Installation

ENGINE ASSEMBLY

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6):

COMPONENTS (Part 7):

COMPONENTS (Part 8):

COMPONENTS (Part 9):

COMPONENTS (Part 10):

COMPONENTS (Part 11):

INSTALLATION

1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
(a) Using SST, install a new gasket and the ECT sensor.
SST 09817-33190
Torque: 20 Nm (208 kgf-cm, 15 ft. lbs.)

2. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
(a) Clean the threads of the oil pressure switch. Apply adhesive to 2 or 3 threads of the oil.
Adhesive: Part No. 08833-00080 THREE BOND 1344 or equivalent

(b) Using a 24 mm deep socket wrench, install the oil pressure switch.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)

3. INSTALL RADIO SETTING CONDENSER
(a) Install the condenser with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)

4. INSTALL KNOCK SENSOR
(a) Install the sensor with the nut as shown in the illustration.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
5. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
6. INSTALL IGNITION COIL ASSEMBLY
(a) Install the 4 ignition coils with the 4 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

7. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
(a) Install the V-ribbed belt tensioner with the bolt and nut.
Torque: 60 Nm (607 kgf-cm, 44 ft. lbs.)

8. INSTALL ENGINE MOUNTING BRACKET RH
(a) Remove the engine mounting bracket RH with the 3 bolts.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)

9. INSTALL OIL COOLER PIPE (w/ Oil Cooler)
(a) Install a new gasket and the pipe with the bolt and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

10. INSTALL NO. 1 WATER BY-PASS PIPE
(a) Install a new gasket and the pipe with the bolt and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
11. INSTALL THERMOSTAT
12. INSTALL WATER INLET
13. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
(a) Except for PZEV:
(1) Install a new gasket onto the cylinder head.
(2) Temporarily tighten the exhaust manifold converter with the 5 nuts.

(3) Tighten the 5 nuts in the sequence shown in the illustration.
Torque: 37 Nm (378 kgf-cm, 27 ft. lbs.)

(4) Connect the air-fuel ratio sensor connector.

(5) Install the exhaust manifold heat insulator with the 4 bolts.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
(b) For PZEV:
(1) Install a new gasket onto the cylinder head.
(2) Temporarily tighten the exhaust manifold converter with the 5 nuts.

(3) Tighten the 5 nuts in the sequence shown in the illustration.
Torque: 37 Nm (378 kgf-cm, 27 ft. lbs.)

(4) Connect the air-fuel ratio sensor connector.

14. INSTALL NO. 2 MANIFOLD STAY
(a) Install the stay with the bolt and nut.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)

15. INSTALL MANIFOLD STAY
(a) Install the stay with the bolt and nut.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)

16. INSTALL OIL LEVEL GAUGE GUIDE
(a) Apply a light coat of engine oil to a new O-ring and install it to the guide.
(b) Install the oil level gauge guide with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
17. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY

18. INSTALL DRIVE SHAFT BEARING BRACKET
(a) Install the bracket with the 3 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)

19. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR
(a) Install the intake manifold insulator onto the cylinder block.
20. INSTALL NO. 2 VENTILATION HOSE
21. INSTALL INTAKE AIR CONTROL VALVE (for PZEV)

22. INSTALL INTAKE MANIFOLD
(a) Install a new gasket into the intake manifold.

(b) Install the intake manifold with the 5 bolts and 2 nuts.
Torque: 30 Nm (305 kgf-cm, 22 ft. lbs.)
23. INSTALL FUEL DELIVERY PIPE WITH INJECTOR
24. REMOVE ENGINE STAND
25. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)
26. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)
27. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)
28. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY (for Automatic Transaxle)
29. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)
30. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for Automatic Transaxle)
31. INSTALL STARTER ASSEMBLY (for Manual Transaxle)
32. INSTALL STARTER ASSEMBLY (for Automatic Transaxle)
33. INSTALL ENGINE WIRE
34. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
35. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

36. INSTALL FRONT FRAME ASSEMBLY
(a) A/T: Install the engine mounting insulator LH with the nut.
Torque: 95 Nm (969 kgf-cm, 70 ft. lbs.)

(b) M/T: Install the engine mounting insulator LH with the bolt.
Torque: 143 Nm (1,459 kgf-cm, 105 ft. lbs.)

(d) Install the engine mounting insulator FR with the bolt.
Torque: 87 Nm (888 kgf-cm, 64 ft. lbs.)

(e) M/T: Install the engine lateral control rod with the bolt.
Torque: 89 Nm (910 kgf-cm, 66 ft. lbs.)

37. INSTALL VANE PUMP ASSEMBLY
(a) Install the vane pump to the engine with the 2 bolts.
Torque: 43 Nm (439 kgf-cm, 32 ft. lbs.)
(b) Connect the oil pressure switch connector.

38. 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 the 4 bolts and 2 nuts.
Torque:
Bolt A 85 Nm (867 kgf-cm, 63 ft. lbs.)
Bolt B and nut 32 Nm (326 kgf-cm, 24 ft. lbs.)

(d) Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts.
Torque:
Bolt C 85 Nm (867 kgf-cm, 63 ft. lbs.)
Bolt D and nut 32 Nm (326 kgf-cm, 24 ft. lbs.)
39. INSTALL STEERING SLIDING YOKE
40. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET
(a) Install the exhaust pipe support bracket with the 2 bolts.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
41. INSTALL DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transaxle)
42. INSTALL FRONT AXLE ASSEMBLY LH
43. INSTALL FRONT AXLE ASSEMBLY RH

HINT: Use the same procedures described for the LH side.

44. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM LH
45. INSTALL FRONT SUSPENSION LOWER NO. 1 ARM RH

HINT: Use the same procedures described for the LH side.

46. INSTALL TIE ROD ASSEMBLY LH
47. INSTALL TIE ROD ASSEMBLY RH

HINT: Use the same procedures described for the LH side.

48. INSTALL FRONT SPEED SENSOR LH
49. INSTALL FRONT SPEED SENSOR RH
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
50. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
51. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT: Use the same procedures described for the LH side.

52. INSTALL FRONT AXLE HUB NUT LH
53. INSTALL FRONT AXLE HUB NUT RH

HINT: Use the same procedures described for the LH side.

54. INSTALL FRONT EXHAUST PIPE ASSEMBLY

55. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
(a) Install the cooler compressor with the 4 bolts.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)

NOTICE: Tighten the bolts in the order shown in the illustration to install the cooler compressor.

56. INSTALL GENERATOR ASSEMBLY

57. CONNECT FUEL TUBE SUB-ASSEMBLY
(a) Push in the fuel tube connector to the fuel pipe until the connector makes a "click" sound.

NOTICE:
- Check for damage or contamination on the connected part of the pipe.
- Check if the pipe and the connector are securely connected by trying to pull them apart.

(b) Install the No. 1 fuel pipe clamp.
58. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle)
59. REMOVE CLUTCH ACCUMULATOR ASSEMBLY (for Manual Transaxle)

60. CONNECT RETURN TUBE SUB-ASSEMBLY
(a) Connect the return tube sub-assembly.

61. CONNECT NO. 1 OIL RESERVOIR TO PUMP HOSE
(a) Connect the No. 1 oil reservoir to pump hose.

62. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)
(a) Connect the ends of the 2 cables and install the 2 washers and 2 clips.
(b) Install 2 new clips to the control cable bracket.

63. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)
(a) Install a new clip and nut, and connect the control lever.
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
(b) Connect the clamp with the cable to the transaxle.

64. CONNECT ENGINE WIRE
(a) Install the 2 bolts and clamp to the body.
Torque:
Bolt A 8.4 Nm (85 kgf-cm, 74 inch lbs.)
Bolt B 12 Nm (123 kgf-cm, 9 ft. lbs.)

(b) Connect the clamp to the bracket.

(c) Connect the wire to the engine room junction block. Then, install it with the nut and 3 connectors.
Torque: 8.4 Nm (85 kgf-cm, 74 inch lbs.)
65. INSTALL ECM

66. CONNECT HEATER INLET WATER HOSE
(a) Connect the heater inlet water hose.

67. CONNECT HEATER OUTLET WATER HOSE
(a) Connect the heater outlet water hose.
68. CONNECT OIL COOLER INLET HOSE
69. CONNECT OIL COOLER OUTLET HOSE

70. CONNECT RADIATOR HOSE INLET
(a) Install the clamp and connect the radiator hose inlet.

71. CONNECT RADIATOR HOSE OUTLET
(a) Install the clamp and connect the radiator hose outlet.

72. CONNECT NO. 1 VACUUM HOSE CONNECTOR
(a) Install the clamp and connect the vacuum hose connector.

73. INSTALL NO. 2 ENGINE MOUNTING BRACKET RH
(a) Install the 3 bolts and No. 2 mounting bracket RH.
Torque: 52 Nm (531 kgf-cm, 38 ft. lbs.)

74. INSTALL ENGINE MOVING CONTROL ROD SUB-ASSEMBLY
(a) Install the engine moving control rod with the 3 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)

(b) Install the ground cable with the bolt.
Torque: 8.4 Nm (85 kgf-cm, 74 inch lbs.)

75. INSTALL NO. 2 ENGINE MOUNTING STAY RH
(a) Install the No. 2 mounting stay RH with the 2 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
76. INSTALL BATTERY
(a) Install the battery and battery tray.

(b) Install the battery clamp with the bolt and nut.
Torque:
Bolt 9.0 Nm (92 kgf-cm, 80 inch lbs.)
Nut 3.5 Nm (36 kgf-cm, 31 inch lbs.)

77. INSTALL AIR CLEANER CASE SUB-ASSEMBLY
(a) Install the air cleaner case with the 3 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
(b) Connect the hose clamp.
78. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

79. INSTALL AIR CLEANER INLET ASSEMBLY
(a) Install the air cleaner inlet with the 2 bolts.
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
80. INSTALL V-RIBBED BELT
81. INSTALL COWL TOP PANEL OUTER SUB-ASSEMBLY
82. INSTALL WINDSHIELD WIPER LINK ASSEMBLY
83. INSTALL FRONT WHEEL
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
84. ADD ENGINE OIL
85. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Torque: 6.9 Nm (70 kgf-cm, 61 inch lbs.)
86. BLEED CLUTCH LINE (for Manual Transaxle)
87. ADD ENGINE COOLANT
88. ADD MANUAL TRANSAXLE OIL (for Manual Transaxle)
89. ADD AUTOMATIC TRANSAXLE FLUID (for Automatic Transaxle)
90. ADD POWER STEERING FLUID
91. BLEED POWER STEERING FLUID
92. CHECK FOR FUEL LEAKS
93. CHECK FOR ENGINE OIL LEAKS
94. CHECK FOR ENGINE COOLANT LEAKS
95. CHECK FOR EXHAUST GAS LEAKS
96. CHECK SHIFT LEVER POSITION
97. ADJUST FRONT WHEEL ALIGNMENT
98. CHECK IGNITION TIMING
99. CHECK ENGINE IDLE SPEED
100. INSPECT CO/HC
101. INSTALL FRONT FENDER APRON SEAL RH
102. INSTALL ENGINE UNDER COVER LH
103. INSTALL ENGINE UNDER COVER RH

104. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY
(a) Install the engine cover with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
105. CHECK ABS SPEED SENSOR SIGNAL