Installation

INSTALLATION

1. INSTALL HEATER INLET WATER HOSE
2. INSTALL RADIATOR HOSE INLET
3. INSTALL WATER BY-PASS HOSE NO. 2
4. INSTALL RADIO SETTING CONDENSER

(a) Install the condenser with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
5. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
(a) Install a new gasket onto the engine coolant temperature sensor.

(b) Using SST, install the engine coolant temperature sensor.
SST: 09817-33190
Torque: 19.6 Nm (200 kgf-cm, 14 ft-lbf)
6. INSTALL EXHAUST MANIFOLD

(a) Install a new gasket and the exhaust manifold with the 5 nuts.
Torque: 37 Nm (377 kgf-cm, 27 ft-lbf)
7. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1

(a) Install the exhaust manifold heat insulator with the 4 bolts [A].
Torque: 18 Nm (184 kgf-cm, 13 ft-lbf)
(b) Connect the air fuel ratio sensor connector [B].
8. INSTALL MANIFOLD STAY

(a) Install the manifold stay with the 3 bolts.
Torque: 49 Nm (500 kgf-cm, 36 ft-lbf)
9. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
(a) Install the V-ribbed belt tensioner assembly (Installation).
10. INSTALL KNOCK SENSOR

(a) Install the knock sensor with the nut.
Torque: 20 Nm (205 kgf-cm, 15 ft-lbf)
11. INSTALL CRANKSHAFT POSITION SENSOR

(a) Install the crankshaft position sensor with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
12. INSTALL CAMSHAFT POSITION SENSOR

(a) Install the camshaft position sensor with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
13. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
(a) Install the engine oil pressure switch assembly (Testing and Inspection).
14. INSTALL THERMOSTAT
(a) Install the thermostat (Installation).
15. INSTALL WATER INLET
(a) Install the water inlet (Installation).
16. INSTALL WATER BY-PASS PIPE NO. 1

(a) Install a new gasket and the water by-pass pipe No. 1 with the 2 nuts and 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 in-lbf)
(b) Connect the knock sensor clamp.
17. INSTALL OIL LEVEL GAGE GUIDE
(a) Apply a light coat of engine oil to a new O-ring and install it onto the oil level gage guide.

(b) Install the oil level gage guide with the bolt.
Torque: 13 Nm (133 kgf-cm, 10 ft-lbf)
(c) Connect the crankshaft position sensor clamp.
18. INSTALL INTAKE MANIFOLD
(a) Install the intake manifold (Installation).
19. INSTALL OIL LEVEL GAGE SUB-ASSEMBLY
20. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
(a) Install the fuel delivery pipe sub-assembly (Installation).
21. INSTALL IGNITION COIL ASSEMBLY
(a) Install the ignition coil assembly (Installation).
22. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transaxle)
(a) Install the flywheel sub-assembly (Installation).
SST: 09960-10010
09962-01000
09963-01000
23. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY (for Automatic Transaxle)
(a) Install the drive plate & ring gear sub-assembly (Installation).
SST: 09960-10010
09962-01000
09963-01000
24. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transaxle)
(a) Install the clutch disc assembly (Installation).
SST: 09301-00210
25. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transaxle)
(a) Install the clutch cover assembly (Installation).
26. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
(a) Install the automatic transaxle assembly (Installation).
27. INSTALL MANUAL TRANSAXLE ASSEMBLY (for Manual Transaxle)
(a) Install the manual transaxle assembly (Installation).
28. INSTALL STARTER ASSEMBLY
(a) Install the starter assembly (Installation).
29. INSTALL FRONT SUSPENSION CROSSMEMBER WITH CENTER MEMBER
(a) Attach the engine and transaxle assembly to the suspension crossmember and engine mounting member.

(b) Install the through bolt, which is used to secure the engine mounting insulator RR, into the engine mounting bracket RR.
Torque: 65 Nm (663 kgf-cm, 48 ft-lbf)

(c) Install the bolt, which is used to secure the engine mounting insulator FR, into the engine mounting bracket FR.
Torque: 52 Nm (530 kgf-cm, 38 ft-lbf)
30. INSTALL VANE PUMP ASSEMBLY
(a) Install the vane pump assembly (Installation).
31. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
(a) Set the engine assembly with transaxle on the engine lifter.
(b) Install the engine assembly with transaxle onto the vehicle.

(d) Install the engine mounting insulator LH with the through bolt and nut.
Torque: 80 Nm (816 kgf-cm, 59 ft-lbf)

(e) Install the engine mounting insulator RH with the 4 bolts and 2 nuts.
Torque: 52 Nm (530 kgf-cm, 38 ft-lbf)

(f) Insert SST into the positioning holes on the right handle crossmember and on the right-handle of the vehicle.
SST: 09670-00010
(g) Temporarily tighten the bolt A first, then bolt B.

(h) Insert SST into the positioning holes on the left handle crossmember and on the left-handle of the vehicle.
SST: 09670-00010
(i) Temporarily tighten the bolt A first, then bolt B.
(j) Insert SST into the positioning holes on the right-handle crossmember and right-handle of the vehicle, then tighten the bolts to the specified torque.
(k) Insert SST into the positioning holes on the right-handle crossmember and left-handle of the vehicle, then tighten the bolts to the specified torque.
SST: 09670-00010
Bolt A - Torque: 157 Nm (1601 kgf-cm, 116 ft-lbf)
Bolt B - Torque: 113 Nm (1152 kgf-cm, 83 ft-lbf)

(l) Tighten the 2 bolts as shown in the illustration.
Torque: 60 Nm (612 kgf-cm, 44 ft-lbf)

NOTE: When installing the crossmember, check that the positioning holes on the crossmember and vehicle are aligned with each other.

32. INSTALL FRONT AXLE ASSEMBLY LH
(a) Install the front axle assembly LH (Installation).
33. INSTALL FRONT AXLE ASSEMBLY RH

HINT: Perform the same procedure as above on the opposite side.

34. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 LH
(a) Install the front suspension arm sub-assembly lower No. 1 LH (Installation).
35. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 RH

HINT: Perform the same procedure as above on the opposite side.

36. INSTALL TIE ROD END SUB-ASSEMBLY LH
(a) Install the tie rod end sub-assembly LH (Installation).
37. INSTALL TIE ROD END SUB-ASSEMBLY RH

HINT: Perform the same procedure as above on the opposite side.

38. INSTALL SPEED SENSOR FRONT LH (w/ ABS)
(a) Install the speed sensor front LH (Installation).
39. INSTALL SPEED SENSOR FRONT RH (w/ ABS)

HINT: Perform the same procedure as above on the opposite side.

40. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
(a) Install the front stabilizer link assembly LH (Installation).
41. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

HINT: Perform the same procedure as above on the opposite side.

42. INSTALL FRONT AXLE SHAFT LH NUT
(a) Install the front axle shaft LH nut (Installation).
43. INSTALL FRONT AXLE SHAFT RH NUT

HINT: Perform the same procedure as above on the opposite side.

44. INSTALL STEERING INTERMEDIATE SHAFT
(a) Install the steering intermediate shaft (Installation).
45. INSTALL COLUMN HOLE COVER SILENCER SHEET
46. INSTALL EXHAUST PIPE ASSEMBLY FRONT
(a) Install the exhaust pipe assembly front (Installation).
47. INSTALL FLOOR PANEL BRACE FRONT
(a) Install the floor panel brace front (Installation).
48. CONNECT ENGINE WIRE
49. INSTALL COWL SIDE TRIM BOARD RH
50. INSTALL FRONT DOOR SCUFF PLATE RH
51. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY
52. INSTALL RETURN TUBE SUB-ASSEMBLY

(a) Install the return tube with the 2 bolts.
Bolt A - Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
Bolt B - Torque: 7.8 Nm (80 kgf-cm, 69 in-lbf)
(b) Install the vane pump oil reservoir onto the oil reservoir bracket.
53. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)
(a) Install the compressor and magnetic clutch (Installation).
54. INSTALL GENERATOR ASSEMBLY
(a) Install the generator assembly (Installation).
55. INSTALL FAN AND GENERATOR V BELT
56. INSTALL CLUTCH RELEASE CYLINDER ASSEMBLY (for Manual Transaxle)
(a) Install the clutch release cylinder assembly (Installation).
57. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Automatic Transaxle)
(a) Install the transmission control cable assembly (Installation).
58. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY (for Manual Transaxle)
(a) Install the transmission control cable assembly (Installation).
59. CONNECT HEATER OUTLET WATER HOSE
60. CONNECT HEATER INLET WATER HOSE
61. CONNECT UNION TO CHECK VALVE HOSE
62. CONNECT FUEL TUBE SUB-ASSEMBLY
(a) Connect the fuel tube sub-assembly (Installation).
63. INSTALL CRUISE CONTROL ACTUATOR ASSEMBLY (w/ Cruise Control)

(a) Install the actuator with the 2 bolts [A].
Torque: 6.0 Nm (61 kgf-cm, 53 in-lbf)
(b) Connect the actuator connector [B].
64. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

(a) Connect the air cleaner case to the air cleaner inlet No. 1 [A].
(b) Install the air cleaner case with the 3 bolts [B].
Torque: 7.0 Nm (71 kgf-cm, 62 in-lbf)
(c) Connect the clamp [C] of the engine wire.
65. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
(a) Install the air cleaner cap sub-assembly (Installation).
66. INSTALL BATTERY CARRIER

(a) Install the battery carrier and bracket with the 4 bolts.
Torque: 12.8 Nm (131 kgf-cm, 9 ft-lbf)
67. INSTALL BATTERY TRAY
68. INSTALL BATTERY
Bolt - Torque: 5.0 Nm (51 kgf-cm, 44 in-lbf)
Nut - Torque: 3.5 Nm (36 kgf-cm, 31 in-lbf)
Terminal - Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
69. INSTALL RADIATOR ASSEMBLY (w/ Air Conditioning System)
(a) Install the radiator assembly (Installation).
70. CONNECT OIL COOLER OUTLET HOSE NO. 1 (for Automatic Transaxle)
71. CONNECT OIL COOLER INLET HOSE NO. 1 (for Automatic Transaxle)
72. CONNECT RADIATOR HOSE OUTLET
73. CONNECT RADIATOR HOSE INLET
74. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76 ft-lbf)
75. ADD ENGINE COOLANT
(a) Add the engine coolant (Testing and Inspection).
76. CONNECT BATTERY NEGATIVE TERMINAL
Torque: 5.4 Nm (55 kgf-cm, 48 in-lbf)
77. INSPECT FOR ENGINE COOLANT LEAK
(a) Check for the engine coolant leakage (Testing and Inspection).
78. INSPECT FOR ENGINE OIL LEAK
79. INSPECT FOR FUEL LEAK
80. INSPECT FOR EXHAUST GAS LEAK
81. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
(a) Inspect and adjust the front wheel alignment (Service and Repair).
82. CHECK ABS SPEED SENSOR SIGNAL (w/ ABS)
(a) Check the ABS speed sensor signal (ABS (Antilock Brake System)).
83. INSPECT IGNITION TIMING
(a) Inspect the ignition timing (On-Vehicle Inspection).
SST: 09843-18040
84. INSPECT ENGINE IDLING SPEED
(a) Inspect the engine idling speed (On-Vehicle Inspection).
85. INSPECT CO/HC
(a) Inspect the CO/HC (On-Vehicle Inspection).
86. INSTALL CYLINDER HEAD COVER NO. 2
(a) Install the cylinder head cover No. 2 (Installation).
87. INSTALL ENGINE UNDER COVER LH
88. INSTALL ENGINE UNDER COVER RH