Partial Engine Assembly Replacement

REPLACEMENT
1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
a. Disconnect fuel pump connector.
b. Start the engine. After the engine has stopped on its own, turn the ignition switch to LOCK.
c. Disconnect negative (-) terminal cable from battery.
d. Connect the fuel pump connector.
2. REMOVE FRONT WHEEL
3. REMOVE ENGINE UNDER COVER NO.1 [51441 / 98-91]
4. REMOVE FRONT FENDER SPLASH SHIELD FRONT RH [53895B / 98-97]
5. REMOVE FRONT FENDER SPLASH SHIELD FRONT LH [53896B / 98-97]
6. REMOVE FRONT FENDER APRON SEAL RH [53736 / 98-99]
7. DRAIN COOLANT
8. DRAIN AUTOMATIC TRANSAXLE FLUID
a. Using a 10 mm hexagon wrench, remove the drain plug and a gasket. Drain automatic transaxle fluid.
b. Install a new gasket and the drain plug.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
9. DRAIN TRANSFER OIL(4WD DRIVE TYPE)
a. Install a new gasket and the drain plug after draining transfer oil.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
10. REMOVE BATTERY
11. REMOVE AIR CLEANER ASSY [17700 / 98-30]
12. SEPARATE RADIATOR HOSE INLET [16571 / 98-20]
13. SEPARATE RADIATOR HOSE OUTLET [16572 / 98-20]
14. SEPARATE OIL COOLER INLET HOSE [32921D / 98-56]
15. SEPARATE OIL COOLER OUTLET HOSE [32922A / 98-56]
16. REMOVE ENGINE MOUNTING STAY NO.2 RH [12327A / 98-10]





17. REMOVE ENGINE MOVING CONTROL ROD W/BRACKET
a. Remove the 3 bolts and the engine moving control rod w/ bracket.
18. REMOVE ENGINE MOUNTING BRACKET NO.2 RH [12316 / 98-10]
19. REMOVE FAN AND GENERATOR V BELT [16361A / 98-25]
SST 09249-63010
20. SEPARATE VANE PUMP OIL RESERVOIR ASSY [44360 / 98-73]





21. SEPARATE RETURN TUBE SUB-ASSY [44406 / 98-74]
a. Remove the 2 bolts and separate the return tube.
22. SEPARATE UNION TO CHECK VALVE HOSE [44773F / 98-82]
23. SEPARATE ACCELERATOR CONTROL CABLE ASSY [78180P / 98-143]
24. SEPARATE FLOOR SHIFT TRANSMISSION CONTROL CABLE ASSY [33820B / 98-43]
25. SEPARATE HEATER INLET WATER HOSE [87245 / 98-190]
26. SEPARATE HEATER OUTLET WATER HOSE [87246 / 98-190]
27. SEPARATE FUEL TUBE SUB-ASSY [23901 / 98-40]





28. SEPARATE ENGINE ROOM MAIN WIRE [82111 /98-151]
a. Separate the engine wire from engine ECU and junction block.
b. Separate the engine wire from engine room junction block.
1. Install the wire harness and remove a nut.
2. Using a screwdriver, unlock the engine room junction block. Separate the engine wire by pulling it upward.
3. Separate the connector.
c. Pull out the engine wire.
d. Separate B terminal of the generator.
e. Remove the body ground.
29. REMOVE EXHAUST PIPE ASSY FRONT [17410 / 98-28]
30. REMOVE PROPELLER SHAFT (4WD DRIVE TYPE)





a. Place the matchmarks on both of the flanges.
b. Remove the 4 nuts, bolts and washers.





c. Insert SST after removing propeller shaft assembly.
SST 09325-20010
31. REMOVE FRONT STABILIZER LINK ASSY LH [48810 / 98-89]
a. Using a 6 mm socket hexagon wrench to fix the stud bolt.
b. Remove the nut and the stabilizer bar link.
32. REMOVE FRONT STABILIZER LINK ASSY RH [48820B / 98-89]

HINT: Perform the same procedure on the opposite side.





33. REMOVE FRONT AXLE HUB LH NUT [43502H / 98-71]
a. Using SST and a hammer, unstake the staked part of the lock nut.
SST 09930-00010

NOTICE:
- When removing the nut, unstake the staked part of it completely.
- Do not damage the threads of the drive shaft.
- Be sure not to sharpen the tip of the SST. Set the SST to the groove with the flat face upward.

b. Using a 30 mm socket wrench, remove the lock nut.
34. REMOVE FRONT AXLE HUB RH NUT [43501H / 98-71]
SST 09930-00010

HINT: Perform the same procedure on the opposite side.

35. SEPARATE SPEED SENSOR FRONT LH [89543 / 98-170]

NOTICE: Keep the tip and connection part of speed sensor off foreign materials.

36. SEPARATE SPEED SENSOR FRONT RH [89542 / 98-170]

HINT: Perform the same procedure on the opposite side.





37. SEPARATE TIE ROD ASSY LH [45470 / 98-76]
a. Remove the cotter pin and a castle nut.
b. Using SST, separate the tie rod end from the steering knuckle.
SST 09628-62011

NOTICE: Be careful not to damage the cover of the ball joint.

38. SEPARATE TIE ROD ASSY RH [45460 / 98-76]
SST 09628-62011

HINT: Perform the same procedure on the opposite side.





39. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH [48069 / 98-88]
a. Remove the bolt and 2 nuts shown in the illustration.
b. Using a plastic hammer, separate the drive shaft from the axle hub.
40. SEPARATE FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH [48068 / 98-88]

HINT: Perform the same procedure on the opposite side.





41. REMOVE DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT [32101A / 98-46]
a. Fix the crankshaft and remove the 6 set bolts.
42. SEPARATE STEERING INTERMEDIATE SHAFT SUB-ASSY [45202 / 98-72]





a. Loosen the sliding yoke bolt.





b. Place matchmarks; on the intermediate shaft and control valve shaft.
c. Remove the bolt, and separate the steering intermediate shaft.





d. To prevent form rotating the steering wheel, fix the wheel with seat belt.

HINT: The operation is useful to prevent the damage of the spiral cable.

43. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH

HINT: Hung up the hoses instead of detaching.

44. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
a. Set the engine lifter.





b. Remove the 6 bolts, frame side rail plate sub-assembly RH and LH.





c. Remove the 6 bolts, front suspension member brace rear RH and LH.
d. Carefully, remove the engine assembly from the vehicle.





e. Install the 2 engine hangers as shown in the illustration.
Parts No.:
No. 1 engine hanger 12281-28010
No. 2 engine hanger 12282-28010
Bolt 91512-61020
Torque: 38 Nm (387 kgf-cm, 28 inch lbs.)
f. Using the chain block and engine sling device, hang the engine assembly.





45. SEPARATE VANE PUMP ASSY [44320 / 98-73]
a. Separate the PS oil pressure switch connector.
b. Remove the 2 bolts and separate the vane pump from the engine.
46. REMOVE STABILIZER BAR FRONT(4WD DRIVE TYPE) [48811 / 98-89]
47. REMOVE RACK & PINION POWER STEERING GEAR ASSY(4WD DRIVE TYPE) [44250 / 98-76]
48. REMOVE FRONT FRAME ASSY [51100G / 98-91]





a. Remove a nut installing the engine mounting insulator LH.





b. Remove a nut installing the engine mounting insulator RH.





c. Remove a nut installing the engine mounting insulator FR.





d. Remove a nut installing the engine mounting insulator RR. (4WD)
e. Raise the engine assembly and separate the front frame.
49. REMOVE FRONT DRIVE SHAFT ASSY RH (4WD DRIVE TYPE) [43410 / 98-68]





50. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (4WD DRIVE TYPE) [12321A / 98-10]
a. Remove the 6 bolts and engine mounting bracket RR.
51. REMOVE TRANSFER ASSY (4WD DRIVE TYPE) [36100 / 98-57]
52. REMOVE FRONT DRIVE SHAFT ASSY LH [43420 / 98-68]
53. REMOVE FRONT DRIVE SHAFT ASSY RH (2WD DRIVE TYPE) [43410 / 98-68]
54. REMOVE STARTER ASSY [28100 / 98-39]
55. REMOVE AUTOMATIC TRANSAXLE ASSY [30500 / 98-45]





56. REMOVE DRIVE PLATE & RING GEAR SUB-ASSY [32101 / 98-46]
a. Fix the crankshaft with SST
SST 09213-54015 (91651-60855), 09330-00021
b. Remove the 8 bolts, rear spacer, drive plate and front spacer.
57. INSTALL ENGINE STAND
58. REMOVE ENGINE COVER SUB-ASSY NO.1 [12601B / 98-5]





59. REMOVE INTAKE MANIFOLD [17111 / 98-26]
a. Remove the 5 bolts, 2 nuts, intake manifold and gasket.
60. REMOVE VENTILATION HOSE [12261 / 98-12]
61. REMOVE VENTILATION HOSE NO.2 [12262 / 98-12]
62. REMOVE ENGINE WIRE [82121 / 98-151]
63. REMOVE INTAKE MANIFOLD INSULATOR NO.1 [17135A / 98-26]
64. REMOVE GENERATOR ASSY [27020 / 98-35]
65. REMOVE OIL LEVEL GAGE SUB-ASSY [15301 / 98-71]
66. REMOVE OIL LEVEL GAGE GUIDE [11452 / 98-71]
67. REMOVE MANIFOLD CONVERTER INSULATOR NO.1 [25586 / 98-26]
68. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSY [25051 / 98-26]





a. Remove the 2 bolts, nuts No. 1 and No. 2 exhaust manifold stay.





b. Remove the 5 nuts, exhaust manifold converter and gasket.
69. REMOVE WATER INLET [16321 / 98-20]
70. REMOVE THERMOSTAT [16331A / 98-20]
71. REMOVE IGNITION COIL ASSY [19500 / 98-34]
72. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY [11101J / 98-5]





73. REMOVE V-RIBBED BELT TENSIONER ASSY [16620 /98-19]
a. Remove the bolt, nut and the drive belt tensioner.
74. REMOVE DRIVE SHAFT BEARING BRACKET(2WD DRIVE TYPE) [43457 / 98-68]
75. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET [12315A / 98-10]
76. REMOVE FUEL DELIVERY PIPE W/ INJECTOR
77. REMOVE WATER BY-PASS PIPE NO.1 [16268 / 98-20]
78. REMOVE OIL COOLER PIPE(W/ OIL COOLER) [15777B / 98-18]
79. REMOVE OIL COOLER HOSE(W/ OIL COOLER) [15777 / 98-18]
80. REMOVE OIL COOLER HOSE(W/ OIL COOLER) [15777C / 98-18]





81. REMOVE ENGINE OIL PRESSURE SWITCH ASSY [8353OF / 98-7]
a. Remove the oil pressure switch.





82. REMOVE KNOCK CONTROL SENSOR [89615B / 98-7]
a. Using SST, remove the knock control sensor.
SST 09816-30010
83. REMOVE ENGINE COOLANT TEMPERATURE SENSOR [89422D / 98-20]
a. Remove the water temperature sensor.
84. REPLACE PARTIAL ENGINE ASSY [11000 / 98-21]
85. INSTALL ENGINE COOLANT TEMPERATURE SENSOR [89422D / 98-20]
a. Install a new gasket to the water temperature sensor.
b. Install the water temperature sensor.
Torque: 20 Nm (208 kgf-cm, 15 ft. lbs.)





86. INSTALL KNOCK CONTROL SENSOR [89615B / 98-7]
a. Using SST, install the knock control sensor.
SST 09816-30010
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
87. INSTALL ENGINE OIL PRESSURE SWITCH ASSY [83530F / 98-7]
a. Clean the threads of the oil pressure switch, apply adhesive there.
Adhesive: Part No. 08833-00080 THREE BOND 1344 or equivalent
b. Install the oil pressure switch.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
88. INSTALL OIL COOLER PIPE(W/ OIL COOLER) [15777B / 98-18]
a. Install a new gasket and the oil cooler pipe with the bolt and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
89. INSTALL WATER BY-PASS PIPE NO.1 [16268 / 98-20]
a. Install a new gasket and the water by-pass pipe No. 1 with the bolt and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
90. INSTALL FUEL DELIVERY PIPE W/ INJECTOR
91. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET [12315A / 98-10]
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)
92. INSTALL DRIVE SHAFT BEARING BRACKET (2WD DRIVE TYPE) [43457 / 98-68]
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)





93. INSTALL V-RIBBED BELT TENSIONER ASSY [16620 / 98-19]
a. Install the drive belt tensioner with the bolt and the nut.
Torque: 60 Nm (607 kgf-cm, 44 ft. lbs.)
94. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY [11101J / 98-5]
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
95. INSTALL IGNITION COIL ASSY [19500 / 98-34]
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
96. INSTALL THERMOSTAT [16331A / 98-20]
97. INSTALL WATER INLET [16321 / 98-20]
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
98. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSY [25051 / 98-26]





a. Install a new gasket and the exhaust manifold converter with the 5 nuts.
Torque: 37 Nm (378 kgf-cm, 27 ft. lbs.)




b. Install the No. 1 and No. 2 exhaust manifold stay with the 2 bolts and 2 nuts.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)
99. INSTALL MANIFOLD CONVERTER INSULATOR NO.1 [25586 / 98-26]
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
100. INSTALL OIL LEVEL GAGE GUIDE [11452 / 98-71]
a. Apply a light coat of engine oil to the O-ring, install it to the guide.
b. Install the oil level gauge and guide with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
101. INSTALL GENERATOR ASSY [27020 / 98-35]





102. INSTALL INTAKE MANIFOLD [17111 / 98-26]
a. Install a new gasket and the intake manifold with the 5 bolts and 2 nuts.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
103. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY [32101 / 98-46]





a. Fix the crankshaft with SST
SST 09213-54015 (91651-60855), 09330-00021
b. Clean the bolt and the bolt hole.
c. Apply Adhesive to 2 to 3 threads of the bolt end.
Adhesive: Part No. 08833-00070, THREE BOND or equivalent.





d. Install and uniformly tighten the 8 bolts, in several passes, in the sequence shown.
Torque: 98 Nm (1000 kgf-cm, 72 ft. lbs.)
104. INSTALL AUTOMATIC TRANSAXLE ASSY [30500 / 98-45]
105. INSTALL STARTER ASSY [28100 / 98-39]
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
106. INSTALL FRONT DRIVE SHAFT ASSY RH (2WD DRIVE TYPE) [43410 / 98-68]
107. INSTALL FRONT DRIVE SHAFT ASSY LH [43420 / 98-68]
108. INSTALL TRANSFER ASSY (4WD DRIVE TYPE) [36100 / 98-57]





109. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (4WD DRIVE TYPE) [12321A / 98-10]
a. Install the mounting bracket with the 6 bolts.
Torque:
Bolt A 34 Nm (347 kgf-cm, 25 ft. lbs.)
Bolt B 64 Nm (653 kgf-cm, 47 ft. lbs.)
110. INSTALL FRONT DRIVE SHAFT ASSY RH (4WD DRIVE TYPE) [43410 / 98-68]
111. INSTALL FRONT FRAME ASSY [51100G / 98-91]





a. Install the engine mounting insulator LH with a nut.
Torque: 95 Nm (969 kgf-cm, 70 ft. lbs.)





b. Install the engine mounting insulator RH with a nut.
Torque: 95 Nm (969 kgf-cm, 70 ft. lbs.)





c. Install the engine mounting insulator FR with a nut.
Torque: 87 Nm (888 kgf-cm, 64 ft. lbs.)





d. Install the engine mounting insulator RR with 2 nuts (4WD DRIVE TYPE).
Torque: 75 Nm (765 kgf-cm, 55 ft. lbs.)
112. INSTALL RACK & PINION POWER STEERING GEAR ASSY (4WD DRIVE TYPE) [44250 / 98-76]
Torque: 70 Nm (714 kgf-cm, 52 ft. lbs.)
113. INSTALL STABILIZER BAR FRONT(4WD DRIVE TYPE) [48811 / 98-89]
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)





114. INSTALL VANE PUMP ASSY [44320 / 98-73]
a. Connect the vane pump to the engine with the 2 bolts.
Torque: 43 Nm (439 kgf-cm, 31 ft. lbs.)
115. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
a. Set the engine assembly with transaxle on the engine lifter.
b. Install the engine assembly to the vehicle.





c. Install the frame side plate LH and RH with 6 bolts.
Torque:
Bolt A 85 Nm (867 kgf-cm, 63 ft. lbs.)
Bolt B 32 Nm (326 kgf-cm, 24 ft. lbs.)





d. Install the front suspension member brace rear RH and LH with 6 bolts.
Torque:
Bolt C 85 Nm (867 kgf-cm, 63 ft. lbs.)
Bolt D 32 Nm (326 kgf-cm, 24 ft. lbs.)
116. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
117. INSTALL STEERING INTERMEDIATE SHAFT SUB-ASSY [45202 / 98-72]





a. Align the matchmarks on the intermediate shaft and control valve shaft.





b. Tighten the bolt.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)





118. INSTALL DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT [32101A / 98-46]
a. Fix the crank shaft, and install the 6 set bolts.
Torque: 41 Nm (418 kgf-cm, 30 ft. lbs.)





119. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH [48069/ 98-88]
a. Install the drive shaft to steering knuckle.
b. Install the suspension lower arm with the bolt and the 2 nuts.
Torque: 127 Nm (1296 kgf-cm, 94 ft. lbs.)
120. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH [48068 / 98-88]

HINT: Perform the same procedure on the opposite side.

121. INSTALL TIE ROD ASSY LH [45470 / 98-76]
a. Connect the tie rod end to the steering knuckle and install a new castle nut.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)

NOTICE: Prevent any lubricant from the thread and the taper portions. After tightening the castle nut, tighten it to the additional direction within 60° to put into a cotter pin.

b. Insert a new cotter pin.
122. INSTALL TIE ROD ASSY RH [45460 / 98-76]

HINT: Perform the same procedure on the opposite side.

123. INSTALL SPEED SENSOR FRONT LH [89543 / 98-170]
Torque: 8.0 Nm (82 kgf-cm, 71 ft. lbs.)
124. INSTALL SPEED SENSOR FRONT RH [89542 / 98-170]
Torque: 8.0 Nm (82 kgf-cm, 71 ft. lbs.)





125. INSTALL FRONT AXLE HUB LH NUT [43502H / 98-71]
a. Using a 30 mm socket wrench, install a new hub nut.
Torque: 294 Nm (3,000 kgf-cm, 217 ft. lbs.)
b. Using a chisel, stake the hub nut.
26. INSTALL FRONT AXLE HUB RH NUT [43501H / 98-71]

HINT: Perform the same procedure on the opposite side.

27. INSTALL FRONT STABILIZER LINK ASSY LH [48810 / 98-89]
a. Install the nut by using a 5 mm socket hexagon wrench to fix the stud bolt.
Torque: 74 Nm (755 kgf-cm, 55 ft. lbs.)
28. INSTALL FRONT STABILIZER LINK ASSY RH [48820B / 98-89]

HINT: Perform the same procedure on the opposite side.





129. INSTALL PROPELLER SHAFT(4WD DRIVE TYPE)
a. Align the matchmarks on both the flanges of the front propeller shaft and intermediate shaft, then install and tighten the 4 bolts, washers and nuts.
Torque: 74 Nm (755 kgf-cm, 55 ft. lbs.)
130. INSTALL EXHAUST PIPE ASSY FRONT [17410 / 98-28]
131. CONNECT FUEL TUBE SUB-ASSY [23901 / 98-40]





132. INSTALL RETURN TUBE SUB-ASSY [44406 / 98-74]
a. Install the return tube with 2 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
133. INSTALL FAN AND GENERATOR V BELT [16361A / 98-25]
SST 09249-63010
134. INSTALL ENGINE MOUNTING BRACKET NO.2 RH [12316 / 98-10]
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)





135. INSTALL ENGINE MOVING CONTROL ROD W/BRACKET
a. Install the engine mounting control rod w/bracket with 3 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
136. INSTALL ENGINE MOUNTING STAY NO.2 RH [12327A / 98-10]
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
137. INSTALL AIR CLEANER ASSY [17700 / 98-30]
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
138. ADD TRANSFER OIL
a. Install a new gasket and the filler plug.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
139. ADD AUTOMATIC TRANSAXLE FLUID
140. ADD ENGINE OIL
141. ADD COOLANT
142. OIL LEAK
143. CHECK ENGINE COOLANT LEAK
144. INSPECT FUEL LEAK
145. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
146. ADJUST FRONT WHEEL ALIGNMENT
147. INSPECT CHECK IDLE SPEED AND IGNITION TIMING
148. INSPECT CO/HC
149. CHECK ABS SPEED SENSOR SIGNAL