Removal and Installation
REMOVAL1. DRAIN ENGINE COOLANT
2. REMOVE V-BANK COVER
3. REMOVE INTAKE AIR CONNECTOR PIPE
4. DISCONNECT THROTTLE BODY FROM INTAKE MANIFOLDS
a. Disconnect the accelerator cable from the throttle body.
b. Remove the 2 bolts and 2 nuts, and disconnect the throttle body from the intake manifolds.
c. Remove the gasket.
5. REMOVE UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
6. REMOVE WATER BYPASS PIPE
7. REMOVE REAR WATER BYPASS JOINT
8. REMOVE STARTER
a. Disconnect the starter connector.
b. Remove the nut, and disconnect the starter cable.
c. Remove the bolt, and disconnect the engine wire protector.
d. Remove the 2 bolts and starter.
INSTALLATION
1. INSTALL STARTER
a. Install the starter with the 2 bolts.
Torque: 37 Nm (380 kg.cm, 27 ft.lb)
b. Connect the starter cable with the nut.
Torque: 9.8 Nm (100 kg.cm, 87 in.lb)
c. Install the engine wire protector to the starter with the bolt.
d. Connect the starter connector.
2. INSTALL REAR WATER BYPASS JOINT
3. INSTALL WATER BYPASS PIPE
4. INSTALL UPPER AND LOWER INTAKE MANIFOLDS ASSEMBLY
5. INSTALL THROTTLE BODY
a. Install a new gasket and the throttle body with the 2 bolts and 2 nuts.
Torque: 18 Nm (185 kg.cm, 13 ft.lb)
b. Connect the accelerator cable to the throttle body.
6. INSTALL INTAKE AIR CONNECTOR PIPE
7. FILL WITH ENGINE COOLANT
8. CHECK THAT ENGINE STARTS
9. START ENGINE AND CHECK FOR ENGINE COOLANT AND FUEL
10. INSTALL V-BANK COVER
REPLACEMENT
1. REPLACE FRONT BEARING
a. Using SST; remove the bearing.
SST 0928-6011
b. Using SST and a press, press in a new bearing.
SST 0982-00030
NOTE: Be careful of the installation direction.
2. REPLACE REAR BEARING
a. Using SST; remove the bearing.
SST 09286-46011
b. Using a press, press in a new bearing.
3. REPLACE MAGNETIC SWITCH TERMINAL KIT PARTS
a. Remove the 3 bolts, lead clamp, end cover, gasket and plunger.
b. Using vernier calipers, measure the contact plate for depth of wear.
Maximum wear: 0.9 mm (0.035 in.)
If the depth of wear is greater than the maximum, replace the contact plate.
c. Remove the terminal kit parts.
1. Using SST, loosen the terminal nuts.
SST 0981-38140
2. Terminal C:
Remove the terminal nut, wave washer, terminal insulator (outside), 0-ring, terminal bolt, contact plate and terminal insulator (inside).
3. Terminal 30:
Remove the terminal nut, wave washer, terminal insulator (outside), packing, O-ring, terminal bolt, contact plate and terminal insulator (inside).
d. Temporarily install these new terminal 30 kit parts:
1. Terminal insulator (inside)
2. Contact plate
3. Terminal bolt
4. O-ring
5. Packing and terminal insulator (outside) Install the packing to the terminal insulator, and install them.
HINT: Match the protrusion of the insulator with the indentation of the housing.
6. Wave washer
7. Terminal nit
NOTE: Be careful to install the terminal insulator (inside) and wave washer in the correct direction.
e. Temporarily install these new terminal C kit parts:
1. Terminal insulator (inside)
2. Contact plate
3. Terminal bolt
4. 0-ring
5. Terminal insulator (outside)
6. Wave washer
7. Terminal nut
NOTE: Be careful to install the terminal insulator (inside) and wave washer in the correct direction.
f. Temporarily tighten the terminal nuts.
g. Tighten terminal nuts.
1. Put a wooden block on the contact plate and press it down with a hand press.
Dimensions of wooden block: 20 x 37 x 40 mm (0.79 x 1.46 x 1.57 in.)
Press force: 981 N (100 kg, 221 lb)
NOTE:
- Check the diameter of the hand press ram. Then calculate the gauge pressure of the press when 981 N (100 kg, 221 lb) of force is applied.
Gauge pressure:
- If the contact plate is not pressed down with the specified pressure, the contact plate may tilt due to coil deformation or the tightening of the nut.
2. Using SST, tighten the nuts to the specified torque.
SST 0981-38140
Torque: 17 Nm (173 kg.cm, 13 ft.lb)
NOTE: It the nut is over tightened, it may cause cracks on the inside of the insulator.
h. Clean the contact surfaces of the remaining contact plate and plunger with a dry shop rag.
i. Reinstall the plunger, a new gasket, the end cover and lead clamp with the 3 bolts.
Torque: 3.6 Nm (37 kg.cm, 32 in.lb)