Part 3
REPLACEMENT100. INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE)
101. INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE)
102. INSTALL STARTER ASSY
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
103. INSTALL FRONT DRIVE SHAFT ASSY RH
104. INSTALL FRONT DRIVE SHAFT ASSY LH
105. INSTALL FRONT FRAME ASSY
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: 1143 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 ASSY
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 lifter.
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-ASSY
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-ASSY 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-ASSY LOWER No.1 RH
HINT: Perform the same procedure as above on the opposite side.
112. INSTALL TIE ROD ASSY 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 ASSY RH
HINT: Perform the same procedure as above 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 as above on the opposite side.
118. INSTALL FRONT STABILIZER LINK ASSY 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 ASSY RH
HINT: Perform the same procedure as above on the opposite side.
120. INSTALL EXHAUST PIPE ASSY FRONT
121. CONNECT FUEL TUBE SUB-ASSY
122. INSTALL RETURN TUBE SUB-ASSY
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 ASSY
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 ASSY
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 FOR ENGINE COOLANT LEAKS
139. INSPECT FUEL LEAK
140. INSTALL FRONT WHEELS
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)