booster vacuum line • Fuel lines • Exhaust Gas Recirculation (EGR) temperature sensor connector • Throttle cable • Accessory drive belts In

• Engine. Tighten the engine mount nuts to 43-58 ft. lbs. (59-78 Nm). • Transmission • Starter motor • CKP sensor • Exhaust front pipes stal

l or

con

nec

t th

e fo

llo

win

g:

•• HO2S Power sensor steeringconnectors pump • • • • • •

A/C compressor manifold Engine under cover Radiator and hoses Cooling fan and shroud Accessory drive belts Throttle cable

• EGR sensor connector Fuel temperature lines • Brake booster vacuum line • MAF sensor connector

• EVAP canister purge valve connec¬ tor and vacuum line • MAP sensor connector and vacuum line • • • •

ECT sensor connector TP sensor and switch connectors IAC Hoodvalve and solenoid connectors Air cleaner assembly

• Negative battery cable 7. Fill the cooling system. 8. Recharge the A/C system, if equipped. 9. Start the engine and check for leaks.

NISSAN AND INFINITI 07_1Q PATHFINDER • QX4

I

JO] 59 - 78 (6.0 - 8.0, 43 - 58)

: N*m

(kg-m, ft-lb) 9359VG01

Front engine mounting — Pathtinder and QX4 with 3.5L engine

Rear engine mounting — Pathtinder and QX4 with 3.5L engine

IU

27-14

NISSAN AND INFINITI PATHFINDER • QX4

Part-time 4WD 2WD M/T

.

[cn : N-m (kg-m, ft-lb) 9359VG03

Rear engine mounting — Pathfinder and QX4 with 3.5L engine

3.5L Engine

isc

1D

1. Release fuel pressure. 2. Remove engine hood and front RH and LH wheels. 3. Remove engine undercover and sus¬ pension member stay. 4. Drain coolant from radiator. 5. Remove the following parts. • Radiator shroud • Radiator • Cooling fan • Drive belts • Battery • Engine cover • Throttle 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. 1 1 . Remove exhaust front tube heat insulators, then remove rear heated oxygen sensors. 12. Remove exhaust front and rear tubes. 13. Remove transmission. 14. Remove TWC (manifold) heat insula¬ tors, then remove TWC (manifold). 15. Install engine slingers.

16. Hoist engine with engine slingers and remove front engine mounting nuts. 17. Remove engine from vehicle. To install: Installation is in the reverse order of removal. Observe the following torques: Front engine • 43-58 ft. lbs. mount-to-bracket: • Front mount-to-frame: 32-41 ft. lbs. • Front bracket-to-block: 32-41 ft. lbs. • Rear engine mount-to-bracket: all exc. 2wd with AT: 58-77 ft. lbs.; 2wd with AT: 32-40 ft. lbs. • Crossmember-to-frame: 58-77 ft. lbs. Heater Core REMOVAL & INSTALLATION

** CAUTION

a. Place the front wheels in the straight-ahead position. b. Remove the lower lid from the steering wheel and disconnect the air bag module connector. c. Remove the side lids from both sides of the steering wheel.

d. Using the Tamper Resistant Torx® tool T50, remove the left and right Torx® bolts. remove the air bag mod¬ ule.e. Carefully, •:* CAUTION Place the air bag module in safe place with the front facing upward. f. Remove the steering wheel nut. g. Using a steering wheel puller, . press the steering wheel from the steer¬ ing column.

onn

b rcya

tte

bea tiv

ga ene etcht

pro the fol by per fa. orm Remove the loglove dur and win box ceclips i bat¬ g negative After disconnecting the ng the passenger’s sidee:air bag disconnect minutes 3 least at for module connector. tery cable, wait b. Remove the lower panel screws; Re before working on the steering column or instrument panel. _ mov then, disconnect the harness connector eth epa and remove the air bag module 2. Drain the cooling system into a clean ssen ger bracket. container for reuse. ’sisd eai c. Using the Tamper Resistant Torx® 3. Disconnect the heater hoses from the rba heater core. toolg T50, remove the passenger’s side air bag module bolts. 4. Remove the driver’s side air bag and d. Carefully, remove the air bag mod¬ steering wheel by performing the following ule. procedure:

NISSAN AND INFINITI 07. 1 R PATHFINDER • QX4 £ ■

1^1

p

.

0

.

FD : N* m (kg-m, ft-lb) 93113GH8

Exploded view of the driver’s side air bag module and steering wheel

c CAUTION Place the air bag module in safe place with the front facing upward. for

pro the fol l ced ure column cover ga. Removeowithe ng steering : and the combination switch. b. Remove the instrument panel side lower finisher.

min

k. Remove the console box; then, remove the screw and disconnect the harness connector.

ins pan e t men 7. ruRemove thel. defroster nozzle and the t heater nozzle from the heater housing. Usi ng8. Disconnect the electrical connector an ssi and/or acontrol sta cable from the heater housing. nt, re ove heater housing-to-chasing. 9. Remove mthe the the heater hous¬ sis fasteners and remove

l. Remove the lower instrument cen¬ panel screws and the lower instru¬ ter ment center panel. m. Remove the defroster grille. n. At both sides, remove the pillar garnishes. o. Remove the instrument panel and pads nuts and bolts.

hea

ter

c. At the driver’s side, remove the lower panel screws, disconnect the elec¬ trical harness connectors and remove the

sin

g

and rem ove

c the hea ter ore.

Special bolt^ Sep

panel. d. Remove the cluster lid “A” screws cluster lid “A”. ande.theRemove the combination meter screws, disconnect the electrical harness connectors and remove the combination meter.

f. Remove the cluster lid “C” screws, disconnect the electrical harness connec¬ tors and remove the cluster lid “C”. g. Remove the audio assembly screws and the audio assembly. h. Remove the air conditioning con¬ trol unit screws, disconnect the electrical harness connectors and the air condi¬ tioning control unit. i. Remove the ashtray. j. Remove the shifter (automatic transmission) or shift lever boot (man¬ ual transmission); then, remove the screw and disconnect the harness con¬ nector.

hou

ara

tet

he h

Front

eat

erc (1. 252.5, |EJ 11 5-- -18 ore l5 ) fro

mt

he

Air bag module

Special bolt G. [^Jl5.5 - 25 , - 2.5 (1 11 - 18)

ra : N*m (kg-m, ft-lb) Exploded view of the passenger’s side air bag module

Steering member view from under side 93113GH9

27-16

NISSAN AND INFINITI PATHFINDER • QX4

1. Steering column cover and combination switch 2. Dash side lower finisher 3. Instrument lower panel on driver side 4. Cluster lid A 5. Combination meter 6. Cluster lid C 7. Audio assembly 8. A/C control unit 9. Ashtray

10. A/T shifter or M/T shift lever boots 11. Console box 12. Glove box 13. Instrument lower panel on passenger side 14. Instrument lower center panel 15. Defroster grille 16. Front pillar garnish 17. Instrument panel and pads 18. Passenger air bag module

★ : Instrument panel assembly

mounting

bolts & nuts

Exploded view of the instrument panel and related accessories

NISSAN AND INFINITI 07.17 PATHFINDER • QX4

*

o 7

IQ

NISSAN AND INFINITI

PATLHF To II "install: N I ODE heater *core 1 1 . Install the R

and* Qassemble X

4

the heater housing. 12. Install the heater housing and the heater housing-to-chassis fasteners. 13. Connect the electrical connector and/or control cable to the heater housing. 14. Install the defroster nozzle and the heater nozzle to the heater housing. 15. Install the passenger's side air bag by performing the following procedure: a. Carefully, install the air bag mod¬ ule.

b. Using the Tamper Resistant Torx® tool T50, install the passenger’s side air bag module bolts. Torque the bolts to 11-18 ft. lbs. (15-25 Nm). c. Connect the harness connector and install the air bag module bracket; then, install the lower panel screws. d. Connect the passenger’s side air bag module connector and install the glove box clips. 16. Install the instrument panel by per¬ forming the following procedure: a. Using an assistant, position the instrument panel. b. Install the instrument pads, nuts and bolts. c. At both sides, install the pillar gar¬ nishes. d. Install the defroster grille. e. Install the lower instrument center panel and the lower instrument center panel screws. f. Install the console box; then, install the screw and connect the harness con¬ nector. g. Connect the harness connector and install the screw; then, install the shifter (automatic transmission) or shift lever boot (manual transmission). h. Install the ashtray. i. Install the air conditioning control unit, connect the electrical harness con¬ nectors and the air conditioning control unit screws. j. Install the audio assembly and the audio assembly screws. k. Install the cluster lid “C”, connect the electrical harness connectors and install the cluster lid “C” screws. l. Install the combination meter, con¬ nect the electrical harness connectors and install the combination meter screws. m. Install the cluster lid “A" and the cluster lid "A’’ screws. n. At the driver's side, install the lower panel, connect the electrical har¬ ness connectors and install the panel screws.

o. Install the instrument panel side lower finisher. p. Install the combination switch and the steering column cover. 17. Install the driver’s side air bag and steering wheel by performing the following procedure: a. Install the steering wheel to the steering column. b. Install the steering wheel nut. Nm). Torque the nut to 22-29 ft. lbs. (29-39 c. Carefully, install the air bag mod¬ ule.

d. Using the Tamper Resistant Torx® tool T50, install the left and right Torx® bolts. Torque the bolts to 11-14 ft. lbs. (15-20 Nm). e. Install the side lids to both sides of the steering wheel. f. Connect the air bag module con¬ nector and install the lower lid to the steering wheel. 18. Connect the heater hoses to the heater core. 19. Refill the cooling system. 20. Connect the negative battery cable. 21. Run the engine to normal operating temperatures; then, check the climate con¬ trol operation and check for leaks.

Water Pump REMOVAL & INSTALLATION 3.3L Engine 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Remove or disconnect the following: • Negative battery cable • Accessory drive belts • Radiator hoses • • • • •

Cooling fan and shroud Water pump pulley Front cover Timing belt Water pump

To install: 4. Install or connect the following: • Water pump. Tighten the bolts to 12-15 ft. lbs. (16-21 Nm). • Timing belt • Front cover • Water pump pulley

• Cooling fan and shroud • Radiator hoses • Accessory drive belts • Negative battery cable

5. Fill the cooling system. 6. Start the engine and check for leaks. 3.5L Engine 1. 2. 3. 4. 5. 6. 7.

Remove undercover. Remove suspension member stay. Drain coolant from radiator. Remove radiator shrouds. Remove drive belts. Remove cooling fan. Remove water drain plug on water

of cylinder block. pump8. side Remove chain tensioner cover and water pump cover. 9. Pushing timing chain tensioner sleeve, apply a stopper pin so it does not return. Then remove the chain tensioner assembly. 10. Remove the 3 water pump fixing bolts. Secure a gap between water pump

gear and timing chain, by turning crankshaft • pulley 11. 20° Put backwards. M8 bolts to two water pump fix¬ ing bolt holes. 12. Tighten M8 bolts by turning half turn , alternately until they reach timing chain rear case. order to prevent damages to water pump or timing chain rear case, do not tighten one bolt continuously. Always turn each bolt half turn each time. 13. Lift up water pump and remove it. ^When lifting up water pump, do not allow water pump gear to hit timing chain. To install:

engine oil and coolant to 014.asApply shown in the figure. rings 15. Install water pump. ^Do not allow cylinder block to nip 0rings when installing water pump. 16. Before installing, remove all traces of liquid gasket from mating surface of water pump cover and chain tensioner cover using a scraper. Also remove traces of liq¬ uid gasket from mating surface of front cover. 17. Apply a continuous bead of liquid gasket to mating surface of chain tensioner cover and water pump cover. Use Genuine RTV silicone sealant or equivalent. 18. Return the crankshaft pulley to its it 20° forward. by turning position original 19. Install timing chain tensioner, then remove the stopper pin. ^When installing the timing chain ten¬ sioner, engine oil should be applied to the oil hole and tensioner.

NISSAN AND INFINITI 07_1Q PATHFINDER • QX4 C- *

■ ^

Gasket n

16 - 21 (1.6 - 2.1, 12 - 15)

Rubber

seal

Water pump

[0) 16 - 21 (1.6 - 2.1, 12 - 15)

ra 16 - 21 (1.6 - 2.1, 12 - 15) ■Rubber

seal ©

ra : N* m (kg-m, ft-lb) 7924VG20

Exploded view of the water pump assembly— 3. 3L engine

S»| 8.5 - 10.7 (0.86-1.10, 75-95)

M

Water

pump

7.0 - 9.3 (0.71 - 0.95, 62 - 82)

Sri *•*1 10-13 Drain plug

4*1 : N*m (kg-m, in-lb) 5

10-13 (1.0 -1.3, 87-113)

: Apply liquid gasket

87 - 113)

.2,) 0420 -11. .40(0.8 69

(1.0 -1.3,

E3£j| 7.8-11.8

9359VG04

Exploded view of the water pump assembly— 3. 5L engine

07 OR L.I’mL. U

NISSAN AND INFINITI PATHFINDER • QX4

(-►After starting engine, let idle for three minutes, then rev engine up to 3,000 rpm under no load to purge air

Cylinder Head REMOVAL & INSTALLATION

from the high-pressure chamber of the chain tensioners. The engine may pro¬ duce a rattling noise. This indicates that air still remains in the chamber and is not a matter of concern.

3.3L Engine

20. Reinstall any parts removed in reverse order of removal.

the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system.

3. Relieve the fuel system pressure. 4. Remove or disconnect the following: • Negative battery cable • Accessory drive belts • Front cover • Timing belt • • • •

1 . Before servicing the vehicle, refer to

Upper intake manifold Lower intake manifold Camshaft sprockets Rear timing cover

1 - 3 (0.1 - 0.3, 0.7 - 23) L.H. rocker cover

Gasket Q

rang] ranu

Rocker arm

Valve collect Valve spring re,ainer Outer valve spring 3 yp^— _ -x —

y

spring valve Inner oil Valve seal ©

Valve guide

Valve seat

Outer spring seat Exhaust valve R.H. rocker cover

R.H. cylinder head assembly

Bolt Rear Cylinder cover gasket head ^ rear cover

78 - 88 (8.0 - 9.0, 58 - 65) Camshaft locate plate

Camshaft front oil seal ©

L.H. camshaft —

n

: N-m (kg-m, ft-lb)

& 7924VG25

Exploded view of the cylinder head assembly — 3.3L engine

NISSAN AND INFINITI 07.91 PATHFINDER • QX4 ^ • • • • • • •

Distributor Exhaust front pipes A/C compressor Alternator Power steering pump Accessory brackets Valve covers. Loosen the bolts in several passes and in sequence. • Cylinder heads with the exhaust manifolds attached. Loosen the bolts in several passes and in sequence.

*>The cylinder head bolts vary in length. Note the bolt locations for assembly.

^

1

Right bank

Engine front

o

®

® ®

Left bank

To install:

at the same time. lower intak manif e old as follo Tight the bolts in seque ws: nthe en c e cylinder head a. Step 1: Tighten bolts to 22 ft. lbs. (29 Nm) b. Step 2: Tighten the cylinder head bolts to 43 ft. lbs. (59 Nm) c. Step 3: Loosen all cylinder head bolts completely d. Step 4: Tighten the cylinder head bolts to 84 inch lbs. (10 Nm) e. Step 5: Tighten the intake manifold fasteners to 35 inch lbs. (4 Nm) f. Step 6: Tighten the intake manifold fasteners to 13 ft. lbs. (18 Nm) g. Step 7: Tighten the intake manifold fasteners to 12-14 ft. lbs. (16-20 Nm) h. Step 8: Loosen all intake fasteners ely complet linde r hea dsi. Step 9: Tighten the cylinder head bolts antod 22 the ft. lbs. (29 Nm) j. Step 10: Tighten the cylinder head bolts 60-65 degrees OR tighten to 40-47 ft. lbs. (54-64 Nm) k. Step 11: Tighten the cylinder head sub-bolts to 80-105 inch lbs. (9-12 Nm)

l. Step 12: Tighten the intake mani¬ fold fasteners to 35 inch lbs. (4 Nm)

9308VG08

Valve cover bolt loosening sequence— 3. 3L engine

• Timing belt • Front cover

6. Remove intake manifold in reverse order of installation. 7. Remove water outlet. 8. Remove rear timing chain case bolts. Loosen in numerical order as shown in the

• Accessory drive belts • Negative battery cable 7. Fill the cooling system. 8. Start the engine and check for leaks.

figure. 9. Remove rear timing chain case. 10. Remove 0-rings to cylinder head. 11 . Remove 0-rings to cylinder block. 12. Remove intake valve timing control solenoid valves. 13. Remove intake and exhaust camshafts and camshaft brackets. Equally loosen camshaft bracket bolts in several

3.5L Engine 1 . Remove engine from vehicle. 2. Remove exhaust manifolds in reverse order of installation. 3. Place engine on a work stand. 4. Remove aluminum oil pan 5. Remove timing chain.

For L.H. cylinder head For R.H. cylinder head No. 5 No. 3 No. 1

m. Step 13: Tighten the intake mani¬ fold fasteners to 78 inch lbs. (9 Nm) n. Step 14: Tighten the intake mani¬ lbs. (6-7 fold Nm) fasteners to 70-84 inch • • • • • • • • • •

Valve covers Accessory brackets Power steering pump Alternator A/C compressor Exhaust front pipes Distributor Rear timing cover Camshaft sprockets Upper intake manifold

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^1 engine front Cylinder head loosening sequence— 3. 3L engine

7924VG26

97

99

LI ~LL

NISSAN AND INFINITI

PATHFINDER • QX4

«

R.H. side No. 1

No. 3

No. 5

steps in the numerical order shown in the figure. For reinstallation, be sure to put marks on camshaft bracket before removal. 14. Remove RH and LH camshaft chain tensioners from cylinder head. 15. Remove cylinder head bolts. Cylin¬ der head bolts should be loosened in two or three steps. 16. Remove cylinder head. To install:

17. Before installing rear timing chain case, remove old liquid gasket from mating surface using a scraper. Also remove old liquid gasket from mating surface of cylin- < der block. Remove old liquid gasket from the bolt hole and thread. 18. Before installing cam bracket, remove old liquid gasket from mating sur¬ face using a scraper. 19. Before installing the cylinder head gasket, be sure that No. 1 cylinder is at TDC. At this time, the crankshaft key should face toward the right bank. 20. Install cylinder heads with new gas- § kets. Do not rotate crankshaft and camshaft separately, or valves will strike piston heads.

** CAUTION Cylinder head bolts are tightened by plastic zone tightening method. Whenever the size difference between dl and d2 exceeds the limit, replace them with new ones. Limit (dl — d2): 0.0043 in. Lubricate threads and seat surfaces of the bolts with new engine oil.

21. Install cylinder head outside bolts Tighten in numerical order shown in the fig¬ ure. Tightening procedure: a. Tighten all bolts to 98 N-m (10 kgm, b. 72 Completely ft- lb). loosen all bolts. c. Tighten all bolts to 34 to 44 N-m (3.5 to 4.5 kg-m, 25 to 33 ft-lb). d. Turn all bolts 90 to 95 degrees clockwise. e. Turn all bolts 90 to 95 degrees clockwise. 22. Install camshaft chain tensioners on both sides of cylinder head. 23. Install exhaust and intake camshafts and camshaft brackets. ^Intake camshaft has a drill mark on camshaft sprocket mounting flange. Install it on the intake side. Position camshaft. RH exhaust camshaft dowel Rear timing case loosening sequence— 3. 5L engine

NISSAN AND INFINITI 07..9Q PATHFINDER

pin at about 10 o’clock; LH exhaust camshaft dowel pin at about 2 o’clock

24. Before installing camshaft brackets, apply sealant to mating surface of No. 1 journal head. Use Genuine RTV silicone

sealant or equivalent. Install camshaft brackets in their original positions. Align stamp mark as shown in the figure. If any part of valve assembly or camshaft is replaced, check valve clearance according

• QX4

to reference data. After completing assembly check valve clearance. Valve clearance (Cold):• 0.013 Intake in) 0.26 — 0.34 mm (0.010 —

RH exhaust camshaft

Engine front

Loosen in numerical order. 9359VG06

Right camshaft loosening sequence— 3. 5L engine

9359VG09

Right cylinder head bolt torque sequence— 3. 5L engine

LH cylinder head

Engine front

Loosen in numerical order. 9359VG10

9359VG07

Left camshaft loosening sequence— 3. 5L engine

Cylinder head bolt

Head bolt checking— 3. 5L engine

Left cylinder head bolt torque sequence— 3. 5L engine

27-24

|NF|N|T| PATHFINDER N,SSAN AND• QX4 Identification marks are present on camshafts. Paint mark Bank

INT/EXH INT

ID mark

Drill mark Yes

R3

No M2

Ml Yes No

Yes

RH EXH

R3 L3

INT LH EXH

No Yes No

Yes No

No Yes

L3

9359VG11

Camshaft identification— 3. 5L engine

Step

Tighten the camshaft brackets in the following steps.

RH exhaust camshaft

Tightening torque

Tightening order

1

1.96 N m (0.2 kg-m, 17 in-lb)

Tighten in the order of 7 to 10, then tighten 1 to 6.

2

5.88 N m (0.6 kg-m, 52 in-lb)

Tighten in the numerical order.

9.02 - 11.8 N m (0.92 - 1.20 kg-m, 79.9 - 104.2 in-lb)

Tighten in the order of 1 to 6.

8.3 - 10.3 N-m (0.9 - 1.0 kg-m, 74 - 91 in-lb)

Tighten in the order of 7 to 10.

o

9359VG12

Right camshaft bolt torque sequence— 3. 5L engine

Camshaft bracket LH intake camshaft

LH exhaust camshaft 9359VG13

Left camshaft bolt torque sequence — 3.5L engine

NISSAN AND INFINITI OT.OC PATHFINDER

• QX4

LU

the throttle body and the air inlet tube bracket. 3. Disconnect the ASCD cable from the throttle body and the air inlet tube bracket, if equipped. 4. Remove the air inlet duct a. Disconnect the PCV hoses. b. Disconnect the resonator hose. 5. Partially drain the cooling system. 6. Remove the supercharger pulley cover and the supercharger/air conditioning drive belt. 7. Remove the air inlet tube upper and lower supports. 8. Remove the air inlet tube bolts, nuts, and studs. Position the air inlet tube aside.

t the evaporative emis¬ Disconnec siona. vacuum hose.

12 - 13 N»m (1.2 - 1.4 kg-m, 9-10 ft-lb) 9359V614

Rear timing case bolt torque sequence— 3. 5L engine

• Exhaust 0.29—0.37 mm (0.01 1— 0.015 in) ’"-Lubricate threads and seat surfaces of camshaft bracket bolts with new engine oil before installing them.

25. Install intake valve timing control solenoid valves. 26. Install 0-rings to cylinder block. 27. Install 0-rings to cylinder head. 28. Apply sealant to the hatched portion of rear timing chain case. Apply continuous bead of liquid gasket to mating surface of rear timing chain case. Before installation, wipe off the protruding sealant. 29. Align rear timing chain case with dowel pins, then install on cylinder head and block. 30. Tighten rear chain case bolts. a. Tighten bolts in numerical order shown in the figure. b. Repeat above step a. 31. Reinstall all removed parts in reverse order of removal.

To install:

3. Lubricate all contact points with clean engine oil and assemble the rocker arms to the shafts in their original positions. 4. Install or connect the following: • Rocker arm and shaft assemblies. Tighten the bolts to 13-16 ft. lbs. (18-22 Nm). • Valve covers • Upper intake manifold • Negative battery cable 5. Start the engine and check for leaks.

Supercharger

i: CAUTION

REMOVAL & INSTALLATION

Do not disassemble or adjust the supercharger.

3.3L Engine

in the beg in

(■►Keep all valvetrain components in order for assembly.

REMOVAL & INSTALLATION

Rocker Arms/Shafts

! pre c

2. Remove or disconnect the following: • Negative battery cable • Upper intake manifold • Valve covers • Rocker arm and shaft assemblies • Rocker arms from the shafts

of thi sec s tio

1 . Disconnect the negative battery cable. 2. Disconnect the accelerator cable from

b. Disconnect the brake booster vac¬ uum hose. c. Disconnect the TPS sensor electri¬ cal connector. d. Disconnect the TPS switch electri¬ cal connector. 9. Remove the supercharger bolts and the supercharger assembly. a. Disconnect the boost control valve vacuum hose. b. Disconnect the PCV hose. INSPECTION Supercharger Flange

1 . Clean the mating surface of the supercharger flange. 2. Check the flange surface for any deformation and flatness. Use a reliable straightedge and feeler gauge, or attach the supercharger flange to the intake collector mating flange, and in). that the flatness is within specifica¬ check tion. Flange flatness limit: 0.12 mm (0.005 Rotor System

1 . Check that the supercharger pulley rotates smoothly when turning it by hand in a clockwise direction. Rotating torque must not exceed specification. Rotating torque:

kg-m, 4 in-lb). (0.05that 0.5 2.N.mCheck both the left and right rotors are free from any cracks or contami¬ nation. Supercharger Bypass Valve Actuator

1. Apply air pressure of less than 12 kPa (90 mmHg, 3.54 inHg) to the supercharger r’s lower valve bypass . side hose port any leakage for actuato check and 2. Check the supercharger bypass valve

07

9G

C. I mCU

NISSAN AND INFINITI

PATHFINDER • QX4

Supercharger (do not disassemble)

Supercharger tightening order (loosen in reverse order)

©

©

©

®

JOJ 24.5-31.3(2.5-3.2,18-23) e

\

/- Supercharger bypass valve actuator 21 -29 (2.2-2.9,16-21)

ra 19.6-23.5 (2.0-2.4,15-17)

Gasket ^

9.8-11.8 (1.0 - 1.2, 87-104)

-Air inlet tube

19.6-23.5 (2.0 -2.4, 15-17)

valve assembly r^-IACV-AAC

20-27 (2.1 -2.7, 15-19)-

[OJ16-21 (1.6-2.1,12-15)-

|: Apply liquid gasket (Use Genuine Silicone R7V or equivalent. Befw to : N-m (kg-m, in-lb) n

: N-m (kg-m, ft-lb) 9359VG35

Supercharger components

NISSAN AND INFINITI 07.97 PATHFINDER

*

• QX4

actuator rod tor smooth movement while maintaining the pressure at the specified levels below: • Rod starts to extend at approxi¬ mately: 12 Kpa (90 mmHg, 3.54 inHg) • Rod is fully extended at approxi¬ mately: 33.3 kPa (250 mmHg, 9.84 inHg) • Rod full extended length: 20.83-22.71 mm (0.82-0.89 in) INSTALLATION To install the supercharger, follow the removal steps in reverse order. Replace all gaskets; make sure that all gasket surfaces are clean and undamaged. Follow all torque sequences for tightening. Refill the cooling system.

Loosen bolts in numerical order. 7924VG32

Intake manifold loosening sequence — 3.3L engine

Intake Manifold REMOVAL & INSTALLATION 3.3L and 3.5L Engines

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: • Negative battery cable • Air intake duct • Accelerator cable • Cruise control cable • Idle Air Control (IAC) valve con¬ nector • Throttle Position (TP) sensor and switch connectors • Ignition coil and power transistor connectors • Exhaust Gas Recirculation (EGR) Solenoid valve connector • EGR temperature sensor connector • Radiator hoses • Heater hoses • Positive Crankcase Ventilation (PCV) valve and hose • Evaporative Emissions (EVAP) can¬ ister vacuum and purge hoses • Brake booster vacuum hose • Fuel pressure regulator vacuum hose • EGR tube • Spark plug wires • Distributor • Left bank injector connectors • Thermal transmitter • Upper intake manifold ground cable

Tighten bolts in numerical order. 7924VG33

Intake manifold torque sequence— 3. 3L engine

Lower intake manitold torque sequence— 3. 5L engine

0Q

07

LI^LQ

NISSAN AND INFINITI

PATHFINDER • QX4

> Cruise control cable > Accelerator cable * Air intake duct > Negative battery cable Fill the cooling system. Start the engine and check for leaks. 10. 9.

Exhaust Manifold REMOVAL & INSTALLATION 3.3L and 3.5L Engines

Engine front

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Negative battery cable • Exhaust manifold heat shields • Exhaust Gas Recirculation (EGR) tube • Heated Oxygen (HO2S) sensor con¬ nectors • Exhaust front pipes

9359VG16

• Exhaust manifolds with catalytic converters attached. Loosen the nuts in the reverse of the torque

Upper intake manifold torque sequence— 3. 5L engine

• • • • • •

Breather pipe Upper intake manifold Fuel lines Right bank injector connectors Fuel supply manifold Engine Coolant Temperature (ECT) sensor connector • Lower intake manifold. Loosen the fasteners in the sequence shown.

To install:

5. Install the lower intake manifold with a new gasket. 6. For 3.3L engines, tighten the fasten¬ ers in sequence as follows: a. Step 1: 35 inch lbs. (4 Nm) b. Step 2: 78 inch lbs. (9 Nm) c. Step 3: 70-84 inch lbs. (8-10 Nm) 7. For 3.5L engines, tighten the fasten¬ ers in sequence as follows: a. Step 1: 86 inch lbs. (4 Nm) b. Step 2: 23 ft. lbs. (9 Nm) 8. Install or connect the following: • ECT sensor connector • Fuel supply manifold • Right bank injector connectors • Fuel lines • • • • • • • • •

Upper intake manifold Breather pipe Upper intake manifold ground cable Thermal transmitter Left bank injector connectors Distributor Spark plug wires EGR tube Fuel pressure regulator vacuum hose

Brake booster vacuum hose EVAP canister vacuum and purge hoses PCV valve and hose Heater hoses Radiator hoses EGR temperature sensor connector EGR Solenoid valve connector Ignition coil and power transistor connectors TP sensor and switch connectors IAC valve connector

sequence. To install: 3. Install or connect the following: • Exhaust manifolds with catalytic converters attached. Tighten the nuts in sequence to 21-25 ft. lbs. (28-33 Nm). • Exhaust front pipes. Tighten the bolts to 21-25 ft. lbs. (28-33 Nm). • Heated nectors Oxygen (HO2S) sensor con¬

RH exhaust manifold

LH exhaust manifold

©| ) Wl

✓

Y ✓

Y

Y

Y

Y

Y

Y

Y

Y

Y

y

Y

Y

Y

Y

Y

Y

✓

Y Y

✓

Y

✓

✓

Y Y

Y

Y

R

Camry, Celica & Supra) Exhaust system

S/I

Y

Y

Fuel lines & connections

S/I

Y

Y

Valve clearance

S/I

y

Engine coolant

R

Fuel tank cap gasket

R

Charcoal canister R: Replace

Y Y

Y

S/I S/I: Service or Inspect

© Supra 2JZ-GTE: change every 5000 miles. © Supra w/LSD: replace every 30,000 miles.

FREQUENT OPERATION MAINTENANCE (SEVERE SERVICE) If a vehicle is operated under any of the following conditions it is considered severe service: • Extremely dusty areas.

- 50% or more of the vehicle operation is in 32°C (90°F) or higher temperatures, or constant operation in temperatures below 0°C (32°F). - Prolonged idling (vehicle operation in stop and go traffic). ■ Frequent short running periods (engine does not warm to normal operating temperatures). • Police, taxi, delivery usage or trailer towing usage. Oil & oil filter: change every 6000 miles.

Oil & oil filter change (Supra 2JZ-GTE): change every 2500 miles. Bolts & nuts on chassis & body: tighten every 7500 miles. Ball joints & dust covers: sen/ice or inspect every 12,000 miles. Brake linings & drums: service or inspect ever 12,000 miles.

Brake pads & discs (front & rear if equipped): service or inspect every 12,000 miles. Drive shaft boots & except Supra): service or inspect every 12,000 miles. Steering linkage: service or inspect every 12,000 miles. Air filter: service or inspect every 15,000 miles. Exhaust system: service or inspect every 15,000 miles. Timing belt: replace every 60,000 miles. 42356-T0YC-C14

PRECAUTIONS Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle:

• Never open, service or drain the radia¬ tor or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. • Observe all applicable safety precau¬ tions when working around tuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. • Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. • Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes

with clean, running water for 15 minutes. If eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance. • The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas as soon as possible after expo¬ sure to used engine oil. Soap and water, or waterless hand cleaner should be used. • All new vehicles are now equipped with an air bag system. The system must be disabled before performing service on or around system components, steering col¬ umn, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in acci¬ dental air bag deployment, possible per¬ sonal injury and unnecessary system repairs. • Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a nondeployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section.

• Clean, high quality brake fluid from a sealed container is essential to the safe and proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in con¬ tact with a painted surface; it will damage the paint. • Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine damage. • Timing belt maintenance is extremely important! Many models utilize an interfer¬ ence-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing poten¬ tially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this section for the recommended replace¬ ment interval for the timing belt. • Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer sys¬ tem^) and may require the computer to undergo a relearning process once the neg¬ ative battery cable is reconnected. • When servicing drum brakes, only dis¬ assemble and assemble one side at a time, leaving the remaining side intact for refer¬ ence.

ENGINE REPAIR temperature sensor, cruise control actuator cable, and the air cleaner sary. hose, if more clearance is neces¬

Distributor REMOVAL

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceed¬ ing. • Electrical connector from the air flow meter. Disconnect the air cleaner hose from the throttle body and remove the air cleaner cover, air flow meter and air duct as 1 unit. • Air intake and intercooler to pro¬ vide clearance. Disconnect the air

• • • •

tor cap.plug wires from the distribu¬ Spark Distributor connector. Distributor mounting bolt O-ring from the distributor housing

^•The marks on the distributor drive gear and distributor housing should be aligned. If the marks are not aligned, mark the distributor housing and rotor position.

INSTALLATION Engine Disturbed

1 . On the 2JZ-GE engine, remove the No. 3 timing belt cover.

• O-ring 2. Bring No. 1 cylinder to TDC 3. Install or connect the following:

• Distributor. Tighten the mounting bolts • Intercooler or the air intake • Spark plug wires • On the 2JZ-GE engine, reinstall the No. 3 timing belt cover • Air flow meter, air hose and the air cleaner cover if removed • Distributor and air flow meter con¬ nectors. • Negative battery cable • Check the ignition timing O-ringDisturbed Engine• Not

1. Install or connect the following: • Distributor. Tighten the mounting bolts

3

AVALON « CAMRY • CAMRY SOLARA • CELICA * COROLLA • ECHO • GT-S • SUPRA ^MR2 32 "1 9 • Alternator . To install: • Alternator

I•nstaDrive ll or cbelt. the pivot bolt onnecTorque t the fol owing: Pivot bolts: l5S-FE: • and Wiriadjusting ng bolt — 40 ft. lbs. (54 Nm); Adjust¬ ing bolt— 14 ft. lbs. (19 Nm). • Negative battery cable Corolla 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

'■►It may be necessary to remove the gravel shield and work from under¬ neath the car in order to gain access to the alternator retaining bolts. 2. Remove or disconnect the following: • Negative battery cable from the alternator • Wiring Drive belt • Alternator

Common

method of properly positioning the distributor drive mechanism

'•Be sure the mark on the engine aligns with the mark on the distributor made during removal. Also be sure the rotor is in the same position as removal • • • •

Intercooler or the air intake Distributor cap Spark plug wires Air flow meter, air hose and the air cleaner cover • Distributor and air flow meter con¬ nectors • Negative battery cable • Check the ignition timing.

to TDC

stay before performing any further work. • On the 5S-FE, the two bolts and the No. 3 right hand engine mounting • Ori 1MZ-FE, the bolt and nut and then remove the No. 2 right hand engine mounting stay • Harness and wire (and nut) from the alternator • Air cleaner, if necessary • Drive belt from the pulley • Alternator To install: • Alternator • Drive Wiringbelt

Alternator

To install: 3. Install or connect the following: • Alternator. Torque the 14mm bolt to 18 ft. lbs. (24 Nm) and the 17 mm bolt to 40 ft. lbs. (54 Nm). •• Alternator Drive belt connector and wiring • Negative battery cable Echo 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Remove or disconnect the following: • Negative battery cable • Wire clamp from the rectifier harness • Alternator 2 bolts • Alternator To install: 3. Install or connect the following: • Alternator and hand tighten the bolts

• Negative and starter battery cables

REMOVAL & INSTALLATION

• Drive belt and adjust if necessary. Torque the 14 mm bolt to 14 ft. lbs. (18 Nm) and the 17 mm bolt to 40 ft. lbs. (54 Nm).

Celica, GT-S, Supra Ins

Avalon, Camry

on olrc tal

owi oll

thef nect

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. ng:

2. Remove or disconnect the following: • Negative battery cable. On models with an airbag, wait at least 90 sec¬ onds from the time that the ignition switch is turned to the LOCK posi¬ tion and the battery is disconnected

1 . Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: • Negative battery cable

'■•On some models it is necessary to remove the fuse/relay block located near the alternator. • Wi Drive ringbelt

• Alternator connector and clamp • Alternator electrical wiring • Negative battery cable MR2 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion.

32-20 BUST. CAMRY • CAMRY SOLARA * CELICA * COROLLA * ECHO • GT-S * SUPRA * MR2 RH Engine Mounting Insulator Generator Wire Generator Connector

Generator

N-m (kgf cm, ft-lbf) : Specified torque 9357WG01

MR2 alternator mounting exploded view

2. Remove or disconnect the following: • Negative battery cable • Accessory drive belt • Right motor mount • Wire harness clamp • Alternator wiring harness • Alternator mounting bolts • Alternator To install: 3. Install or connect the following: • Alternator. Tighten the upper mounting bolt to 18 ft. lbs. (25 Nm) and the lower mounting bolt to 40 ft. lbs. (54 Nm).

Alternator wiring harness Wire harness clamp Right motor mount. Tighten the bolts to 38 ft. lbs. (52 Nm). Accessory drive belt Negative battery cable

Ignition Timing

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Perform the following: • Start the engine and let it reach operating temperature. • Connect the tachometer tester probe to terminal IG of the DLC1.

ADJUSTMENT

(■►Never allow the tachometer test

(-►The timing on engines equipped with DIS is not adjustable.

probe to touch ground as it could result in damage to the igniter and or ignition coil.

TOYOTA

OO

04

AVALON • CAMRY • CAMRY SOLARA • CELICA * COROLLA • ECHO • GT-S • SUPRA • MR2 OL.mC • Heater hoses

I

• On manual transaxles, clutch release cylinder • Transaxle control cables • Power steering pump. Do not dis¬ connect the power steering hoses. • Air conditioning compressor. Leave lines connected. • the Frontrefrigerant exhaust pipe • Halfshafts

Attach the tachometer test probe to the IG terminal of the data link connector

• Connect a suitable lifting device to the engine lifting hooks. • On manual transaxles, rear mount¬ ing through-bolt and the rear mounting assembly. On automatic transaxle, front mounting throughbolt and front mounting assembly. • Right and left side mounting bolts and brackets. • Lift the engine/transaxle assembly out of the vehicle. • Starter

~-Not all tachometers are compatible with this system. Be sure to confirm compatibility of your unit before use. • Using a jumper connector, connect terminals TEiand Eiof the DLC1 . • Check the timing. Timing should be 8-12 degrees BTDC. Set the timing as needed. • Tighten the hold-down bolt. • Check that the ignition timing advances. Engine Assembly I REMOVAL & INSTALLATION ■

5E-FE Engine 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. Drain the engine oil. 3. Drain the transaxle fluid. 4. Remove or disconnect the following:

• Negative battery cable. On vehicles equipped with an air bag, wait at ing. least 90 seconds before proceed¬ • Hood

• For automatic transaxles, torque converter clutch mounting bolts. • Engine from the transaxle by removing the bolts. To install: 5. Install or connect the following: • Transaxle to the engine. On auto¬ matic transaxles, install the torque converter clutch and mounting bolts. Install the gray bolt first. Bolts: 20 ft. lbs. (27 Nm). • Starter. Bolts: 29 ft. lbs. (39 Nm). • Lower the engine and transaxle assembly in the vehicle. • Right side mounting insulator and temporarily install the through-bolt • Left side mounting bracket. Bolts Nm). marked (NT): 47 ft. lbs. (64 Nm), Bolts marked (7T): 35 ft. lbs. (48

• Undercovers • Radiator • Accelerator cable • Throttle cable • • • • •

Air cleaner assembly and bracket. Charcoal canister Fuel return and inlet hoses Speedometer cable Idle up air hoses from the power steering air control valve • Oxygen sensor wire, the oil pres¬ sure switch wire, the coolant fan switch wire, the water temperature gauge wire, the back-up light switch and neutral safety switch wires • All remaining wiring harnesses connected to the engine • All necessary vacuum hoses • Starter wires • If equipped with cruise control, actuator assembly

• Ground strap. Tighten to 35 ft. lbs. (49 Nm). • Rear mounting bracket. Bolts: 35 ft. lbs. (48 Nm). • Rear insulator through-bolt. Bolt: 47 ft. lbs. (64 Nm). • Halfshafts • 2 bolts, nut and through-bolt of the right side mounting insulator. Bolts and nut: 47 ft. lbs. (64 Nm). 54 ft. lbs. (73 Nm). • Through-bolt: Front exhaust pipe •• Air compressor Poweconditioning r steering pump • Transaxle control cables • On manual transaxles, clutch release cylinder. Bolts: 108 inch lbs. (12 Nm). • Idle up air hoses • Speedometer cable

• Heater hoses. • If equipped with cruise control, actuator assembly. • Starter wires and nut. • Vacuum hoses • Oxygen sensor wire, oil pressure switch, coolant fan switch wire, water temperature gauge wire, back-up light switch, and the neu¬ tral safety switch wires. • All wiring • Fuel line • Charcoal canister • Air cleaner assembly and bracket • Radiator, coolant hoses and on vehicles with automatic transmis¬ sion, cooling lines • All fluids • Undercovers • Hood

• Engine/transaxle assembly into • Right engine mount insulator. position Nm). Torque the bolts to 35 ft. lbs. (47

• Left engine mount. Torque the bolts to 35 ft. lbs. (47 Nm). • Rear engine mount bracket. Torque the bolts to 35 ft. lbs. (47 Nm). • Rear engine mount insulator. Nm). the bolt to 47 ft. lbs. (64 Torque • Suspension crossmember. Torque the rear mount bolts to 86 ft. lbs. (116 Nm); the front mount bolts to 52 ft. lbs. (70 Nm). • Halfshafts • Center exhaust pipe • Power steering pump • Fusible link • Transaxle control cables • Clutch release cylinder. Torque the 2 bolts to 10 ft. lbs. (13 Nm). • Compressor. Torque the 4 bolts to 18 ft. lbs. (25 Nm). • Radiator • Alternator

• Negative battery cable. 1NZ-FE

1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Drain the engine oil. 4. Drain the transaxle fluid. 5. Remove or disconnect the follow¬ ing: • Hood • Battery and tray • Outer front cowl top panel • Engine under covers • Accelerator cable • Air cleaner cap and related parts • Air cleaner case and related parts • All tubes, hoses and connectors attached to the engine • Accessory drive belts • Alternator • Radiator • With A/C, position the compressor out of the way • With MT, the clutch release cylinder • Transaxle control cables • Fusible link • Power steering pump • Center exhaustStapipe rtt • Halfshafts hev ehi • Suspension crossmember cle c,he • Rear engine mount ckf orl 6. Attach a shop crane to the engine eak san hangers. d 7. Remove all remaining engine mount bolts/nuts.

8. Remove the engine/transaxle assem¬ bly. To install: 9. Install or connect the following:

• All remaining tubes, hoses and connectors • Air cleaner case • Air cleaner cap • Accelerator cable • Outer front cowl top panel • Engine under covers • Battery and tray • Coolant • Engine oil •• Transaxle oil Hood

• • • •

throttle cable from the accelerator cable. Radiator and cooling fan Air cleaner assembly Coolant reservoir tank stay Electrical connector, the hose, the

mounting bolt, and remove the washer tank • Cruise control actuator • The Manifold Absolute Pressure (MAP) sensor vacuum hose from the gas filter on the intake manifold • The brake booster vacuum hose from the intake manifold • With air conditioning: the air con¬ ditioning vacuum hose from the actuator the air hose power With the • from air steering: pipe

• With air conditioning: the air con¬ ditioning actuator connector 7. Install the following wires and connectors from the right-hand fender apron: a. The ground strap connector b. The MAP sensor connector

c. With air conditioning: the air con¬ ditioning pressure switch ing wiring harness from the d. The engine fender apron 8. Remove or disconnect the following: • Data Link Connector 1(DLC1) con¬ nector and ground strap from the left-hand fender apron. • Engine relay box and 4 connectors. • Charcoal canister

• Heater hoses from water inlet hous¬ • Fuel inlet and return hoses • With manual transmission, clutch

rep

i n air f eces sar y. 1ZZ-FE Engines

COROLLA 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4. Drain the engine oil. 5. Drain the transaxle fluid. 6. Remove or disconnect the following: • Negative battery cable. On vehicles equipped with an air bag, wait at ing. seconds before proceed¬ least • Bat ter90 y • Hood • Undercover • Accelerator cable • With automatic transmission,

necting the pipe without discon¬ release cylinder • Transaxle control cable(s)

9. To disconnect the engine wiring har¬ ness, disconnect or remove the following components: • Left-hand and right-hand front door scuff plate • Lower finish panel

• Lower panel with the glove com¬ • Radio and center cluster finish partment • Rear console box

On manual transmission, shift lever • knob • Onpanel automatic transmission, shifting hole bezel • Lower center finish panel • Floor carpet bracket • The 3 ECM connectors and cowl wire connector

TOYOTA

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• Battery AVALON « CAMRY • CAMRY SOLARA » CELICA * COROLLA • ECHO • GT-S • SUPRA • MR2 OL.’L.O • Hood 10. Remove or disconnect the remaining • Fuel return and inlet hose. Torque the bolt to 22 ft. lbs. (29 Nm). components: • Undercover • housing Heater hoses to the water inlet • Air conditioning compressor • Accelerator cable, cable bracket, • Front exhaust pipe and clamps. • Charcoal canister • Halfshafts • Air cleaner 14. Connect the following wires and • Power steering pump Cruise control actuator cable • Radiator • Engine mounting center member connectors on the left-hand fender apron: • The 4 connectors to the engine • Through-bolt and nut holding the relay box • MAP sensor vacuum hose from the mounting insulator to the mounting • Engine relay box bracket gas filter on the intake manifold • The DLC1 connector • Power steering air hose from the • Engine and transaxle assembly intake manifold • The connector on the fender apron • Front and rear engine mounting the air steering bracket pipe • Power hose from the air • The ground strap on the fender • Starter apron or connect on the right-hand • Brake booster vacuum hose from • Separate the transaxle from the 15. Install the intake manifold fender apron: engine To install: • Air conditioning idle-up valve • The ground strap connector • The MAP sensor connector • Air conditioning idle-up valve hose 1 1 . Install or connect the following: from the intake manifold • Engine to the transaxle • With air conditioning, the air con¬ • Starter • from Air condition ditioning pressure switch the air ing pipe idle-up valve hose • Rear engine mounting bracket • The engine wire from the fender • DLC1 from the bracket bolts: 57 ft. lbs. (77 Nm). apron 16. Install or connect the following: • Front engine mounting bracket, • bracket Engine wiring harness from the bolts: 57 ft. lbs. (77 Nm). • With A/C, the actuator connector • Ground cable from the body and • Engine and transaxle assembly into • to With steering, the air hoses the power air pipe the vehicle the ground strap from the body • Heater hoses from the water outlet • The vacuum hose from the MAP • Engine mounting center member. • Heater hose from the water bypass sensor to the gas filter to the intake • Front engine mounting insulator chamber through-bolt and nut. Torque the • The brake booster vacuum hose to • Fuel inlet hose from the fuel filter bolt to 64 ft. lbs. (87 Nm). the air intake chamber • Halfshafts and fuel return hose from the returnthepipe • Front exhaust pipe • With A/C, the vacuum hose from pipe the actuator • EVAP • Power steering pump. Torque the ister hose from the charcoal can¬ bolts to 29 ft. lbs. (39 Nm). • With cruise control, actuator, actua¬ tor cable and cover • Drive belt • Engine wiring harness from the engine compartment relay box • Electrical connector and vinyl hose • Air conditioner compressor. Torque 7. To • Washer tank with the bolt remove the engine wiring harness the bolts to 18 ft. lbs. (25 Nm). • Drive belt and reconnect the con¬ • Coolant reservoir tank stay from the passenger’s compartment, remove • Air cleaner nector. or disconnect the following: • The scuff plate • Radiator and cooling fan 12. To install and connect the engine • The cowl side trim wiring harness, perform the following: • With automatic transmission, con¬ nect the throttle cable. • The finish panel from the lower • Push the wire through the cowl instrument panel • Accelerator cable • Connect the 3 ECM connectors • All fluids • Front side of the floor carpet • Attach the cowl wire connector • Negative battery cable • Floor carpet bracket • The wiring harness from the clamp of the ECM bracket • Undercovers and hood • Center lower finish panel • The 3 ECM connectors 17. Start the vehicle, check for leaks and • With automatic transmission, repair if necessary. • The circuit opening relay connector install the shifting hole bezel, with manual transmission, install the • The 3 connectors from the connec¬ CELICA shift lever knob tors on the bracket • Rear console box 1. Before servicing the vehicle, refer to • The A/C amplifier connector • The MAP sensor connector • Center cluster finish panel and the the precautions in the beginning of this sec¬ radio tion. • The MAP sensor wire from the 2. Release the fuel system pressure. • Lower panel with the glove com¬ clamp on the bracket 3. Drain the engine oil. partment door • The wire clamp from the bracket • The 2 nuts holding the engine 4. Drain the cooling system. • Right and left-hand door scuff 5. Drain the transaxle fluid. wiring harness to the cowl plates • Lower finish panel 8.• Remove or disconnect 6. Remove or disconnect the following: Front exhau st pipe the following: 13. Install or connect the following: • Negative battery cable. On vehicles • Halfshafts. • With manual transmission, clutch equipped with an air bag, wait at • Alternator drive belt release cylinder ing. least 90 seconds before proceed¬ • Transaxle control cable(s) • Air conditioning drive belt, com-

32 "24 AVALON^ CAMRY • CAMRY SOLARA • CELICA * COROLLA * ECHO » GT-S * SUPRA * MR2 install the 2 bolts and nut. Bolts and nut: 47 ft. lbs. (64 Nm). • Left-hand engine mounting through-bolt to the body. Bolt: 54 ft. lbs. (73 Nm). • Right-hand mounting bracket to the insulator. 12mm nut: 21 ft. lbs. (28 Nm). 14mm nut: 38 ft. lbs. (52 Nm),

pressor connector, and compressor. Do not disconnect the air condi¬ tioning lines • Remove the drive belt and remove the 4 bolts that secure the power

steering pump. Without discon¬ necting the lines, securely hang the pump out of the way • A/C relay box • On manual transmission, clutch release cylinder from the transaxle • Transaxle control cable(s) • On automatic transmission, 2 transaxle control cable from the . engine mounting center member. • Exhaust pipe support bracket. 9. To remove the engine mounting cen¬ ter member, remove the following compo¬ nents: • The 2 dust covers from the rear side of the member • The A/C pipe from the bracket • The bolt and nut holding the front engine mounting bracket to the mounting insulator • The bolt holding the rear engine mounting bracket to the insula¬ tor • The bolt and 2 nuts holding the rear engine mounting insulator to the front suspension member • The 2 bolts and the rear engine mounting bracket, and the center member with the rear mounting insulator 10. Remove or disconnect the remaining components: • Attach an engine chain hoist to the engine hangers • Left-hand engine mounting bracket from the mounting insulator • Through-bolt and the left-hand mounting insulator • Ground strap connector • Right-hand engine mounting bracket from the mounting insulator • Lift the engine and transaxle assembly from the vehicle • Transaxle from the engine assembly To install: 1 1 . Install or connect the following: • Transaxle to the engine assembly. • Engine into the engine compart¬ ment

ol thef nect

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• Right-hand engine mounting bracket to the mounting insulator. Temporarily install the 3 nuts. • Left-hand engine mounting insula¬ tor to the body with the throughbolt

ing

low

• Left-hand engine mounting bracket to the mounting insulator and

• Engine ground strap connector and remove the engine hoist. membe

perfo the follo rmthe center wmember r•, Attach ing: together with the rear engine mounting insulator to the front suspension member • Temporarily install the 2 bolts and To in nut body holding the center member to stall the the e ng • Installinethemourear mounting nti engine g ceft. bracket. Bolts: n58 lbs. nter (78 Nm) • Temporarily install the bolt and 2 nuts holding the rear engine

mounting insulator to the front sus¬ pension member • Temporarily install the bolt holding the rear engine mounting bracket to the insulator • Temporarily install the bolt and nut holding the front engine mounting bracket to the insulator • Tighten the 2 bolts holding the center member to the body to 26 ft. lbs. (35 Nm) • Tighten the bolt and 2 nuts holding the rear mounting insulator to the front suspension member to 59 ft. lbs. (80 Nm) • Tighten the bolt holding the rear engine mounting bracket to the insulator to 65 ft. lbs. (88 Nm) • Tighten the bolt and nut holding the front engine mounting bracket to the insulator to 65 ft. lbs. (88 Nm • Install the air conditioning pipe to the bracket and install the 2 dust covers to the center member • Exhaust pipe support bracket. Bolts to 14 ft. lbs. (19 Nm). • Transaxle control cable(s) • On automatic transmission, transaxle control cable to the engine mounting center member. • On manual transmission, clutch release cylinder. Bolts: 108 inch lbs. (12 Nm), then attach the bracket with the bolt. • A/C relay box to the body. • Power steering pump. 12mm bolts:

14 ft. lbs. (19 Nm). 14mm bolts: 29 Nm). ft. lbs. (39 Nm). Install the drive belt. Adjusting bolt: 29 ft. lbs. (39 • A/C compressor. Bolts: 18 ft. lbs. (25 Nm). • A/C drive belt with the adjusting bolt. Torque the locknut to 29 ft. tor. lbs. (39 Nm). Connect the connec¬ • Alternator drive belt • Halfshafts • Front exhaust pipe 14. To install the engine wiring harness in the passenger compartment, perform the following: • Push the harness through the cowl panel, install the retainer to the cowl with the 2 nuts and install the wire clamp to the bracket • Connect the harness to the clamp on the ECM • Connect the 3 ECM connectors and the circuit opening relay con¬ nector • Connect the 3 connectors to the connectors on the bracket • Connect the A/C amplifier connec¬ • tor Install the floor carpet, the lower instrument panel finish panel, the cowl side trim panel, and the scuff 15. Install or connect the following: • Engine wiring harness with the 2 connectors to the engine compart¬ ment relay box and install the relay boxplate covers • MAP sensor connector • MAP sensor wire to the clamp on the bracket • MAP sensor vacuum hose to the gas filter on the intake manifold • Brake booster vacuum hose to the intake manifold • A/C idle-up valve connector • A/C idle-up valve hose to the intake manifold • A/C idle-up valve hose to the air • DLC1 to the bracket • Engine harness protector to the bracket pipe • Ground cable and the ground strap • Heater hose to the water outlet and the heater hose to the water bypass • Fuel inlet hose to the fuel filter • Fuel inlet hose with 2 new gaskets and the union bolt. Bolt: 22 ft. lbs. pipe • (30 Fuel Nm). return hose to the return pipe

:

TOYOTA QO AVALON • CAMRY • CAMRY SOLARA » CELICA • COROLLA • ECHO • GT-S • SUPRA • MR2 OC.

.

Hood tray and battery •• Battery

and connect the EVAP hose to the charcoal canister Power steering air hoses to the intake manifold and the air pipe. Radiator On models equipped with cruise control, install the actuator cable to the clamps. Accelerator cable to the throttle body, cable bracket, and the clamps. Air cleaner

• Rear suspension upper brace Engine undercovers •• Batte ry and tray

MR2

hosecleaner assembly and intake air • Air • Accelerator cable

in the begin o t s ning f his ection. s

ution

*2Washer A/C Compressor *2Shift Cable

Back-up

,

1 Be fore servi cing the ve hicle, Engine Wire Bracket refer to the ♦ Clip*2 Light Switch Connector

—

Connector A/C Compressor

LH Engine Mounting Insulator Drive Belt

Front Engine Mounting Insulator

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^System

Engine and Transaxle Assembly

Hoses-

*1HPU Assembly

ABS Wire Rear Engine Mounting Insulator N-m (kgf-cm. ft-lbf) j : Specified torque ♦ Non-reusable part *1 : Only for SMT

ABS Wire

80(816, 59)

*2: Only for MT 9357WG02

MR2 engine mounting exploded view

0

2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Drain the engine oil 5. Drain the transaxle fluid 6. Remove or disconnect the following: • Engine hood

• Refill the transaxle assembly, engine oil and coolant. • Negative battery cable • Engine undercover 16. Start the vehicle, check for leaks and repair if necessary.

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OO OC TOYOTA • CELICA * COROLLA • ECHO » GT-S * SUPRA * MR2 OL.-L.0 AVALON • CAMRY • CAMRY SOLARA • Bat • Rear bumper cover • Heated Oxygen (HO2S) sensor con¬ nectors • Front exhaust pipe • Accessory drive belt • A/C compressor • Engine wiring harness connectors in the luggage compartment. Pull the harness through the firewall. • Transaxle control ECU harness connector • Engine wire at Junction Box No. 1 • Engine ground wires • Wire brackets • Heater hoses • Radiator hoses • Fuel line • Clutch hose • Shift cables • Axle halfshafts 7. Support the drivetrain from below. • Left and right motor mounts • Front and rear motor mounts • Rear subframe 8. Lower the drivetrain assembly from the vehicle. 9. Remove the starter. 10. Remove the transaxle flange bolts and separate the engine and transaxle. To install: 11. Installation is the reverse of the removal procedure, while using the follow¬ ing torque values: • Rear subframe. Tighten the bolts to 59 ft. lbs. (80 Nm). • Front and rear motor mounts. Tighten the through bolts to 69 ft. lbs. (93 Nm). • Left and right motor mounts. Tighten the mounting fasteners to 38 ft. lbs. (52 Nm) and the through bolts to 64 ft. lbs. (87 Nm). • A/C compressor. Tighten the bolts to 18 ft. lbs. (25 Nm). • Front exhaust pipe. Tighten the bolts to 32 ft. lbs. (43 Nm) and the nut to 46 ft. lbs. (62 Nm). 2ZZ-GE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Release the fuel system pressure. 3. Drain the cooling system. 4. Drain the engine oil. 5. Drain the transaxle fluid. 6. Remove or disconnect the following: • Negative battery cable. On vehicles equipped with an air bag, wait at least ing. 90 seconds before proceed¬

tery • Hood

• Undercover • Accelerator cable, cable bracket, and clamps. • Air cleaner • ECM box • Cruise control actuator cable • Radiator • MAP sensor vacuum hose from the gas filter on the intake manifold • Power steering air hose from the intake manifold • the Powerair steering hose from the air pipe • Brake booster vacuum hose from the intake manifold • A/C idle-up valve • Ai/C idle-up valve hose from the intake manifold • A/C idle-up valve hose from the air • DLC1 from the bracket • pipe Engine wiring harness from the bracket • Ground cable from the body and the ground strap from the body • Heater hoses from the water outlet • Heater hose from the water bypass • Fuel inlet hose from the fuel filter and fuel return hose from the pipe returnthepipe • EVAP hose from the charcoal can¬ ister • Engine wiring harness from the engine compartment relay box 7. To remove the engine wiring harness from the passenger's compartment, remove or disconnect the following: • The scuff plate • The cowl side trim • The finish panel from the lower instrument panel • Remove the front side of the floor carpet • The wiring harness from the clamp of the ECM bracket • The 3 ECM connectors • The circuit opening relay connector • The 3 connectors from the connec¬ tors on the bracket • The A/C amplifier connector • The MAP sensor connector • The MAP sensor wire from the clamp on the bracket • The wire clamp from the bracket • The 2 nuts holding the engine wiring harness to the cowl 8. Remove or disconnect the following: • Front exhaust pipe • Exhaust manifold

• Halfshafts

• Alternator drive belt • A/C drive belt, compressor connec¬ dis¬ and compressor. tor, connect the A/C lines Do not • Remove the drive belt and remove the 4 bolts that secure the power pump. steering necting the lines,Without securelydiscon¬ hang the • A/C pump relay out box of the way. • On manual transmission, clutch release cylinder from the transaxle • Transaxle control cable(s) • On automatic transmission, transaxle control cable from the engine mounting center member. • Exhaust pipe support bracket 9. To remove the engine mounting cen¬ ter member, remove the following compo¬ nents: • The 2 dust covers from the rear side of the member • The air conditioning pipe from the bracket • The bolt and nut holding the front engine mounting bracket to the mounting insulator • The bolt holding the rear engine mounting bracket to the insulator • The bolt and 2 nuts holding the rear engine mounting insulator to the front suspension member • The 2 bolts and the rear engine mounting bracket, and the center member with the rear mounting insulator 10. Remove or disconnect the remaining components: • Attach an engine chain hoist to the engine hangers • Left-hand engine mounting bracket from the mounting insulator • Through-bolt and the left-hand mounting insulator • Ground strap connector • Right-hand engine mounting bracket from the mounting insulator • Lift the engine and transaxle assembly from the vehicle • Transaxle from the engine assembly To install: 11. Install or connect the following: • Transaxle to the engine assembly • Engine ment into the engine compart¬ • Right-hand engine mounting bracket to the mounting insulator. Temporarily install the 3 nuts. • Left-hand engine mounting insula¬ tor boltto the body with the through-

TOYOTA OO AVALON • CAMRY • CAMRY SOLARA • CELICA • COROLLA • ECHO • GT-S • SUPRA • MR2 OC. and connect the EVAP hose to the charcoal canister • Power steering air hoses to the intake manifold and the air pipe. • Radiator

• A/C relay box to the body • Left-hand engine mounting bracket to the mounting insulator and • Power steering pump. 12mm bolts: install the 2 bolts and nut. Bolts 14 ft. lbs. (19 Nm). 14mm bolts: 29 and nut: 47 ft. lbs. (64 Nm). ft. lbs. (39 Nm). Install the drive Nm). belt. Adjusting bolt: 29 ft. lbs. (39 • Left-hand engine mounting through-bolt to the body. Bolt: 54 ft. lbs. (73 Nm). • A/C compressor. Bolts: 18 ft. lbs. 1 (25 Nm). • Right-hand mounting bracket to the insulator. 12mm nut: 21 ft. lbs. (28 • A/C drive belt with the adjusting bolt and tighten the idler pulley Nm), 14mm nut: 38 ft. lbs. (52 Nm). 6 • Engine ground strap connector and locknut to 29 ft. lbs. (39 Nm). Con¬ nect the connector. remove the engine hoist • Alternator drive belt 12. To install the engine mounting center • Halfshafts member, perform the following: . • Front exhaust pipe • Attach the center member together 14. To install the engine wiring harness with the rear engine mounting insulator to the front suspension in the passenger compartment, perform the following: member • Temporarily install the 2 bolts and nut holding the center member to the body • Install the rear engine mounting bracket. Bolts: 58 ft. lbs. (78 Nm) • Temporarily install the bolt and 2 nuts holding the rear engine mounting insulator to the front sus¬ pension member • Temporarily install the bolt holding the rear engine mounting bracket to the insulator • Temporarily install the bolt and nut holding the front engine mounting bracket to the insulator • Tighten the 2 bolts holding the center member to the body to 26 ft. lbs. (35 Nm) • Tighten the bolt and 2 nuts holding the rear mounting insulator to the front suspension member to 59 ft. lbs. (80 Nm) • Tighten the bolt holding the rear engine mounting bracket to the insulator to 65 ft. lbs. (88 Nm) • Tighten the bolt and nut holding the front engine mounting bracket to the insulator to 65 ft. lbs. (88 Nm • Install the A/C pipe to the bracket and install the 2 dust covers to the center member • Exhaust manifold 13. Install or connect the following: • Exhaust pipe support bracket. Bolts to 14 ft. lbs. (19 Nm). • Transaxle control cable(s) • On automatic transmission, transaxle control cable to the engine mounting center member. • On manual transmission, clutch release cylinder. Bolts: 108 inch lbs. (12 Nm), then attach the bracket with the bolt

• Push the harness through the cowl panel, install the retainer to the cowl with the 2 nuts and install the wire clamp to the bracket • Connect the harness to the clamp on the ECM • Connect the 3 ECM connectors and the circuit opening relay connector • Connect the 3 connectors to the connectors on the bracket • A/C amplifier connector • Install the floor carpet, the lower instrument panel finish panel, the cowl side trim panel, and the scuff 15. Install or connect the following: • plate Engine wiring harness with the 2 connectors to the engine compart¬ ment relay box and install the relay box covers. • MAP sensor connector • MAP sensor wire to the clamp on the bracket • MAP sensor vacuum hose to the gas filter on the intake manifold • Brake booster vacuum hose to the intake manifold • A/C idle-up valve connector • A/C idle-up valve hose to the intake manifold • A/C idle-up valve hose to the air • DLC1 to the bracket • Engine pipe harness protector to the bracket • Ground cable and the ground strap • Heater hose to the water outlet and the heater hose to the water bypass • Fuel inlet hose to the fuel filter pipe inlet hose with 2 new gaskets • Fuel and the union bolt. Bolt: 22 ft. lbs. (30 Nm). • Fuel return hose to the return pipe

• On models equipped with cruise control, install the actuator cable to the clamps. • Accelerator cable to the throttle body, cable bracket, and the clamps. • Air cleaner • Hood • Battery tray and battery • Refill the transaxle assembly, engine oil and coolant. • Negative battery cable • Engine undercover i n ir f ecessar y 5S-FE Engine . repa

CAMRY

AND

CAMRY

SOLARA

Start 1 . Before servicing the vehicle, refer to the vehi cle, in the beginning of this sec¬ the precautions chec tion. k fo r le system. 2. Drain the cooling aks a 3. Drain the engine oil.nd 4. Drain the transaxle fluid. 5. Remove or disconnect the following: • Negative battery cable. On vehicles equipped with an air bag, wait at ing. least 90 seconds before proceed¬

• • •

On the Camry Solara, strut tower brace Hood Battery and battery tray

• Engine undercover • Accelerator cable from the throttle body. With automatic transmission, throttle cable • Air hosecleaner, resonator, and air intake • On models with cruise control, actuator cover, actuator with the bracket. • Ground strap at the battery carrier • Radiator and coolant reservoir hose • Washer tank, electrical lead and hose 6. To disconnect the wiring harness, tag and disconnect the following: • The 5 connectors to the engine relay box • The igniter connector • The noise filter connector • The connector at the left-hand fender apron • The 2 ground straps from the lefthand and right-hand fender aprons

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TOYOTA AVALON • CAMRY • CAMRY SOLARA • CELICA • COROLLA • ECHO « GT-S * SUPRA * MR2

1

• The 2 cowl wire connectors • Install the glove compartment and door • Install the lower instrument panel and the undercover

2 .

• Vacuum hoses and the transaxle Instacontrol ll or cocables nn t t he follo vehicles, • On manualectransmission wing: release cylinder and the starter • Fuel inlet hose and tighten it to 22 ft. lbs. (29 Nm). Connect the return hose and the 2 heater hoses. • Attach the 5 connectors to the relay box • The connectors from the left-hand fender apron • Install the engine relay box • The igniter connector • On California models, the ignition coil connector • The noise filter connector

3

• The 2 ground straps from the lefthand and right-hand fender apron • The MAP sensor connector. Use a hoist to remove the engine assembly — Camry 5S-FE engine

. The DLC1 • Disconnect the MAP sensor con¬ . nector • Dash panel undercover, glove com¬ partment door, glove compartment, cowl harness connectors and the 2 ECM connectors • Heater hoses, fuel return hose, and fuel inlet hose • With manual transmission, starter and the clutch release cylinder. Don’t disconnect the hydraulic line, way hang the cylinder out of the simply • Transaxle control cables at the transaxle • Tag and disconnect all remaining vacuum hoses and connectors • Engine wire from the cowl panel • Without disconnecting the refriger¬ ant lines, A/C compressor • Front exhaust pipe bracket and the front pipe from the exhaust mani¬ fold • Halfshafts • Without disconnecting the hydraulic lines, power steering pump • Left engine mounting insulator • Right rear engine mounting insula¬ tor • Front right engine mounting insula¬ tor

• Washer tank and connect the elec¬ C1and' hose lead The DL • trical • Coolant reservoir hose and the radiator • With cruise control, actuator and

8. Attach an engine lifting device to the lift hooks. Remove the 3 bolts and discon¬ nect the control rod. Slowly and carefully, lift the engine/transaxle assembly out of the engine compartment. 9. If equipped with automatic transmis¬ sion, remove the starter. Separate the engine assembly from the transaxle. To install: 10. Install or connect the following: • Engine assembly to the transaxle • With automatic transmission, starter • Engine control rod. Bolts: 47 ft. lbs. (64 Nm). • Front right engine mount. Bolts: 59 ft. lbs. (80 Nm). • Rear engine mount. Nuts: 48 ft. lbs. (66 Nm). • Left mount. Bolts (3 or 4): 47 ft. lbs. (64 Nm). • Power steering pump. Bolts: 31 ft. lbs. (43 Nm). Install the drive belt and connect the 2 air hoses to the air pipe. • Halfshafts

bracket. Connect the actuator con¬ nector and install the cover. • Ground strap to the battery carrier. • Air cleaner assembly • On California models, air hose to

• • • •

the air cleaner assembly and con¬ nect the air intake temperature sen¬ sor connector With automatic transmission, throttle cable Accelerator cable Battery tray and battery HoodCamry Solara models, strut On tower brace

'EL•ICOil A

and coolant. • Negative battery cable • Undercover

rep

air

if nec ess ary . 1 . Before servicing the vehicle, refer to

• Front pipe to the manifold. Nuts: 46 le precautions in the beginning of this secft. lbs. (62 Nm). Sta on. • A/C compressor. Bolts: 20 rft. 2. Properly relieve the fuel system tth lbs. eve ressure. (27 Nm). hi lec, 3. Drain the cooling system. 11 . Feed the engine harness through cthe he c 4. Drain the engine oil. cowl and reattach the clamp to the cowl. kfo rle Make the following connections: aks 5. Drain the transaxle fluid. an 6. Remove or disconnect the following: • The 2 ECM connectors d

TOYOTA AVALON • CAMRY • CAMRY SOLARA • CELICA • COROLLA • ECHO • GT-S • SUPRA • MR2 • Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceed¬ ing. • Battery • Hood • Undercover • Accelerator cable from the throttle body, the cable bracket and clamps • Air cleaner assembly • With cruise control, actuator from the bracket • Radiator • The MAP sensor • The MAP sensor wire from the clamp • The MAP sensor vacuum hose from the gas filter on the intake manifold • The brake booster vacuum hose from the intake manifold • The DLC1 from the bracket • The igniter connector • On California models, the ignition coil connector • On California models, the ignition coil high tension wire, the noise fil¬ ter, the wire clamp from bracket, the ignition coil and igniter assembly, and disconnect the wire from the bracket • The ground cable from the body • The ground strap from the body • The heater hose from the water out¬ let and bypass pipe • The fuel inlet hose from the fuel fil¬ ter and the fuel return hose from the return pipe • The EVAP hose from the charcoal canister • Engine wiring harness from the engine compartment relay box.

fro the pas c rem or mdis sen the fol ompa ove low rtm con ger • neThe scuff’s plateing en t, ct cowl side trim : • The • The finish panel from the lower instrument panel • Remove the front side of the floor carpet • The wiring harness from the clamp of the ECM bracket • The 3 ECM connectors • The circuit opening relay connector • The 3 connectors from the connec¬ tors on the bracket • The air conditioning amplifier con¬ nector • The wire clamp from the bracket • The 2 nuts holding the engine wiring harness to the cowl

8. Remove or disconnect the following: • Front exhaust pipe • Halfshafts • Alternator drive belt • A/C compressor and suspend it securely out of the way • Power steering pump. Securely hang the pump out of the way • On manual transmission, the starter • On manual transmission, the clutch release cylinder and associated components • Transaxle control cable(s) from the transaxle • On automatic transmission model, transaxle control cable from the engine mounting center member. • Exhaust pipe support bracket 9. To remove the engine mounting cen¬ ter member, remove the following compo¬ nents: • The 2 dust covers from the rear side of the member • The air conditioning pipe from the bracket • The bolt and nut holding the front engine mounting bracket to the mounting insulator • The bolt holding the rear engine mounting bracket to the insulator • The bolt and 2 nuts holding the rear engine mounting insulator to the front suspension member • The 2 bolts (automatic transmis¬ sion) or 3 bolts (manual transmis¬ sion) and rear engine mounting bracket. • Center member with the rear mounting insulator 10. Attach an engine chain hoist to the engine hangers 11. Remove or disconnect the following: • Left-hand engine mount bracket from the mounting insulator • Left-hand mounting insulator • Ground strap connector • Right-hand engine mount bracket from the mounting insulator • Halfshaft bearing bracket • Transaxle To install: 12. Install or connect the following: • Transaxle to the engine assembly and reattach the halfshaft bearing bracket. Bolts: 47 ft. lbs. (64 Nm). • Transaxle/engine assembly into engine compartment. • Right-hand engine mount bracket to the mounting insulator, and tem¬ porarily install the bolt and 2 nuts. • Left-hand engine mounting insula¬

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tor to the body with the throughbolt • Left-hand engine mount bracket to the mounting insulator and install the 2 nuts and bolt (manual trans¬ mission) or the 2 bolts (automatic transmission). Bolts and nuts: 47 ft. lbs. (64 Nm). 13. Tighten the left-hand engine mount¬ ing through-bolt to the body: 54 ft. lbs. (73 Nm). Tighten the bolt and 2 nuts holding the right-hand mounting bracket to the insulator: 27 ft. lbs. (37 Nm) and nut: 38 ft. lbs. (52 Nm). 14. Install the engine ground strap con¬ nector 15. To install the engine mounting center member, perform the following: • Attach the center member together with the rear engine mounting insulator to the front suspension member • Temporarily install the 2 bolts hold¬ ing the center member to the body • Install the rear engine mounting bracket with the 2 bolts (automatic transmission) or the 3 bolts (man¬ ual transmission). Bolt: 58 ft. lbs. (79 Nm). • Temporarily install the bolt and 2 nuts holding the rear engine mounting insulator to the front sus¬ pension member • Temporarily install the bolt holding the rear engine mounting bracket to the insulator • Temporarily install the bolt and nut holding the front engine mounting bracket to the insulator • Tighten the 2 bolts holding the center member to the body to 26 ft. lbs. (35 Nm). • Tighten the bolt and 2 nuts holding the rear mounting insulator to the front suspension member to 59 ft. lbs. (80 Nm). • Tighten the bolt holding the rear engine mounting bracket to the insulator to 65 ft. lbs. (88 Nm). • Tighten the bolt and nut holding Nm).front engine mounting bracket the to the insulator to 65 ft. lbs. (88 • Install the A/C pipe to the bracket and install the 2 dust covers to the center member 16. Install or connect the following: • Exhaust pipe support bracket. Bolts: 14 ft. lbs. (19 Nm). • Transaxle control cable(s) to the transaxle. 17. On the automatic transmission vehi-

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AVALON • CAMRY • CAMRY SOLARA • CELICA • COROLLA • ECHO • GT-S • SUPRA « MR2 harness to the bracket • The igniter connector • On California model, the ignition coil connector, high tension wire to the coil, and the noise filter • The ground cable and the ground strap to the body • The heater hose to the water outlet and the heater hose to the water

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cles, transaxle control cable to the engine mounting center member. 18. On manual transmission model only, install and/or connect the following: • The clutch release cylinder. Bolts: 108 inch lbs. (12 Nm). • The bracket with the bolt and the tube to the bracket with the clamp • The tube with the clamp and bolt • The back-up switch connector 19. Install or connect the following: • On manual transmission model only, starter, starter wire, and starter connector. • Power steering pump. 3 mounting bolts: 32 ft. lbs. (44 Nm); adjusting bolt: 29 ft. lbs. (39 Nm); pivot bolt: 32 ft. lbs. (44 Nm) • Hoses to the air tube • A/C compressor. Bolts: 18 ft. lbs. (24 Nm). • Alternator drive belt • Halfshafts • Front exhaust pipe 20. To install the engine wiring harness

to the passenger’s compartment, perform the following: • Push the harness through the cowl . panel, install the retainer to the cowl with the 2 nuts and install the wire clamp to the bracket • Connect the harness to the clamp on the ECM • Connect the 3 ECM connectors and the circuit opening relay connector • Connect the 3 connectors to the connectors on the bracket

• 2 ground straps and any other elec¬ trical connections keeping them from being removed. • Vacuum hoses from the engine. • Fuel inlet and return hoses • Heater hoses • Transaxle control cable from the transaxle • Instrument panel undercover, the lower instrument panel and glove box assembly

bypass pipe • Fuel inlet hose to the fuel filter • Fuel inlet hose with 2 new gaskets and the union bolt. Bolt: 22 ft. lbs.

• 3 ECM connectors, the 5 cowl wire connectors, and the cooling fan ECM connector. Push the engine wire • Front through exhaust the pipecowl panel

(30 Nm). • Fuel return hose to the return pipe and connect the EVAP hose to the charcoal canister • Radiator

• Halfshafts •• Power tube Power steering steering pressure pump

• With cruise control, actuator and connect the connector • Accelerator cable to the throttle body, the cable bracket, and the clamps. • Air cleaner

• A/C compressor without discon¬ necting the hoses • Left-hand engine mounting insula¬ tor • Right-hand engine mounting insu¬ lator

Hood tray and battery • Battery • • • •

• Engine mounting shock absorber

Oil and coolant Transaxle fluid to the proper level Negative battery cable Undercover

• tor Front right engine mounting insula¬ 7. Attach a hoist chain to the engine hangers. 8. Remove or disconnect the following: • Coolant reservoir hose and reser¬ voir tank • Right-side engine mounting stay bracket assembly • Engine control rod and bracket

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'•-Make certain all wires, connectors and hoses are cleared from the engine. • Engine/transaxle assembly from the vehicle To install: 9. Carefully lower the engine position. Keep the engine level while aligning the engine mounts. • Engine control rod and bracket. Tighten to 47 ft. lbs. (64 Nm). • Right engine mount stay bracket. Tighten to 23 ft. lbs. (31 Nm). • Engine ground straps. • Coolant reservoir tank • Front engine insulator. Tighten to 48 ft. lbs. (66 Nm). • Engine mounting shock absorber. Tighten to 35 ft. lbs. (48 Nm). • Left and right engine mounts. Tighten to 48 ft. lbs. (66 Nm). • Power steering pump and A/C

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1 . Before servicing the vehicle, refer to • Connect the A/C amplifier connec¬ tor the precautions in the beginning of this sec¬ tion. • Install the floor carpet, the lower 2. Properly relieve the fuel system instrument panel finishS panel, the tar t ththe scuff cowl side trim panel, and e ve pressure. 3. Drain the cooling system. hic l plate e 4. Drain the engine oil. , 21 . Install or connect the following: che ck f 5. Drain the transaxle fluid. • Engine wiring harness with the 2 or l eak 6. Remove or disconnect the following: s an connectors to the engine compart¬ d • Negative battery cable. On vehicles ment relay box and install the relay box covers equipped with an air bag, wait at • The MAP sensor connector ing. least 90 seconds before proceed¬ • Hood • The MAP sensor wire to the clamp on the bracket • Battery and battery tray • The MAP sensor vacuum hose to • Accelerator and throttle cables the gas filter on the intake manifold • Cruise control actuator, if equipped • The brake booster vacuum hose to • Air cleaner assembly, mass air flow the intake manifold meter and air cleaner hose • The DLC1 to the bracket • Radiator • The engine harness protector to the • Engine relay box bracket • 2 igniter connectors • On California models, the engine • Noise filter connector harness clamp to the bracket and • Connector from the left-hand fender the ignition coil and igniter assem¬ bly with the 3 bolts, and install the apron

compressor • Power steering pressure tube

TOYOTA OO

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• Engine from the vehicle • Halfshafts and front exhaust pipe • Rubber cap, nut and wire from the AVAL alternator ON * CAMRY • CAMRY SOLAR • Engine wires * and connectors OilSUPRA dipstick •guide the trans¬ A • CELICA • COROLLA • ECHO • GT-S• •mission MR2 from 041 O I • Transaxle control cable to the • Engine room main wire transaxle • Igniter connector • Engine wire from the transmis¬ • Theft deterrent horn connector • Fuel hoses and heater hoses sion • Starter connector, 2 bolts, engine • Engine wire from the 2 wire clamps • All vacuum hoses, wiring and con¬ nectors wire bracket, and the starter • Wire clamp and power steering • Radiator solenoid valve connector • With automatic transmissions, oil • Cruise control actuator • Ground strap from the cylinder cooler tubes from the transmis¬ sion • Throttle cable and accelerator cable block by removing the bolt • With automatic transmissions, • MAF meter, the air cleaner assem¬ • Rubber cap, nut, and the wire from the starter bly, and air cleaner hose torque converter clutch mounting bolts • Fuel inlet hose from the engine. • Coolant and engine oil • Transmission Suspend the hose union upward • Battery tray and battery. To install: • Fuel return hose from the fuel • Transaxle fluid to the proper level • Hood return guide 10. Assemble the engine and transmis¬ • Fuel return hose from the fuel sion. Tighten the bolts as follows: • Negative battery cable • 14mm: 29 ft. lbs. (39 Nm) return hose. Plug the hose end • 17mm: 43 ft. lbs. (72 Nm) repair if neces • fold Engine staywire from the intake mani¬ sary. 1 1 . Install or connect the following: • Power steering pump • With automatic transmission, 2JZ-GE and 2JZ-GTE Engines torque converter clutch mounting • Power steering pressure tube 1 . Before servicing the vehicle, refer to bolts by first installing the gray • A/C compressor without discon¬ the precautions in the beginning of this sec¬ necting the hoses bolt, then install the other 5 bolts. tion. Bolts: 25 ft. lbs. (33 Nm). • Engine wire from the cowl panel 2. Properly relieve the fuel system • With automatic transmission, • Remove the scuff plate from the pressure. Nm). right door oil cooler tubes to the transmis¬ 3. Drain the cooling system. sion. Union nuts: 25 ft. lbs. (33 • Take out the front side of the floor 4. Drain the engine oil. • Starter carpet 5. Remove or disconnect the follow¬ • Remove the 2 nuts and ECM pro¬ ing: tector • Engine wire to the transmission • Negative battery cable. Do not start • With automatic transmission, oil • Remove the nut and disconnect the any work for at least 90 seconds to ECM from the floor panel dipstick guide and dipstick prevent accidental deployment of • Disconnect the 2 connectors from • Engine and transmission as an the air bag. the ECM assembly to the vehicle. Keep • Hood • Disconnect the connector from the slight tension on the engine until • Radiator vehic le, c instrument panel wire the mounting bolts and nuts are heck installed t CAUTION • Disconnect the connector from the for le aks a connector cassette nd • Engine front mounting insulators to The fuel injection system remains the front suspension crossmember. • Pull out the engine wire from the Nuts: 43 ft. lbs. (59 Nm). under pressure even after the engine cabin has been turned OFF. The fuel system • With manual transmission, upper • Bolts Nm). holding the support member , to the body. Bolts: 19 ft. lbs. (25 pressure must be relieved before dis¬ console panel, shift lever boots, connecting any fuel lines. Failure to and holding bolts • With manual transmission, clutch do so may result in fire and/or per¬ • Nuts holding the support member sonal injury. release cylinder and the ground to the engine rear mounting insula¬ tor. Nuts: 10 ft. lbs. (13 Nm). strap from the transmission. • Driveshaft • Accelerator cable and cruise control • No. 2 front exhaust pipe actuator • Exhaust pipe heat insulator 12. With automatic transmissions, trans¬ • Driveshaft • Air cleaner assembly, volume air mission control rod as follows: flow meter, and the air intake hose • With automatic transmissions, con¬ • Shift the shift lever to the N posi¬ • Drive belt by turning the tensioner trol rod from the shift lever by tion. clockwise removing the nut. • Fully turn the control shaft lever • Fan, fan clutch, and the water pump back and return 2 notches. The 6. Support the transmission with a jack. pulley control shaft is now in the neutral 7. Remove the rear support member by • Charcoal canister removing the 8 bolts. • Heater water hoses • Connect the control rod to the shift 8. Attach the engine hoist chain to the • Brake booster vacuum hose position lever with the nut. Tighten the nut engine and raise the engine slightly. • EVAP hose to 108 inch lbs. (13 Nm). 9. Remove or disconnect the following: • Noise filter connector 13. Install or connect the following: • Nuts holding the engine front • Ignition coil connector mounting insulators to the front • Exhaust pipe heat insulator • No. 2 front exhaust pipe • Engine wire from the wire clamp suspension crossmember.

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TOYOTA

AVALON • CAMRY • CAMRY SOLARA • CELICA • COROLLA • ECHO * GT-S * SUPRA * MR2 Nm). • With manual transmission, clutch • Water pump. Bolts: 13 ft. lbs. (17 Water Pump release cylinder and ground strap. • Oil dipstick guide Tighten the clutch release cylinder REMOVAL & INSTALLATION • Alternator adjusting bar bolts to 108 inch lbs. (13 Nm) and • Dipstick guide clamp bolt the ground strap bolt to 27 ft. lbs. 5E-FE Engine • Water inlet pipe. Bolt: 65 inch lbs. (37 Nm). • With manual transmission, upper (7.5 Nm). 1 . Before servicing the vehicle, refer to • Water bypass, heater inlet and console panel, shift lever boots, water inlet hoses and holding bolts. the precautions in the beginning of this sec¬ tion. • For distributorless ignition engines, • Engine wire through the cowl 2. Drain the cooling system. install the intake manifold bracket panel. 3. Remove or disconnect the follow¬ ing: Nm).installing the 2 bolts and the • Connect the connector to the con¬ by nector cassette wire clamp. Bolts: 15 ft. lbs. (20 • Negative battery cable. On vehicles • Connect the connector to the equipped with an air bag, wait at • For distributor ignition, install the instrument panel wire connector ing. 90 seconds before proceed¬ intake manifold bracket by least • Connect the 2 connectors to the ECM installing the 2 bolts. Bolts: 15 ft. • Alternator lbs. (20 Nm). • Insert the ECM bracket into the stay • With distributorless ignition, intake • Alternator and belt on the floor panel • Negative battery cable manifold stay bracket by discon¬ • Install the ECM with the nut necting the wire clamps and 5. Fill the coolant system to the proper • Install the ECM protector with the 2 removing the 2 nuts level. nuts • With distributor ignition, remove 6. Start the vehicle, check for leaks and • Install the floor carpet the intake manifold stay bracket by repair if necessary. • Install the scuff plate removing the 2 nuts and 2 bolts. • Engine wire to the cowl panel • Water inlet pipe 1NZ-FE Engine • Air conditioning compressor to the • Oil dipstick guide engine • Alternator adjusting bar 1 . Before servicing the vehicle, refer to • Power steering tube with the 2 Waterr pum pumpp attaching bolt and nuts • Wate the precautions in the beginning of this sec¬ clamp bolts tion. • Power steering pump. Lower bolt: 2. Drain the cooling system. To install: 43 ft. lbs. (58 Nm); upper bolt: 29 3. Remove or disconnect the following: 4. Install or connect the following: ft. lbs. (39 Nm); rear stay bolts: 29 • Negative battery cable • 0.08—0.12 in. (2— 3mm) bead of ft. lbs. (39 Nm); front bracket bolts: nuts) • Accessory drive belt sealant to the groove in the pump. 43 ft. lbs. (58 Nm). • Water pump pulley, using a holding • O-ring, lubricated with a little • Engine wire bracket tool soap and water, on the water inlet • Fuel return hose to the fuel return • Water pump and gasket (3 bolts; 2 pipe • Fuel return hose to the clamp of the pipe. oil dipstick guide

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• Fuel inlet hose with the 2 new gas¬ kets and the union bolt. Bolt: 22 ft. lbs. (29 Nm). • Wires and connectors • EVAP hose • Brake booster vacuum hose • Heater hoses • Charcoal canister • Water pump pulley, fan, and the fan clutch • Drive belt to the engine • Air cleaner, VAF meter, and the intake air connector pipe. • Control cables to the throttle body • Oil • Radiator • Cooling system • Negative battery cable • Hood 14. Start the vehicle, check for leaks and repair if necessary.

TOYOTA OOOO AVALON • CAMRY • CAMRY SOLARA • CELICA • COROLLA • ECHO • GT-S • SUPRA • MR2

To install: 6 . 4. Install or connect: • Water pump, with a new gasket. Torque the nuts and bolts to 96 inch lbs. (11 Nm). • Pulley. Torque the bolts to 11 ft. lbs. (15 Nm). • Drive belt • Negative battery cable 5. Fill the cooling system to the proper level. 6. Start the vehicle, check for leaks and repair if necessary. 1ZZ-FE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Remove or disconnect the following: • Negative battery cable • Right-hand engine under cover • Drive belt • Water pump To install: 4. Install or connect the following: • Water pump. Bolts marked A (short): 80 inch lbs. (9 Nm). Bolts marked B (long): 96 inch lbs. (11 Nm). • Drive belt • Right engine undercover • Negative battery cable 5. Fill the cooling system to the proper level. 6. Start the vehicle, check for leaks and repair if necessary. 2ZZ-GE Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Remove or disconnect the follow¬ ing: • Negative battery cable • Right-hand engine under cover • Drive belt • Water pump pulley • Water pump and O-ring To install: 4. Install or connect the following: • Water pump with new O-ring. Bolts: 80 inch lbs. (9 Nm). • Water pump pulley. Bolts: 11 ft. lbs. (15 Nm). • Drive belt • Right engine under cover • Negative battery cable 5. Fill the cooling system to the proper level.

repair if necessary. t the vehicle, 5S-FEStarEngine check for le aks and 1 . Before servicing the vehicle, refer to

the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Remove or disconnect the following: • Negative battery cable. On vehicles equipped with an air bag, wait at least ing. 90 seconds before proceed¬ • Right engine undercover • Lower radiator hose from the water outlet • Timing belt, timing belt tension spring, and the No. 2 idler pulley • Alternator, drive belt and the adjust¬ ing bar if necessary • 2 nuts holding the water pump to the water bypass pipe and remove the 3 bolts in sequence. • Water pump cover assembly • Gasket and 2 O-rings from the water pump and the bypass pipe. • Water pump from the water pump cover by removing the 3 bolts in sequence. To install: 4. Install or connect the following: • Water pump to the water pump cover. Bolts: 78 inch lbs. (9 Nm) in proper sequence. • Water pump cover to the water bypass pipe, but do not install the nuts yet. • Water pump and tighten the 3 bolts in sequence. Bolts: 78 inch lbs. (9 Nm). Nuts: 82 inch lbs. (9 Nm).

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• Alternator drive belt adjusting bar. Bolt: 13 ft. lbs. (18 Nm). • No. 2 idler pulley and the timing belt tension spring • Lower radiator hose • Timing belt • Right engine undercover • Negative battery cable 5. Fill the cooling system to the proper level. 6. Start the vehicle, check for leaks and repair if necessary. 1MZ-FE Engine 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Remove or disconnect the following: • Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding • Timing belt • No. 2 idler pulley • 3 clamps and engine wire from the rear timing belt cover • pump belt cover • Wat Rearertiming To install: 4. Install or connect the following: • Liquid sealer to the gasket, water pump and engine block. • Water pump. Bolts and nuts: 53 inch lbs. (6 Nm). • Rear timing belt cover. Bolts: 74 inch lbs. (9 Nm). • Engine wire with the 3 clamps to the rear timing belt cover. • No. 2 idler pulley. Bolt: 32 ft. lbs. (43 Nm).

Q A TOYOTA

“04 AVALON • CAMRY • CAMRY SOLARA • CELICA • COROLLA • ECHO • GT-S • SUPRA • MR2

• With the flange side outward, right-hand camshaft pulley. Align the knock pin hole on the camshaft 4 pulley with the knock pin on the camshaft. Bolt: 65 ft. lbs. (88 Nm). . • With the flange side inward, lefthand camshaft pulley. Align the knock pin hole on the camshaft pulley with the knock pin on the camshaft. Bolt: 94 ft. lbs. (125 Nm).

• Water pump. Be sure to replace the bolts to their original positions. Bolts: 15 ft. lbs. (21 Nm). • 2 nuts holding the No. 2 water bypass pipe to the water pump. Nuts: 15 ft. lbs. (21 Nm). • No. 3 turbo water hose to the water pump. bypass outlet and No. 1 • Water water bypass pipe. • Turbo water hoses to the water out¬ let. • Alternator

• Timing belt • Negative battery cable 5. Fill the cooling system to the proper level. 6. Start the vehicle, check for leaks and repair if necessary.

• Except for California vehicle, exhaust manifold heat insulator • Engine wire bracket • Timing belt • Thermostat, water inlet, and the lower radiator hose assembly. • Water pump pulley, fan, fluid clutch assembly, and the drive belt. Fan nuts: 12 ft. lbs. (16 Nm). • With manual transmission, drive belt tensioner damper. • Radiator

2JZ-GE and 2JZ-GTE Engines 1 . Before servicing the vehicle, refer to the precautions in the beginning of this sec¬ tion. 2. Drain the cooling system. 3. Remove or disconnect the following: • Negative battery cable. On vehicles equipped with an air bag, wait at least 90 seconds before proceeding. bly • Air cleaner and MAF meter assem¬

ence ring catches on the screw case. • Carefully, remove the air bag mod¬ ule and disconnect the electrical connector. • Remove the steering wheel nut. • Using a steering wheel puller, press the steering wheel from the steering column. p t f g he ollowing rocedure: • Remove the front pillar garnishes Removand the door scuff plates. e the inthe • Remove struhood ment lock release lever anel b and the cowl side ptrims. y per¬ • Remove the steering column covers and the combination switch. • Remove the lower finish panel assembly and the instrument panel finish lower leftside panel. • Remove the fuse box bolt and the

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No. 2 heater-to-register duct. • Remove the parking brake release lever and the No. 2 undercover. • Remove the lower No. 2 finish

bly. cleaner and MAF meter assem¬ • Air • No. 1 air hose

Heater Core REMOVAL & INSTALLATION Avalon

• Remove the steering column shaftto-intermediate shaft bolt. • Remove the steering column-toinstrument panel nuts and remove the steering column assembly. • Inside the glove compartment, pry out the glove compartment door finish plate.

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• Radiator • With manual transmission, drive belt tensioner damper. • Loosen the 4 nuts holding the fan clutch to the water pump. • Drive belt from the engine • Fan, fan clutch, and the water pump pulley • Water inlet, lower radiator hose assembly, and the thermostat • Timing belt • Alternator • On turbo models, turbo water hoses from the water outlet • Except for the California vehicles, exhaust manifold heat insulator • Water outlet and No. 1 water bypass pipe • No. 2 water bypass from the water pump • No. 3 turbo water hose from the water pump • Water pump • O-ring To install: 4. Install or connect the following: • O-ring • Water pump to the water bypass pipe, with thin layer of liquid sealant applied on engine and water pump. Do not install the nut at this time.

• Negative battery cable 5. Fill the cooling system to the proper level. 6. Start the vehicle, check for leaks and repair if necessary.

• If equipped with a column shifter, disconnect the shift control cable from panel.the shift lever housing; then, disconnect the shift control cable from the steering column cable bracket. • Matchmark the steering column shaft and the control valve shaft.

CAUTION

After disconnecting the negative bat¬ tery cable, wait for at least Yh min¬ utes for the SRS to deplete its energy. 2. Drain the cooling system into a clean container for reuse. 3. Remove the air bag module and the steering wheel by performing the following procedure: • Place the front wheels in the straight-ahead position. • At both sides of the steering wheel, remove the screw covers. • Using a Torx socket, loosen the 2 air bag module-to-steering wheel Torx screws until the circumfer¬

• Pull out the air bag electrical con¬ nector and disconnect it. • Remove the 3 glove compartment door-to-instrument panel nuts and the door. • Remove the 4 glove compartmentto-instrument panel screws and the glove compartment; then, discon¬ nect the glove box light connector. • Remove the passenger's side air bag module-to-instrument panel 2 bolts and 4 nuts. Carefully, remove the air bag module from the instru¬ ment panel. • Remove the center cluster finish panel and the radio. • Remove the heater control assem• If equipped with a floor shifter, remove the upper console panel,

TOYOTA QO

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AVALON • CAMRY • CAMRY SOLARA • CELICA • COROLLA • ECHO • GT-S • SUPRA • MR2 Ol

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Steering Wheel Pad Torx Screw Steering Assembly Column

Steering Wheel Lower No. 2 Cover Combination Switch (w/ Spiral Cable)

Column Upper Cover

Column Lower Cover

Instrument Panel Finish Lower LH Panel

Lower LH Instrument Cover

No. 2 Duct Heater to Register

Cowl Side Trim

Front Door Inside Scuff Plate

N-m (kgf-cm, ft-lbf) : Specified torque 931 12GL2

Exploded view of the air bag module, the steering wheel, the floor shift steering column and related components— Avalon

32-36

TOYOTA AVALON • CAMRY • CAMRY SOLARA • CELICA • COROLLA • ECHO • GT-S • SUPRA » MR2

Steering Wheel Pad Torx Screw Steering Column Assembly

Steering Wheel Lower No. 2 Cover Combination Switch (w/ Spiral Cable)

Column Upper Cover

Column Lower Cover

Lower LH Instrument

Instrument Panel Finish Lower LH Panel

Cover

No. 2 Duct Heater to Register

Cowl Side Trim

Front Door Inside Scuff Plate N-m (kgf-cm, ft-lbf) : Specified torque 93112GL3

Exploded view of the air bag module, the steering wheel, the column shift steering column and related components — Avalon

TOYOTA

90

07

AVALON • CAMRY • CAMRY SOLARA • CELICA • COROLLA • ECHO • GT-S • SUPRA • MR2 Ot

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the rear console box and the front console box. • If equipped with a column shifter, remove the finish panel. • Pry out the cluster finish panel. • Remove the 6 cluster finish panel screws, assembly.the cluster finish panel • Remove the 4 combination meter screws and the combination meter. • Disconnect instrument panel elec¬ trical connectors. • Remove the instrument panel-tochassis nuts/bolts and the remove the instrument panel. 5. Remove the instrument panels No. 2 brace. 6. Disconnect the heater hoses from the heater core. 93112GL6

Releasing the air bag module-to-steering wheel screws— Avalon

7. Remove the 2 heater pipes-to-heater core screws and clips; then, disconnect the heater pipes from the heater core. 8. Remove the heater core O-rings and discard them. 9. Remove the heater core from the heater housing.

To install: 10. Install the heater core to the heater housing. 11. Install new heater core O-rings. 12. Install the heater pipes to the heater

Airbag Connector Correct

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core; 2 heater pipes-to-heater core screwsthen, and the clips. 13. Install the heater hoses to the heater core. 14. Install the instrument panels No. 2 brace. 15. Install the instrument panel by per¬ forming the following procedure: • Install the instrument panel and the

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• •

• •

instrument panel-to-chassis nuts/bolts. Install instrument panel electrical connectors. Install the combination meter and the 4 combination meter screws. Install the cluster finish panel, the 6 cluster finish panel assembly screws. Install the cluster finish panel. If equipped with a column shifter, install the finish panel.

• If equipped with a floor shifter, install the upper console panel, the rear console box and the front con¬ sole box. • Install the heater control assembly. • Install the center cluster finish panel and the radio. • Carefully, install the air bag module to the instrument panel; then, Disconnecting and positioning the air bag module— Avalon

32-38

TOYOTA AVALON • CAMRY • CAMRY SOLARA • CELICA • COROLLA • ECHO • GT-S • SUPRA • MR2

Instrument Panel Reinforcement

Instrument Panel No.1 Brace

Front Pillar Garnish

Front Door Scuff Plate

Front Pillar Garnish

No. 5 Duct Heater to Register

Center Cluster Finish Panel

Glove Steering Wheel Lower No. 2 Cover

Compartment

Lower No. 2 Finish Panel Instrument Panel Finish Lower LH Panel

Cowl Side Trim

93112GA5

Exploded view of the iostrument panel and related components — Avalon

TOYOTA qo

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AVALON • CAMRY • CAMRY SOLARA • CELICA • COROLLA • ECHO • GT-S • SUPRA • MR2 OL Instrument Panel Wire Harness

No. 4 Duct Side Defroster Nozzle Defroster Nozzle Assembly

No. 1 Duct Side Defroster Nozzle

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No.3 Duct Heater (g) to Register Instrument Panel

No.1 Duct Heater to Register

No.1 Brace

No.1 Side Defroster Nozzle No.1 Defroster Nozzle Garnish No.2 Defroster Nozzle Garnish Lower Finish Panel Sub-Assembly 93112GL4

Exploded view of the wiring harness, ventilation system and related components— Avalon

32-40

TOYOTA AVALON • CAMRY • CAMRY SOLARA • CELICA • COROLLA • ECHO • GT-S • SUPRA • MR2

Water Valve

Auto A/C Only Solar Sensor

A/C Amplifier Relay Block No. 4

Auto A/C Only Room Temp. Sensor

A/C Control Upper Panel A/C Control Lower Panel Manual A/C

Auto A/C Air Inlet Servomotor

Air Inlet Servomotor

Blower Motor Evaporator

Expansion Valve

Expansion Valve Blower Resistor

Blower Resistor

Blower Motor Evaporator Evaporator Temp. Sensor Air Outlet Servomotor

Power Transistor Aspirator

Air Outlet Servomotor Extra-Hi Relay Air Mix Servomotor

Heater Radiator

Engine Coolant Temp. Sensor

Evaporator Temp. Sensor Heater Radiator 93112GA6

View of the heater/air conditioning assembly and related components — Avalon

TOYOTA QO AVALON • CAMRY • CAMRY SOLARA • CELICA • COROLLA • ECHO • GT-S • SUPRA • MR2

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Instrument Panel

Reinforcement

A/C Unit

No. 1 Brace

Rear Heater Duct

Blower Unit emp. Sensor

Defroster Nozzle

Heater Radiator Pipe

Evaporator Cover

♦ O-Ring Heater Radiator

Evaporator Air Duct

Manual A/C: Blower Resistor Auto A/C: Blower Resistor Auto A/C models Blower Motor Linear Controller

Air Vent Duct

Manual A/C: Water Valve Control Cable Guide N-m (kgf-cm, ft-lbf) ♦ Non-reusable part

: Specified torque

93112GL5

Exploded view of the evaporator housing, heater housing, heater core and related components— Avalon

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TOYOTA

AVALON • CAMRY • CAMRY SOLARA • CELICA • COROLLA • ECHO * GT-S * SUPRA * MR2 shift lever housing; then, install the shift control cable to the steering column cable bracket. Install the lower No. 2 finish

Inside the glove compartment, install the glove compartment door finish plate.

install the passenger’s side air bag module-to-instrument panel 2 bolts and 4 nuts. Install the glove compartment and

Install the steering column assem¬ column-tosteering and the panel bly instrument nuts; then, torque

the 4 glove compartment-to-instrument panel screws; then, install the glove box light connector. Install the glove compartment door and the 3 door-to-instrument panel nuts.

Install the parking brake release lever and the No. 2 undercover. Install panel.the fuse box bolt and the No. 2 heater-to-register duct. Install the lower finish panel assembly and the instrument panel finish lower left side panel.

the nuts to 19 ft. lbs. (25 Nm). Align the matchmarks and install shaft-to-intersteering the mediate shaftcolumn bolt. If equipped with a column shifter, install the shift control cable to the

Connect the air bag electrical con¬ nector.

Instrument Panel Reinforcement Instrumental Panel Bracket No.1 Instrumental Panel Bracket Na2 Instrumental Panel Brace

Instrument Panel Brace Mount I

No.1 Panel InstrumentBrace (gT

Front Pillar Garnish

A

Front Passenger ^ & Airbag

Front Pillar Garnish

No.2 Side Defroster Nozzle Cowl Side Trim -Front Door Opening

Assembly

Cover Front Door Glove Compartment Door Finish Plate

Instrument Panel

Inside Scuff Plate

Hazard Warning Switch Lower Finish Remote Control Mirror Hole Base