Remove the cargo box half from the vehicle. Lift up on the shaft and remove it through the floor panel. The sensor can be accessed with the air box assembly removed. Remove the spark plug wires to gain access to valve cover as shown below. The bezel is a snap-on assembly and is a serviceable part.
Disconnect cooling fan electrical connector. Reinstall center console, shift knob and screws. Bend both ends of cotter pin around end of spindle in different directions. The rollers should spin freely. Inspect the condition of the stator windings output wires.
Slide engagement dog X off of shift fork guides. Install the fuel tank vent line onto the tank fitting. Press the old bushing out of the planet gear. Install a new water pump cover gasket 13. Drive Clutch Cover Bolts: 9 ft-lb 12 Nm 5.
Remove recovery bottle cap and add coolant using a funnel. Apply Loctite® 648 evenly to bushing bore in the cover. Ensure bearing is fully seated upon assembly. Brake Disc Mounting Bolts 30 ft-lb 41 Nm 9. Tighten all bolts lightly by hand.
Remove nut from puller rod and set aside. If electrical tests are within specification, remove gearcase see Chapter 7 — Front Gearcase Removal, page 7. Start engine and check for any oil or coolant leaks. Tie Rod Jamb Nut: 14 ft-lbs 19 Nm 2. Move the prop shaft support bearing assembly to the drivers side to slide the rear prop shaft yoke off the transmission output shaft. The delay time ensures the oxygen sensor heater has run long enough to provide accurate data.
Press out the spring pins in the inner sheave. Manually cycle the throttle pedal to verify the throttle pedal moves freely. Visually inspect cylinder head gasket surface and combustion chamber for cracks or damage. Do not Hitch Tongue Capacity modify the vehicle by adding a hitch. Pay close attention to areas around spark plug and valve seats.
Install new bolts and finger tighten the six cylinder head bolts evenly. Check level after filling and add oil as needed. Bolt Washers Oil Seal Loctite 204 Drive Tab Impeller Mechanical Seal Water Pump Shaft Washer O-Rings Water Pump Housing 3. Remove both A-arm to frame mounting bolts and remove the A-arm from the chassis. Crankcase Drain Plug: 12 ft-lbs 16 Nm 3. Press the old bushing out of the planet gear. Carefully lift the crankshaft out of the crankcase.
Install a new circlip on the end of the shaft. Change oil and oil filter after 25 hour break-in period. Install the vent line Cover Plate Screws: 11 ft-lbs 15 Nm 7. Apply cutting oil to valve seat and cutter. Install the eleven M6 and two M8 upper crankcase bolts. Charge the battery as recommended see Chapter 11 — Charging Procedure , page 11. Torque valve cover bolts to specification.