Service Manual
Contents
1. Disconnect the connectors and the wiring of each sensor and the earth wires NOTE e Disconnect the body earth of the battery from the body side 28 Remove the steering intermediate shaft Ay CAUTION e Put matchmark on each shaft and remove the shafts Refer to Page G1 2 29 Remove the suspension LWR arms S A W bush RH LH Refer to Page C1 5 30 Remove the ball joint section of the tie rod end S A Refer to Page D2 2 31 Remove the FR stabilizer bar Refer to Page C1 9 32 Remove the front exhaust pipe Ay Refer to Page B4 3 33 Remove the propeller FR shaft Ay CAUTION e Put matchmark on the universal joint yoke and the differential flange and remove them Refer to TERIOS SERVICE MANUAL 34 Disconnect the automatic transmission control cable Ay A T vehicles Refer to TERIOS SERVICE MANUAL 35 Disconnect the manual transmission control cable Ay M T vehicles Refer to TERIOS SERVICE MANUAL 36 Remove the clutch release cylinder Ay M T vehicles Refer to TERIOS SERVICE MANUAL 37 Set the engine Ay W transmission to the engine lifter NOTE e Set the engine Ay W transmission to the engine lifter with the FR suspension member Ay and the RR engine support member Ay still attached e Use wooden blocks etc to support the engine Ay W transmission Ay in a well balanced way 38 Disconnect the fuel hose from the fuel delivery pipe Ay Refer to TERIOS SERVICE MANUAL B2 4 1 1 3 REMOVAL AND INSTALLATION P2. oil cooler hose A T vehicles Refer to TERIOS SERVICE MANUAL 13 Remove the V ribbed belt Refer to TERIOS SERVICE MANUAL 14 Remove the compressor Ay W magnet clutch Refer to Page K1 11 NOTE e Without disconnecting the pipe suspend it from the body side using a cord etc 15 Disconnect the vacuum hose Ay from the brake booster Ay Refer to TERIOS SERVICE MANUAL U A q P21E5559T10 16 Remove the charcoal canister Ay Refer to Page B9 1 17 Remove the air cleaner case S A Refer to TERIOS SERVICE MANUAL 18 Disconnect the accelerator control cable Ay from the throttle body Ay Refer to Page B3 1 19 Remove the glove compartment door Ay Refer to TERIOS SERVICE MANUAL 20 Remove the front door scuff plate RH and the front door scuff plate LH Refer to TERIOS SERVICE MANUAL 21 Remove the cowl side trim board RH and the cowl side trim board LH Refer to TERIOS SERVICE MANUAL 22 Remove the No 1 instrument panel under cover Refer to Page 12 4 23 Remove the No 2 instrument panel under cover Refer to Page 12 4 24 Disconnect the engine wire from the transmission con trol computer Ay A T vehicles Refer to TERIOS SERVICE MANUAL 25 Disconnect the engine wire from the fuel injection com puter Ay and pull out the wire on the engine compart ment side Refer to TERIOS SERVICE MANUAL 26 Disconnect the wire harness from the relay block lo cated in the engine compartment B2 3 27
3. steering vane pump Ay still attached 2 Install the transmission Ay M T vehicles Refer to Page F2 1 A T vehicles Refer to TERIOS SERVICE MANUAL 3 Support the engine Ay W transmission and the FR suspension member using the chain block B2 8 4 Set the engine lifter in the position indicated in the illus tration NOTE e Set the engine Ay W transmission to the engine lifter with the FR suspension member Ay and the RR en gine support member Ay still attached e Use wooden blocks etc to support the engine Ay W transmission Ay in a well balanced way CAUTION e Do not place wooden blocks against the crankshaft pulley Ay 1 1 6 OPERATION AFTER INSTALLATION 1 Operate the engine lifter and mount the engine Ay into the vehicle with the transmission Ay still at tached CAUTION e Perform the installation making sure that no parts are coming into contact with other parts e Perform the installation in such a way that it does not come into contact with the LWR suspension arm S A or components within the engine compartment P22E5504T10 NOTE In cases where an engine lifter is not used move the side of the vehicle Two post lift etc up and down during the operation 2 Install the FR suspension member and tighten the bolts to the specified torque Refer to Page C1 12 3 Install the rear engine support member Ay and tighten the bolts to the specified torque Refer to Page B12 6 4 Connect the fuel ho
4. still attached CAUTION e Perform the removal making sure that no connectors or hoses are still connected or coming into contact with other parts e Perform the removal in such a way that the part does not come into contact with the components within the engine compartment NOTE e In cases where an engine lifter is not used move the side of the vehicle Two post lift etc up and down during the operation Remove the transmission Ay M T vehicles Refer to Page F2 1 A T vehicles Refer to TERIOS SERVICE MANUAL Install the support tools engine hangers etc in the po sitions indicated in the figure on the right Support the engine Ay using the chain block Remove the engine mounting FR RH insulator and the engine mounting bracket FR RH Refer to Page B12 1 Remove the engine mounting FR LH insulator and the engine mounting bracket FR No 2 Refer to Page B12 4 f Gear S A drive plate and ring g Bracket engine mounting FR RH h Bracket engine mounting FR No 2 i Engine Ay P22E5504T10 P22E5505T10 P22C5806T10 B2 6 9 Suspend the engine Ay using the chain block CAUTION e Make sure that the engine Ay is supported in a well balanced way during the removal 10 Remove the guide S A oil level gauge and the engine mounting bracket FR RH 11 Remove the engine mounting bracket FR RH 12 Remove the engine mounting bracket FR No 2 1 1 5 POINTS OF INSTALL
5. ATION 1 Bracket engine mounting FR RH 1 Temporarily tighten the bolt 2 lighten the bolts securely in the sequence Q TIGHTENING TORQUE 37 0 11 1N m 877 113kgf cm P22E5506T 10 3 Tighten the bolt indicated in the illustration and install the guide S A oil level gauge I P22E5530T10 2 Bracket engine mounting FR No 2 1 Temporarily tighten the bolt 2 lighten the bolts securely in the sequence Q O TIGHTENING TORQUE 18 0 5 4N m 183 55kgf cm P22E5507T 10 B2 7 3 Gear flywheel ring M T vehicles 1 Clean off any adhesive adhered to the female threaded section of the crankshaft or the installation surface of the flywheel ring gear 2 Apply the looseness prevent agent on the threaded area ADHESIVE Three Bond1324 3 Temporarily tighten the bolts 4 Tighten the bolts in the sequence shown in the figure TIGHTENING TORQUE 78 4 7N m 795 48kgf cm P21E5599ET16 4 Gear S A drive plate amp ring A T vehicles Refer to TERIOS SERVICE MANUAL 5 Engine Ay Automatic transaxle Ay RR engine support member Ay FR suspension member Ay 1 Slowly lower the engine Ay using the chain block and then attach the insulators and the engine brackets CAUTION e Make sure that the engine Ay is supported in a well balanced way during the removal NOTE e Install the FR suspension member Ay with the steering gear box and the power
6. ENGINE ASSY B2 ENGINE MECHANICAL REMOVAL AND INSTALLATION RHD PWD VEHICLES perreo ces B2 1 B2 1 E 3SZ 1 ENGINE ASSY 1 1 REMOVAL AND INSTALLATION RHD 2WD VEHICLES WARNING e No fire should be brought near when servicing the fuel system e When removing the fuel hose prevent the fuel from splashing e When the coolant is hot do not remove the radiator cap drain plug or water hose e When the oil is hot do not remove the drain plug or oil cooler hose 1 1 1 ARTICLES TO BE PREPARED Lubricant adhesive others Engine hanger attaching bolt Replacement parts Wooden block Three Bond1324 1 1 2 OPERATION BEFORE REMOVAL 1 Release the fuel pressure Refer to TERIOS SERVICE MANUAL 2 Remove the battery and the battery carrier Refer to TERIOS SERVICE MANUAL 3 Ensure that the disc wheels FR are in a position where the vehicle will move straight ahead 4 Remove the disc wheel FR Refer to TERIOS SERVICE MANUAL 5 Remove the engine under cover Refer to Page 12 1 6 Drain the engine oll Refer to TERIOS SERVICE MANUAL 7 Drain the ATF A T vehicles Refer to TERIOS SERVICE MANUAL 8 Drain the transmission oil M T vehicles Refer to TERIOS SERVICE MANUAL 9 Drain the coolant Refer to TERIOS SERVICE MANUAL 10 Disconnect radiator hose No 1 and radiator hose No 2 from the radiator Refer to TERIOS SERVICE MANUAL 11 Disconnect water hose No 1 and water hose No 2 from the heater radiator Ay 12 Remove the
7. ROCEDURES 1 Components T 37 0 11 1 377113 T 48 1 13 7 490 139 N 7 Q 7 Zz T 18 0 5 4 183455 lt Z ra Q c T 8 8 0 9 190 9 BD T 27 5 4 9 280349 T 110 0422 0 1122 224 T 37 0 11 1 377113 S T 58 8 9 8 600 99 T 36 8 7 3 375 74 T 36 8 7 3 1375 74 T 39 0 7 8 398 79 X Non reusable parts gt gt Equivalent to Three Bond1324 Unit N mikgf cm Ilust Vehicles with Automatic transaxle Ay P22E5503ES40 B2 9 2 Removal and installation procedures qdd44 gt gt p gt gt 1 a Starter Ay 2 b Member Ay engine support rear 3 c Member Ay FR suspension A 5 AG E pp gt gt om NO d Transaxle Ay automatic 9 e Converter Ay torque 1 1 4 POINTS OF REMOVAL 1 Engine Ay Automatic transaxle Ay RR engine sup nwo 4 port member Ay FR suspension member Ay Set the engine lifter at the position shown in the figure Use wooden blocks etc to support the engine Ay W transmission Ay in a well balanced way NOTE e Put a wooden piece etc on the installation position of the compressor Ay W magnet clutch on the left side of the engine block Ay CAUTION e Do not apply wooden blocks to the crankshaft pulley Operate the engine lifter and remove the engine Ay with the transmission Ay and the member
8. RVICE MANUAL 39 Install the battery and the battery carrier Refer to TERIOS SERVICE MANUAL 40 Check for any leakage of oil coolant water and fuel Perform the engine tune up Refer to TERIOS SERVICE MANUAL 41 Install the engine under cover Refer to Page 12 1
9. se to the fuel delivery pipe Ay Refer to TERIOS SERVICE MANUAL 5 Install the automatic transmission control cable Ay A T vehicles Refer to TERIOS SERVICE MANUAL 6 Install the manual transmission control cable Ay M T vehicles Refer to TERIOS SERVICE MANUAL 7 Install the clutch release cylinder Ay M T vehicles Refer to TERIOS SERVICE MANUAL 8 Install the propeller FR shaft Ay Refer to TERIOS SERVICE MANUAL CAUTION e Align the matchmark of the universal joint yoke and the differential flange and attach them B2 9 9 Install the FR exhaust pipe Ay Refer to Page B4 3 10 Install the FR stabilizer bar Refer to Page C1 9 11 Install the ball joint section of the tie rod end S A Refer to Page D2 2 12 Install the suspension lower arms S A W bush RH LH Refer to Page C1 5 13 Install the steering intermediate shaft Ay Refer to Page G1 2 CAUTION e Align the matchmark of each shaft and attach the shafts 14 Remove the support tools Engine hangers etc 15 Connect the connectors and the wiring of each sensor and the earth wires 16 Install the wire harness to the relay block located in the engine compartment 17 Connect the engine wire to the fuel injection computer Ay Refer to TERIOS SERVICE MANUAL Wl CC ee P22C5806T 10 18 Connect the engine wire to the transmission control computer Ay A T vehicles Refer to TERIOS SERVICE MANUAL 19 Install the No 1 instrumen
10. t panel under cover Refer to Page 12 4 20 Install the No 2 instrument panel under cover Refer to Page 12 4 21 Install the cowl side trim board RH and the cowl side trim board LH Refer to TERIOS SERVICE MANUAL 22 Install the front door scuff plate RH and the front door scuff plate LH Refer to TERIOS SERVICE MANUAL 23 Install the glove compartment door Ay Refer to TERIOS SERVICE MANUAL 24 Connect the accelerator control cable Ay Refer to Page B3 1 B2 10 25 Install the air cleaner case S A Refer to TERIOS SERVICE MANUAL 26 Install the charcoal canister Ay Refer to Page B9 1 27 Install the vacuum hose Ay Refer to TERIOS SERVICE MANUAL 28 Install the compressor Ay W magnet clutch Refer to Page K1 11 29 Install the oil cooler hose A T vehicles Refer to TERIOS SERVICE MANUAL 30 Install the radiator hose No 1 and the radiator hose No 2 Refer to TERIOS SERVICE MANUAL 31 Install the water hose No 1 and the water hose No 2 32 Connect the fuel hose Refer to TERIOS SERVICE MANUAL 33 Install the V ribbed belt and adjust the tension Refer to TERIOS SERVICE MANUAL 34 Replenish the transmission oil M T vehicles Refer to TERIOS SERVICE MANUAL 35 Replenish the ATF A T vehicles Refer to TERIOS SERVICE MANUAL 36 Replenish the engine oil Refer to TERIOS SERVICE MANUAL 37 Fill the coolant Refer to TERIOS SERVICE MANUAL 38 Install the disc wheel FR Refer to TERIOS SE
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