Part 3
PARTIAL ENGINE ASSYREPLACEMENT
101. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY
102. INSTALL AUTOMATIC TRANSAXLE ASSY
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 RH and LH with the 2 nuts.
Torque: 95 Nm (969 kgf-cm, 70 ft. lbs.)
b. Install the engine mounting insulator FR with the bolt.
Torque: 87 Nm (887 kgf-cm, 64 ft. lbs.)
106. INSTALL VANE PUMP ASSY
a. Install the vane pump with the 2 bolts.
Torque: 43 Nm (439 kgf-cm, 32 ft. lbs.)
HINT: After adjusting the V-ribbed belt, tighten bolt A.
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 rail plate RH and LH with the 4 bolts and 2 nuts.
Torque:
85 Nm (867 kgf-cm, 63 ft. lbs.) for bolt A
32 Nm (326 kgf-cm, 24 ft. lbs.) for bolt B and nut
d. Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts.
Torque:
85 Nm (867 kgf-cm, 63 ft. lbs.) for bolt C
32 Nm (326 kgf-cm, 24 ft. lbs.) for bolt D and nut
108. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
a. Install the compressor with the 3 bolts.
Torque: 25 Nm (250 kgf-cm, 18 ft. lbs.)
b. Install the adjusting bar bracket with the bolt and nut.
Torque:
25 Nm (250 kgf-cm, 18 ft. lbs.) for bolt
26 Nm (260 kgf-cm, 19 ft. lbs.) for nut
109. INSTALL GENERATOR BELT ADJUSTING BAR
a. Install the adjusting bar with the 2 bolts and 2 nuts.
Torque:
43 Nm (438 kgf-cm, 32 ft. lbs.) for nut A
18 Nm (184 kgf-cm, 13 ft. lbs.) for bolt B
8.0 Nm (82 kgf-cm, 71 inch lbs.) for bolt C
110. INSTALL GENERATOR BRACKET NO.2
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
111. INSTALL GENERATOR ASSY
112. INSTALL STEERING INTERMEDIATE SHAFT ASSY
a. Align the matchmarks on the intermediate shaft and control valve shaft, and install the bolt.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)
b. Tighten the sliding yoke bolt.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)
113. INSTALL DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT
a. Using SST, hold the crankshaft.
SST 09213-54015 (91651-60855), 09330-00021
b. Using kerosene or gasoline, clean the bolts thoroughly.
c. Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
d. Install the 6 torque converter set bolts.
Torque: 41 Nm (418 kgf-cm, 30 ft. lbs.)
NOTICE: First tighten the green colored bolt and then tighten the 5 bolts.
e. Install the flywheel housing under cover with the 2 bolts.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)
114. INSTALL EXHAUST PIPE SUPPORT BRACKET NO.1
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)
115. INSTALL STARTER ASSY
116. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH
a. Install the drive shaft to the steering knuckle.
b. Install the suspension lower arm with the bolt and 2 nuts.
Torque: 75 Nm (764 kgf-cm, 55 ft. lbs.)
117. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH
HINT: Use the same procedures described for the LH side.
118. 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 contacting 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.
119. INSTALL TIE ROD ASSY RH
HINT: Use the same procedures described for the LH side.
120. INSTALL SPEED SENSOR FRONT LH
121. INSTALL SPEED SENSOR FRONT RH
HINT: Use the same procedures described for the LH side.
122. INSTALL FRONT AXLE HUB LH NUT
a. Using a 30 mm socket wrench, install a new hub nut.
Torque: 294 Nm (2,998 kgf-cm, 217 ft. lbs.)
b. Using a chisel and hammer, tapped the front axle hub LH nut.
123. INSTALL FRONT AXLE HUB RH NUT
HINT: Use the same procedures described for the LH side.
124. INSTALL FRONT STABILIZER LINK ASSY LH
a. Using a 6 mm socket hexagon wrench, hold the ball stud, and install the nut.
Torque: 74 Nm (755 kgf-cm, 55 ft. lbs.)
125. INSTALL FRONT STABILIZER LINK ASSY RH
HINT: Use the same procedures described for the LH side.
126. INSTALL EXHAUST PIPE ASSY FRONT
127. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET
128. CONNECT FUEL PIPE SUB-ASSY NO.1
a. Push in the fuel tube connector to the fuel pipe until connector makes a "click" sound.
NOTICE:
^ Check for damage or contamination on the connected part of the pipe.
^ After having finished the connection, check if the pipe and the connector are securely connected by trying to pull them apart.
b. Install the fuel pipe clamp.
129. INSTALL AIR CLEANER ASSEMBLY WITH HOSE
130. CONNECT VACUUM HOSES
131. INSTALL V-BANK COVER SUB-ASSY
a. Using a 5 mm socket hexagon wrench, install the V-bank cover with the 2 nuts.
Torque: 7.9 Nm (81 kgf-cm, 70 inch lbs.)
132. INSTALL ENGINE MOUNTING STAY NO.2 RH
a. Install the mounting stay and mounting bracket with the bolt.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
133. INSTALL ENGINE MOVING CONTROL ROD
a. Install the control rod and bracket with the 4 bolts.
Torque:
64 Nm (653 kgf-cm, 47 ft. lbs.) for bolt A
23 Nm (235 kgf-cm, 17 ft. lbs.) for bolt B
134. INSTALL VANE PUMP V BELT
135. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
136. INSPECT DRIVE BELT TENSION
137. INSTALL FRONT WHEELS
138. ADD AUTOMATIC TRANSAXLE FLUID
139. ADD ENGINE OIL
140. ADD ENGINE COOLANT
141. ADD POWER STEERING FLUID
142. BLEED POWER STEERING FLUID
143. CHECK FOR OIL LEAKS
144. CHECK FOR ENGINE COOLANT LEAKS
145. INSPECT FOR FUEL LEAKS
146. CHECK FOR EXHAUST GAS LEAKS
147. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
148. INSPECT IGNITION TIMING
149. INSPECT ENGINE IDLE SPEED
150. INSPECT CO/HC
151. CHECK ABS SPEED SENSOR SIGNAL