Part 2
REPLACEMENT70. REMOVE THERMOSTAT
71. REMOVE IGNITION COIL ASSEMBLY
72. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
a. Remove the bolt, nut and the drive belt tensioner.
73. REMOVE DRIVE SHAFT BEARING BRACKET
74. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
75. REMOVE FUEL DELIVERY PIPE W/ INJECTOR
76. REMOVE WATER BY-PASS PIPE NO. 1
77. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
a. Remove the oil pressure switch.
78. REMOVE KNOCK CONTROL SENSOR
a. Using SST, remove the knock control sensor.
SST 09816-30010
79. REMOVE E.F.I. ENGINE COOLANT TEMPERATURE SENSOR
a. Remove the water temperature sensor.
80. REPLACE PARTIAL ENGINE ASSEMBLY
81. INSTALL E.F.I. ENGINE COOLANT TEMPERATURE SENSOR
a. Install a new gasket to the water temperature sensor.
b. Install the water temperature sensor.
Torque: 20 Nm (208 kgf-cm, 15 ft. lbs.)
82. INSTALL KNOCK CONTROL SENSOR
a. Using SST, install the knock control sensor.
SST 09816-30010
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
83. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
a. Clean the threads of the oil pressure switch, apply adhesive there.
Adhesive: Part No. 08833-00080 THREE BOND 1344 or equivalent
b. Install the oil pressure switch.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
84. INSTALL WATER BY-PASS PIPE NO. 1
a. Install a new gasket and the water by-pass pipe No. 1 with the bolt and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
85. INSTALL FUEL DELIVERY PIPE W/ INJECTOR
86. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)
87. DRIVE SHAFT BEARING BRACKET
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
88. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
a. Install the drive belt tensioner with the bolt and the nut.
Torque: 59.5 Nm (607 kgf-cm, 44 ft. lbs.)
89. INSTALL IGNITION COIL ASSEMBLY
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
90. INSTALL THERMOSTAT
91. INSTALL WATER INLET
Torque: 9.0 Nm (92kgf-cm, 80 inch lbs.)
92. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
a. Install a new gasket and the exhaust manifold converter with the 5 nuts.
Torque: 37 Nm (378 kgf-cm, 27 ft. lbs.)
b. Install the No. 1 and No. 2 exhaust manifold stay with the 3 bolts and 2 nuts.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)
93. INSTALL MANIFOLD CONVERTER INSULATOR NO. 1
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
94. INSTALL OIL LEVEL GAGE GUIDE
a. Apply a light coat of engine oil to the O-ring, install it to the guide.
b. Install the oil level gage and guide with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
95. INSTALL INTAKE MANIFOLD
a. Install a new gasket and the intake manifold with the 5 bolts and 2 nuts.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
96. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY (A/T TRANSAXLE)
a. Fix the crankshaft with SST (TMC made).
SST 09213-54015 (91651-60855), 09330-00021
b. Fix the crankshaft with SST (TMMK made).
SST 09960-10010 (09962-01000, 09963-01000)
c. Clean the bolt and the bolt hole.
d. Apply Adhesive to 2 or 3 threads of the bolt end.
Adhesive: 4, Part No. 08833-00070, THREE BOND or equivalent.
e. Install and uniformly tighten the 8 bolts, in several passes, in the sequence shown.
Torque: 98 Nm (1,000 kgf-cm, 72 ft. lbs.)
97. INSTALL FLYWHEEL SUB-ASSEMBLY (M/T TRANSAXLE)
a. Fix the crankshaft with SST.
SST 09213-54015 (91651-60855), 09330-00021
b. Clean the bolt and the bolt hole.
c. Apply Adhesive to 2 or 3 threads of the bolt end.
Adhesive: Part No. 08833-00070, THREE BOND or equivalent.
d. Install and uniformly tighten the 8 bolts, in several passes, in the sequence shown.
Torque: 130 Nm (1,330 kgf-cm, 96 ft. lbs.)
98. INSTALL CLUTCH DISC ASSEMBLY (M/T TRANSAXLE)
99. INSTALL CLUTCH COVER ASSEMBLY (M/T TRANSAXLE)
100. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (A/T TRANSAXLE)
101. INSTALL MANUAL TRANSAXLE ASSEMBLY (M/T TRANSAXLE)
102. INSTALL STARTER ASSEMBLY
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
103. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
104. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
105. INSTALL FRONT FRAME ASSEMBLY
a. Install the engine mounting insulator LH with a nut (A/T).
Torque: 95 Nm (969 kgf-cm, 70 ft. lbs.)
b. Install the engine mounting insulator LH with a bolt (M/T).
Torque: 143 Nm (1,459 kgf-cm, 106 ft. lbs.)
c. Install the engine mounting insulator RH with a nut.
Torque: 95 Nm (969 kgf-cm, 70 ft. lbs.)
d. Install the engine mounting insulator FR with a bolt.
Torque: 87 Nm (888 kgf-cm, 64 ft. lbs.)
e. Install the engine lateral control rod with the bolt (M/T).
Torque: 89 Nm (910 kgf-cm, 69 ft. lbs.)
106. INSTALL VANE PUMP ASSEMBLY
a. Connect the vane pump to the engine with the 2 bolts.
Torque: 43 Nm (439 kgf-cm, 31 ft. lbs.)
107. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
a. Set the engine assembly with transaxle on the engine lifted.
b. Install the engine assembly to the vehicle.
c. Install the frame side plate LH and RH with 4 bolts and 2 nuts.
Torque:
Bolt A 85 Nm (867 kgf-cm, 63 ft. lbs.)
Bolt B, Nut 32 Nm (326 kgf-cm, 24 ft. lbs.)
d. Install the front suspension member brace rear RH and LH with 4 bolts and 2 nuts.
Torque: Bolt C 85 Nm (867 kgf-cm, 63 ft. lbs.)
Bolt D, Nut 32 Nm (326 kgf-cm, 24 ft. lbs.)
108. INSTALL STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY
a. Align the matchmarks on the intermediate shaft and control valve shaft.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)
b. Tighten the bolt.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)
109. INSTALL DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT (A/T TRANSAXLE)
a. Fix the crankshaft, and install the 6 set bolts.
Torque: 41 Nm (418 kgf-cm, 30 ft. lbs.)
110. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 LH
a. Install the drive shaft to steering knuckle.
b. Install the suspension lower arm with the bolt and the 2 nuts.
Torque: 127 Nm (1,296 kgf-cm, 94 ft. lbs.)
111. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 RH
HINT: Perform the same procedure on the opposite side.
112. INSTALL TIE ROD ASSEMBLY LH
a. Connect the tie rod end to the steering knuckle and install a new castle nut.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
NOTICE:
- Prevent any lubricant from the thread and the taper portions.
- After tightening the castle nut, tighten it to the additional direction within 60° to put into a cotter pin.
b. Insert a new cotter pin.
113. INSTALL TIE ROD ASSEMBLY RH
HINT: Perform the same procedure on the opposite side.
114. INSTALL SPEED SENSOR FRONT LH
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
115. INSTALL SPEED SENSOR FRONT RH
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
116. INSTALL FRONT AXLE HUB LH NUT
a. Using a 30 mm socket wrench, install a new hub nut.
Torque: 294 Nm (3,000 kgf-cm, 217 ft. lbs.)
b. Using a chisel, stake the hub nut.
117. INSTALL FRONT AXLE HUB RH NUT
HINT: Perform the same procedure on the opposite side.
118. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
a. Install the nut by using a 5 mm socket hexagon wrench to fix the stud bolt.
Torque: 74 Nm (755 kgf-cm, 55 ft. lbs.)
119. INSTALL FRONT STABILIZER LINK ASSEMBLY RH
HINT: Perform the same procedure on the opposite side.
120. INSTALL EXHAUST PIPE ASSEMBLY FRONT
121. CONNECT FUEL TUBE SUB-ASSEMBLY
122. INSTALL RETURN TUBE SUB-ASSEMBLY
a. Install the return tube.
123. INSTALL OIL RESERVOIR TO PUMP HOSE NO. 1
a. Install the hose No. 1.
124. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
125. INSTALL GENERATOR ASSEMBLY
126. INSTALL FAN AND GENERATOR V BELT
SST 09249-63010
127. INSTALL ENGINE MOUNTING BRACKET NO. 2 RH
Torque: 52 Nm (531 kgf-cm, 38 ft. lbs.)
128. INSTALL ENGINE MOUNTING STAY NO. 2 RH
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
129. INSTALL ENGINE MOVING CONTROL ROD W/ BRACKET
a. Install the engine mounting control rod w/ bracket with 3 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
130. INSTALL AIR CLEANER ASSEMBLY
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
131. ADD AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
132. MANUAL TRANSAXLE OIL (M/T TRANSAXLE)
133. ADD ENGINE OIL
134. ADD COOLANT
135. ADD POWER STEERING FLUID
136. BLEED POWER STEERING FLUID
137. INSPECT OIL LEAK
138. CHECK ENGINE COOLANT LEAK
139. INSPECT FUEL LEAK
140. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
141. ADJUST FRONT WHEEL ALIGNMENT
142. INSPECT CHECK IDLE SPEED AND IGNITION TIMING
143. INSPECT CO/HC
144. CHECK ABS SPEED SENSOR SIGNAL (W/ ABS)