FRONT CRANKSHAFT OIL SEAL INSTALLATION

INSTALL FAN AND GENERATOR V BELT

Text in Illustration

*1	Crankshaft Pulley
*2	Water Pump Assembly
*3	Generator Assembly

1. Temporarily install the V-ribbed belt onto each pulley.

   Note

   
   

   • Before installing the V-ribbed belt, check each pulley for any kind of liquid and chips.

   • Check that the ribs of the V-ribbed belt are correctly fitted into the grooves of the pulleys.

2. 

   Text in Illustration

   *1	Bolt B
   *2	Bolt A
   *3	Bolt C

   Turn the bolt B to adjust the tension of the V-ribbed belt.

3. Tighten fixing bolts A and C.

   Torque:

   Bolt A

   54 N*m  { 551 kgf*cm, 40 ft.*lbf }

   Bolt C

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

INSTALL NO. 1 V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT

Text in Illustration

*1	Crankshaft Pulley
*2	Idler Pulley
*3	Cooler Compressor Assembly

1. Temporarily install the V-ribbed belt onto each pulley.

   Note

   
   

   • Before installing the V-ribbed belt, check each pulley for any kind of liquid and chips.

   • Check that the ribs of the V-ribbed belt are correctly fitted into the grooves of the pulleys.

2. 

   Text in Illustration

   *1	Bolt B
   *2	Bolt A

   Turn the bolt B to adjust the tension of the V-ribbed belt.

3. Tighten bolt A.

INSPECT FAN AND GENERATOR V BELT

1. 

   Text in Illustration

   *1	Crankshaft Pulley
   *2	Water Pump Pulley
   *3	Generator Pulley
   	Specified Point

   Check the fan and generator V-ribbed belt deflection (when inspecting a vehicle without the No. 1 engine cover installed).

   Deflection
   Pressing Force N (kg, Ib) New Belt mm (in.) Used Belt mm (in.) 10 (10, 22) 8.0 to 10.5 (0.315 to 0.413) 11.0 to 14.0 (0.433 to 0.551)

   Note

   
   

   • Check the belt deflection between the pulleys at the indicated measurement point (directly between the pulleys).

   • When installing a new belt, set its deflection value as specified.

   • When checking a belt used for over 5 minutes, confirm that the deflection value is within the specified range for a used belt.

   • When reinstalling a belt used for over 5 minutes, check whether its deflection value is within the specified range for a used belt.

2. 

   Text in Illustration

   *1	Crankshaft Pulley
   *2	Water Pump Pulley
   *3	Generator Pulley
   	Specified Point

   Check the fan and generator V-ribbed belt deflection (when inspecting a vehicle while the No. 1 engine cover is installed).

   Deflection
   Pressing Force N (kg, Ib) New Belt mm (in.) Used Belt mm (in.) 10 (10, 22) 4.5 to 6.0 (0.177 to 0.236) 6.5 to 7.5 (0.256 to 0.295)

   Note

   
   

   • Check the belt deflection between the pulleys at the indicated measurement point (on the left side of the generator pulley, 55 mm (2.165 in.) from the center of the pulley).

   • When installing a new belt, set its deflection value as specified.

   • When checking a belt used for over 5 minutes, confirm that the deflection value is within the specified range for a used belt.

   • When reinstalling a belt used for over 5 minutes, check whether its deflection value is within the specified range for a used belt.

INSPECT NO. 1 V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT

1. 

   Text in Illustration

   *1	Crankshaft Pulley
   *2	Idler Pulley
   *3	Cooler Compressor Assembly
   	Specified Point

   Check the No. 1 (cooler compressor to crankshaft pulley) belt.

   Deflection
   Pressing Force N (kg, Ib) New Belt mm (in.) Used Belt mm (in.) 10 (10, 22) 8.0 to 10.0 (0.315 to 0.394) 11.0 to 14.0 (0.433 to 0.551)

   Note

   
   

   • Check the No. 1 (cooler compressor to crankshaft pulley) belt deflection at the specified point.

   • When installing a new belt, set its deflection value as specified.

   • When checking a belt used for over 5 minutes, confirm that the deflection value is within the specified range for a used belt.

   • When reinstalling a belt used for over 5 minutes, check whether its deflection value is within the specified range for a used belt.

ADD ENGINE OIL

1. Add new engine oil and install the oil filler cap.

   Engine Oil

   Oil Grade	Oil Viscosity (SAE)
   API grade SL or SM multigrade engine oil	20W-50 15W-40
   API grade SL "Energy-Conserving" "Energy-Conserving SM or ILSAC multigrade engine oil"	10W-30 5W-30 5W-20 0W-20

   Capacity

   Item	Standard Condition
   Drain and refill with oil filter change	3.1 liters (3.3 US qts, 2.7 Imp. qts)
   Drain and refill without oil filter change	2.9 liters (3.1 US qts, 2.6 Imp. qts)
   Dry fill	3.4 liters (3.6 US qts, 3.0 Imp. qts)

CHARGE REFRIGERANT

Tech Tips

Charge refrigerant in accordance with the equipment manual.

1. Perform vacuum purging using a vacuum pump.

2. Charge refrigerant HFC-134a (R134a).

   SST

   09985-20010   ( 09985-02010, 09985-02050, 09985-02060, 09985-02070, 09985-02080, 09985-02090, 09985-02110, 09985-02130, 09985-02140, 09985-02150 )

   Standard
   330 to 390 g (11.6 to 13.8 oz.)

   Note

   
   

   • Do not start the engine before charging it with refrigerant as the cooler compressor does not work properly without sufficient refrigerant. This could cause the compressor to overheat.

   • Approximately 100 g (3.5 oz.) of refrigerant may need to be charged after bubbles disappear.

     The volume of refrigerant should be measured, not checked with the sight glass.

   Tech Tips

   
   

   • The relationship between the refrigerant charge amount and the pressure is as follows.

     

   • High Charge Range:

     If the refrigerant is overcharged, the pressure rises on the high-pressure side. High-pressure cut off frequently occurs. This causes insufficient cooling performance and also insufficient compressor lubrication.

   • Low Charge Range:

     A shortage of refrigerant causes insufficient cooling performance and low circulation of refrigerant oil, which shortens the compressor life. Operation with insufficient coolant raises the refrigerant temperature and causes heat deterioration of the rubber seals and hoses. Cracking and subsequent refrigerant leakage may occur.

   
   

   1. Install the caps onto the service valves on the refrigerant line.

WARM UP ENGINE

INSPECT REFRIGERANT LEAK

1. After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.

2. Perform the operation as follows:

   
   

   • Stop the engine.

   • Secure good ventilation (the halogen leak detector may react to volatile gases other than refrigerant, such as evaporated gasoline or exhaust gas).

   • Repeat the test 2 or 3 times.

   • Make sure that some refrigerant remains in the refrigeration system.

     When the compressor is off: approximately 392 to 588 kPa (4 to 6 kgf/cm², 57 to 85 psi)

   Tech Tips

   It is impossible for the above pressure to be maintained if there is leakage.

3. Using the halogen leak detector, check the refrigerant line, especially at the connection points, for leakage.

4. 

   Text in illustration

   *1	Drain hose
   *2	Halogen leak detector

   Bring the halogen leak detector close to the drain hose before performing the test.

   Tech Tips

   
   

   • After the blower motor has stopped, leave the cooling unit for at least 15 minutes.

   • Place the halogen leak detector sensor under the drain hose.

   • When bringing the halogen leak detector close to the drain hose, make sure that the halogen leak detector does not react to other volatile gases.

   If such a reaction is unavoidable, the vehicle must be lifted up.

5. If no gas leakage is detected from the drain hose, remove the blower motor from the cooling unit. Insert the halogen leak detector sensor into the unit and perform the test.

6. Disconnect the pressure switch connector and leave it for approximately 20 minutes. Bring the halogen leak detector close to the pressure switch and perform the test.

INSTALL NO. 1 ENGINE COVER

1. Temporarily install the No. 1 engine cover with the 2 bolts and nut.

2. Fully tighten the 2 bolts and nut in the order shown in the illustration.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

INSTALL NO. 1 COOLER COVER

1. Temporarily install the No. 1 cooler cover with the 2 nuts.

2. Fully tighten the 2 nuts in the order shown in the illustration.

   Torque:

   9.8 N*m  { 100 kgf*cm, 87 in.*lbf }