Special Tool(s)
Illustration Name Number TKITNumber Dial Indicator Gauge With Holding Fixture 100-002 (TOOL-4201-C) - Timing Peg, Crankshaft TDC 303-507 TKIT-2001N-FLM
Scheme 675
Scheme 676
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Scheme 680
- Install the 303-507 and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the 303-507 . The engine is now at TDC .
- Mark the balancer unit and shafts on the top for reference that the balancer unit is at TDC .
- NOTE: Due to the precision interior construction of the balancer unit, it should not be disassembled. Remove the 4 bolts and the balancer unit.
- Remove the adjustment shims from the seat faces of the balancer unit.
- NOTE: Visually inspect the balancer unit gear for damage and verify that the shaft turns smoothly. If there is any damage or malfunction, replace the balancer unit. Install the master adjustment shims (No. 50) on the seat faces of the balancer unit.
- With the balancer unit shaft marks at the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.
- Install the balancer unit bolts. Tighten in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 25 Nm (18 lb-ft). Stage 2: Tighten to 42 Nm (31 lb-ft).
- Remove the 303-507 . Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and the crankshaft gear.
- Install the 303-507 and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the 303-507 . Remove the 303-507 .
- NOTE: Measure the backlash and verify that it is within specified range at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. It will be necessary to reset the measuring equipment between measurements. NOTE: The measurement must be taken with the 100-002 (TOOL-4201-C), a 5-mm Allen wrench and worm clamp set up as shown in illustration. Mark the Allen wrench with a file 80 mm (3.149 in) above the driven gear shaft center. Make sure the worm clamp and Allen wrench are not touching the balance shaft housing. NOTE: For an accurate measurement while measuring the gear backlash, insert a screwdriver as shown in illustration into the crankshaft No. 1 crankweight area and set both the rotation and the thrust direction with the screwdriver, using a prying action as shown in illustration. Position the 100-002 (TOOL-4201-C) as shown in illustration. Measure the gear backlash. Position the 100-002 (TOOL-4201-C) (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balancer unit. Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees.
- NOTE: If maximum backlash exceeds 0.101 mm (0.003 in), install a new balancer unit. Using the backlash measurement, select the proper shims from the Adjustment Shim Selection Table. Remove the balancer unit from the cylinder block. Install the selected adjustment shims on the seat faces of the balancer unit.
- Install the 303-507 and rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the 303-507 . The engine is now at TDC .
- With the balancer unit shaft marks in the TDC position, slowly install the balancer unit to the cylinder block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.
- Install the balancer unit bolts. Tighten in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 25 Nm (18 lb-ft). Stage 2: Tighten to 42 Nm (31 lb-ft).
- NOTE: Remeasure the backlash and verify that it is within specified range at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. It will be necessary to reset the measuring equipment between measurements. NOTE: The measurement must be taken with the 100-002 (TOOL-4201-C), a 5-mm Allen wrench and worm clamp set up as shown in illustration. Mark the Allen wrench with a file 80 mm (3.149 in) above the driven gear shaft center. Make sure the worm clamp and Allen wrench are not touching the balance shaft housing. NOTE: For an accurate measurement while measuring the gear backlash, insert a screwdriver as shown in illustration into the crankshaft No. 1 crankweight area and set both the rotation and the thrust direction with the screwdriver, using a prying action as shown in illustration. Position the 100-002 (TOOL-4201-C) as shown in illustration. Measure the gear backlash. Position the 100-002 (TOOL-4201-C) (1) on the Allen wrench 80 mm (3.149 in) above the driven gear shaft center (2) on the balancer unit. Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees. If the backlash exceeds the specified range of 0.005 to 0.101 mm (0.00019 to 0.0039 in), install a new balancer unit and repeat the procedure.
Scheme 681
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Scheme 688
- With vehicle in NEUTRAL, position it on a hoist. REFER to «JACKING AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
- Loosen the 4 retainers and remove the underbody shield.
- Disconnect the battery ground cable. REFER to «BATTERY DISCONNECT»(ref-517589-S39248827582012121200000) .
- Disconnect the EVAP tube from the CAC outlet tube. REFER to «QUICK CONNECT COUPLING»(ref-517564-S07557795332012121200000) . Loosen the clamp and disconnect the CAC outlet tube from the TB.
- Disconnect the FRP sensor and MAP sensor electrical connectors. Detach the 2 EVAP tube retainers from the intake manifold. Detach the heater hose from the retaining clip.
- Disconnect the EVAP tube from the EVAP canister purge valve and the ACL outlet pipe. REFER to «QUICK CONNECT COUPLING»(ref-517564-S07557795332012121200000) . Disconnect the EVAP canister purge valve electrical connector. Remove the engine appearance cover mounting stud. Remove the EVAP canister purge valve and EVAP tube assembly.
- Detach the 2 fuel tube retaining clips from the intake manifold.
- Disconnect the 2 vacuum hoses from the intake manifold. Disconnect the vacuum tube quick connect coupling. REFER to «QUICK CONNECT COUPLING»(ref-517564-S07557795332012121200000) . Detach the vacuum hose retainer from the intake manifold.
- Depress the red quick connect locking ring and pull the vacuum tube out of the quick connect fitting. Remove the 5 intake manifold bolts and position the intake manifold forward.
- Disconnect the TB electrical connector and detach the wiring harness retainer from the TB . Detach the 2 KS wiring harness retainers from the intake manifold. Disconnect the crankcase ventilation oil separator tube and remove the intake manifold.
Illustration Name Number TKITNumber Adapter For 303-224 (Handle) 205-153 (T80T-4000-W) - Installer, VCT Spark Plug Tube Seal 303-1247/2 - Remover, VCT Spark Plug Tube Seal 303-1247/1
Scheme 689
Scheme 690
Illustration Name Number TKITNumber Tool, Camshaft Alignment 303-1565 2009A-FLM Crank Sensor Alignment Tool 303-1521 2009A-FLM Timing Peg, Crankshaft TDC 303-507 TKIT-2001N-FLM Strap Wrench 303-D055 (D85L-6000-A)
Scheme 691
Scheme 692
Illustration Name Number TKITNumber Installer, Camshaft Front Oil Seal 303-096 (T74P-6150-A) TKIT-2009TC-F Remover, Oil Seal 303-409 (T92C-6700-CH) TKIT-1992-FH/FMH/FLMH TKIT-1993-LMH/MH
Illustration Name Number TKITNumber Tool, Camshaft Alignment 303-1565 2009A-FLM
Illustration Name Number TKITNumber Tool, Camshaft Alignment 303-1565 2009A-FLM
Illustration Name Number TKITNumber Compressor, Valve Spring 303-300 (T87C-6565-A) TKIT-2009TC-F Compressor, Valve Spring 303-350 (T89P-6565-A) TKIT-1989-F TKIT-1989-FLM TKIT-1989-FM TKIT-1990-LMH TKIT-2009TC-F Compressor, Valve Spring 303-472 (T94P-6565-AH) TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 Valve Spring Compressor 303-1249 TKIT-2006UF-FLM
Scheme 693
Illustration Name Number TKITNumber Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH) TKIT-2009TC-F Remover, Valve Stem Oil Seal 303-468 (T94P-6510-AH) TKIT-1994-FH/FMH/FLMH TKIT-1994-LMH/MH2 Slide Hammer 307-005 (T59L-100-B)
Scheme 694
Illustration Name Number TKITNumber Support Bar, Engine 303-F072
Scheme 695
Illustration Name Number TKITNumber Holding Tool, Flywheel 303-103 (T74P-6375-A) TKIT-2009TC-F
Scheme 696
- With the vehicle in NEUTRAL, position it on a hoist. REFER to «JACKING AND LIFTING»(ref-517532-S17733021342012121200000) for lifting points.
- Remove the transaxle. REFER to the apprpriate Transmission.
- NOTE: Do not reuse the flexplate bolts. Install 303-103 (T74P-6375-A) and remove the 6 bolts and the flexplate. Discard the bolts.
Scheme 697
- NOTE: Special bolts are used for installation. Do not use standard bolts. Install the flexplate, the 6 new bolts and the Flywheel Holding Tool. Tighten in the sequence shown in illustration in 3 stages: Stage 1: Tighten to 50 Nm (37 lb-ft). Stage 2: Tighten to 80 Nm (59 lb-ft). Stage 3: Tighten to 120 Nm (89 lb-ft).
- Install the transaxle. REFER to the appropriate Transmission.
- After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.
Illustration Name Number TKITNumber Installer, Crankshaft Rear Main Oil Seal 303-328 (T88P-6701-B1) TKIT-1988-F TKIT-1988-FLM TKIT-1988-LM TKIT-2009TC-F
Illustration Name Number TKITNumber 2, 200# FLOOR CRANE, FOLD AWAY 300-OTC1819E - ADJUSTABLE GRIP 1735A 014-00001 - Disconnect Tool TOC Line (1/2") 307-569 TKIT-2006U-F/FM TKIT-2006U-FLM/LM Protector, Differential Oil Seal (pair) 205-461 TKIT-2000AP-FLM/LM TKIT-2002-F/FM Remover, Halfshaft 205-832 TKIT-2006C-FFMFLM TKIT-2006C-LM POWER TRAIN LIFT 300-OTC1585AE - Retainer, Torque Converter 307-566 TKIT-2006C-FFMFLM TKIT-2006C-LM Slide Hammer 100-001 (T50T-100-A) - Spreader Bar 303-D089 (D93P-6001-A3)
