Part 2
REPLACEMENT50. REMOVE GENERATOR BRACKET NO.2
51. REMOVE: GENERATOR BELT ADJUSTING BAR
a. Remove the 2 bolts, 2 nuts and the adjusting bar.
52. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH
a. Remove the bolt, nut and adjusting bar bracket.
b. Remove the 3 bolts and compressor.
HINT: Hang up the hoses instead of detaching.
53. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
a. Set the engine lifter.
b. Remove the 4 bolts and 2 nuts, frame side rail plate subassembly RH and LH.
c. Remove the 4 bolts and 2 nuts, front suspension member brace rear RH and LH.
d. Carefully, remove the engine assembly from the vehicle.
e. Install the No. 2 engine hanger in the correct direction.
Part No.: No. 2 engine hanger 12282-20020
Bolt 91621-60822
Torque: 20 Nm (199 kgf-cm, 14 ft. lbs.)
f. Using the chain block and engine sling device, hang the engine assembly.
54. REMOVE VANE PUMP ASSY
a. Separate the power steering oil pressure sensor harness.
b. Separate the pressure feed tube clamp.
c. Remove the 2 bolts and vane pump assembly.
55. REMOVE FRONT FRAME ASSY
a. Remove the 2 nuts, and separate engine mounting insulator RH and LH.
b. Remove the bolt, and separate engine mounting insulator FR.
56. REMOVE FRONT DRIVE SHAFT ASSY LH
SST 09520-01010, 09520-24010 (09520-32040)
57. REMOVE FRONT DRIVE SHAFT ASSY RH
58. REMOVE ENGINE WIRE
59. REMOVE AUTOMATIC TRANSAXLE ASSY
60. REMOVE DRIVE PLATE & RING GEAR SUB-ASSY
SST 09213-54015 (91651-60855), 09330-00021
61. INSTALL ENGINE STAND
62. REMOVE INTAKE AIR SURGE TANK
63. REMOVE IGNITION COIL ASSY
64. REMOVE INTAKE MANIFOLD
65. REMOVE WATER OUTLET
66. REMOVE EGR PIPE SUB-ASSY NO.2
67. REMOVE EGR PIPE SUB-ASSY NO.1
68. REMOVE EXHAUST MANIFOLD SUB-ASSY RH
69. REMOVE EGR COOLER NO.1
70. REMOVE MANIFOLD STAY NO.2
71. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2
72. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSY NO.2
73. REMOVE DRIVE SHAFT BEARING BRACKET
74. REMOVE PUMP BRACKET
a. Remove the 3 bolts and pump bracket.
75. REMOVE GENERATOR BRACKET No.1
76. REMOVE COMPRESSOR MOUNTING BRACKET No.1
77. REMOVE WATER INLET PIPE
78. REMOVE WATER INLET
79. REMOVE THERMOSTAT
80. REMOVE ENGINE OIL PRESSURE SWITCH ASSY
a. Remove the oil pressure switch.
81. REMOVE KNOCK CONTROL SENSOR
a. Using SST, remove the 2 knock control sensors.
SST 09816-30010
82. REPLACE PARTIAL ENGINE ASSY
83. INSTALL KNOCK CONTROL SENSOR
a. Using SST, install the 2 knock control sensors.
SST 09816-30010
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
84. INSTALL ENGINE OIL PRESSURE SWITCH ASSY
a. Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive: Part No. 08833-00080 THREE BOND 1344, LOCTITE 242 or equivalent.
b. Install the oil pressure switch.
Torque: 15 Nm (152 kgf-cm, 11 ft. lbs.)
85. INSTALL THERMOSTAT
86. INSTALL WATER INLET
87. INSTALL WATER INLET PIPE
88. INSTALL COMPRESSOR MOUNTING BRACKET No.1
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
89. INSTALL GENERATOR BRACKET NO.1
Torque: 58 Nm (591 kgf-cm, 43 ft. lbs.)
90. INSTALL PUMP BRACKET
Torque: 32 Nm (326 kgf-cm, 24 ft. lbs.)
91. INSTALL DRIVE SHAFT BEARING BRACKET
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
92. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSY NO.2
a. Install a new gasket and the exhaust manifold LH.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
93. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2
Torque: 8.5 Nm (87 kgf-cm, 55 inch lbs.)
94. INSTALL MANIFOLD STAY NO.2
Torque: 34 Nm (347 kgf-cm, 25 ft. lbs.)
95. INSTALL EGR COOLER NO.1
a. Install a new gasket and the EGR cooler No. 1.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
96. INSTALL EXHAUST MANIFOLD SUB-ASSY RH
a. Install a. new gasket and the exhaust manifold RH. Uniformly tighten the nuts in several passes, in the sequence shown.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
97. INSTALL EGR PIPE SUB-ASSY NO.1
a. Install 2 new gaskets and the EGR pipe.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
98. INSTALL EGR PIPE SUB-ASSY NO.2
a. Install 2 new gaskets and the EGR pipe.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
99. INSTALL WATER OUTLET