Part 2
REPLACEMENT
73. REMOVE KNOCK CONTROL SENSOR
a. Remove the nut and the knock control sensor.
74. REMOVE CAM POSITION SENSOR
75. REMOVE E.F.I. ENGINE COOLANT TEMPERATURE SENSOR
a. Using a SST, remove the water temperature sensor.
SST 09817-33190
76. REPLACE PARTIAL ENGINE ASSY
77. INSTALL E.F.I. ENGINE COOLANT TEMPERATURE SENSOR
a. Install a new gasket to the water temperature sensor.
b. Using a SST, install the water temperature sensor.
SST 09817-33190
Torque: 20 Nm (208 kgf-cm, 15 ft. lbs.)
78. INSTALL CAM POSITION SENSOR
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
79. INSTALL KNOCK CONTROL SENSOR
a. install the nut and the knock control sensor.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
80. INSTALL ENGINE OIL PRESSURE SWITCH ASSY
a. Clean the threads of the oil pressure switch, apply adhesive there.
Adhesive: Part No. 08833-00080, THREE BOND 1344,
b. Using a SST, install the oil pressure switch.
c. Using a 24 mm deep socket wrench, install the oil pressure switch.
Torque: 15 Nm (153 kgf-cm, 11 ft-lbf)
81. INSTALL CRANK POSITION SENSOR
a. Install the crank position sensor and cord wiring clamp.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
82. INSTALL WATER BY-PASS PIPE NO.1
a. Install the 2 bolts, the 2 nuts, the new gasket and the water by-pass pipe.
Torque:
8.5 Nm (87 kgf-cm, 75 inch lbs.) for M6
21 Nm (214 kgf-cm, 15 ft. lbs.) for M8
10 Nm (102 kgf-cm, 7 ft. lbs.) for Nut
83. INSTALL VENTILATION NO.1 TUBE
a. Install a new gasket and the ventilation case No. 1 with the 3 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 in.-lbf)
b. Install a new gasket and the ventilation No. 1 tube with the 2 nuts.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
84. INSTALL THERMOSTAT
85. INSTALL WATER INLET
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
86. INSTALL INTAKE MANIFOLD
a. Install the new gasket, the intake manifold with the 4 bolts and 2 nuts.
Torque:
A: 34 Nm (347 kgf-cm, 25 ft. lbs.)
B: 46 Nm (469 kgf-cm, 34 ft. lbs.)
87. INSTALL SURGE TANK STAY NO.1
a. Install the surge tank stay with the 2 bolts and nut.
Torque: 24 Nm (245 kgf-cm, 18 ft. lbs.)
88. INSTALL OIL LEVEL GAGE GUIDE
a. Apply a light coat of engine oil to a new O-ring, install it to the oil level gage guide.
b. Install the oil level gage and guide with the bolt.
Torque: 24 Nm (245 kgf-cm, 18 ft. lbs.)
89. INSTALL FUEL DELIVERY PIPE SUB-ASSY
90. INSTALL IGNITION COIL ASSY
a. Install the 3 bolts, the nut and the 4 ignition coils.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
91. INSTALL EXHAUST MANIFOLD
a. Install a new gasket.
b. Install and uniformly tighten the 4 bolts and 2 nuts.
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.) for bolts A and nut A
Torque: 21 Nm (214 kgf-cm, 16 ft. lbs.) for bolt B
92. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
93. INSTALL MANIFOLD STAY
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)
94. INSTALL V-RIBBED BELT TENSIONER ASSY
a. Install the bolt, the nut and v-ribbed belt tensioner assy.
Torque:
Nut: 29 Nm (296 kgf-cm, 21 ft. lbs.)
Bolt: 100 Nm (1,020 kgf-cm, 74 ft. lbs.)
95. INSTALL FLYWHEEL SUB-ASSY (M/T TRANSAXLE)
a. Fix the crankshaft with SST
SST 09213-70011 (09213-70020), 09330-00021
b. Clean the bolt and bolt hole.
c. Apply adhesive to the bolts.
Adhesive:
Part No. 09330-00070, THREE BOND or equivalent.
d. Install and uniformly tighten the 8 bolts, in several passes, in the sequence shown.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
e. Mark the bolts with paint.
f. Retighten the bolts by an additional 90°.
g. Check that the point marked bolts are moved at 90° angle.
96. INSTALL CLUTCH DISC ASSY (M/T TRANSAXLE)
SST 09301-00210
97. INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE)
SST 09301-00210
98. INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE)
99. INSTALL FRONT DRIVE SHAFT ASSY LH
100. INSTALL STARTER ASSY
101. INSTALL FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER
a. Attach the engine and transaxle assembly to the suspension crossmember w/center member.
b. Install the bolt holding the rear engine mounting bracket to the mounting insulator.
Torque: 65 Nm (663 kgf-cm, 48 ft. lbs.)
c. Install the bolt holding the front engine mounting bracket to the mounting insulator.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)
102. 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. Temporarily, install the suspension crossmember and 6 bolts.
d. Install the engine mounting insulator LH.
Torque: 80 Nm (816 kgf-cm, 60 ft. lbs.)
e. Install the engine mounting insulator RH
Torque: 52 Nm (531 kgf-cm, 38 ft. lbs.)
f. Insert SST to 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 to 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 to the positioning holes on the right-handle crossmember and the right-handle of the vehicle, then the bolts with a specified torque.
SST 09670-00010
Torque:
Bolt A: 157 Nm (1,601 kgf-cm, 116 ft. lbs.)
Bolt B: 113 Nm (1,152 kgf-cm, 83 ft. lbs.)
k. Insert SST to the positioning holes on the left-handle crossmember and the left-handle of the vehicle, then tighten the bolts with a specified torque.
SST 09670-00010
Torque:
Bolt A: 157 Nm (1,601 kgf-cm, 116 ft. lbs.)
Bolt B: 113 Nm (1,152 kgf-cm, 83 ft. lbs.)
1 Tighten the 2 bolts as shown in the illustration.
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
NOTICE: After installing the crossmember, check that the positioning holes on the crossmember and the vehicle are aligned with each other.
103. INSTALL FRONT AXLE ASSY LH
104. INSTALL FRONT AXLE ASSY RH
HINT: Perform the same procedure on the opposite side.
105. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH
106. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH
HINT: Perform the same procedure on the opposite side.
107. INSTALL TIE ROD END SUB-ASSY LH
108. INSTALL TIE ROD END SUB-ASSY RH
HINT: Perform the same procedure on the opposite side.
109. INSTALL SPEED SENSOR FRONT LH
110. INSTALL SPEED SENSOR FRONT RH
HINT: Perform the same procedure on the opposite side.
111. INSTALL FRONT STABILIZER LINK ASSY LH
112. INSTALL FRONT STABILIZER LINK ASSY RH
HINT: Perform the same procedure on the opposite side.
113. INSTALL FRONT AXLE HUB LH NUT
114. INSTALL FRONT AXLE HUB RH NUT
HINT: Perform the same procedure on the opposite side.
115. INSTALL STEERING INTERMEDIATE SHAFT
116. INSTALL EXHAUST PIPE ASSY FRONT
117. INSTALL VANE PUMP OIL RESERVOIR ASSY
Torque: 7.8 Nm (80 kgf-cm, 69 in-lbf)
118. INSTALL RETURN TUBE SUB-ASSY
a. Install the return tube with the 2 bolts.
Torque:
Bolt A: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
Bolt B: 7.8 Nm (80 kgf-cm, 69 inch lbs.)
119. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONER)
120. INSTALL GENERATOR ASSY
121. INSTALL GENERATOR BRACKET NO.1
122. INSTALL SUCTION HOSE SUB-ASSY
Torque: 9.8 Nm (100 kgf-cm, 7 ft. lbs.)
123. INSTALL AIR SWITCHING VALVE
124. INSTALL CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE)
125. CONNECT FUEL TUBE SUB-ASSY
126. INSTALL EFI FUEL PIPE CLAMP
127. INSTALL CRUISE CONTROL ACTUATOR ASSY (W/ CRUISE CONTROL)
a. Install the actuator with the 2 bolts.
Torque: 6.0 Nm (61 kgf-cm, 53 inch lbs.)
b. Connect the actuator connector.
128. INSTALL AIR CLEANER CASE SUB-ASSY
Torque: 7.0 Nm (71 kgf-cm, 62 in.-lbf)
129. INSTALL BATTERY CARRIER
a. Install the battery carrier with the 4 bolts.
Torque: 13 Nm (132 kgf-cm, 10 ft. lbs.)
130. INSTALL CYLINDER HEAD COVER NO.2
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
131. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
132. ADD MANUAL TRANSAXLE OIL (M/T TRANSAXLE)
133. ADD ENGINE OIL
134. ADD COOLANT
135. CHECK ENGINE OIL LEAK
136. CHECK ENGINE COOLANT LEAK
137. CHECK FUEL LEAK
138. CHECK EXHAUST GAS LEAK
139. INSPECT CHECK IDLE SPEED AND IGNITION TIMING
SST 09843-18040
140. INSPECT CO/HC
141. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
142. CHECK ABS SPEED SENSOR SIGNAL