Part 2
REPLACEMENT
86. REMOVE CAM POSITION SENSOR
a. Remove the bolt and cam position sensor.
87. REMOVE CRANK POSITION SENSOR
a. Remove the 2 bolts and crank position sensor.
88. REMOVE KNOCK CONTROL SENSOR
a. Remove the nut and knock control sensor.
89. REMOVE V-RIBBED BELT TENSIONER ASSY
a. Remove the bolts, nut and V-ribbed belt tensioner.
90. REMOVE MANIFOLD STAY (2WD DRIVE TYPE)
a. Remove the 3 bolts and manifold stay.
91. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1 (2WD DRIVE TYPE)
a. Remove the 4 bolts and exhaust manifold heat insulator.
92. REMOVE EXHAUST MANIFOLD (2WD DRIVE TYPE)
a. Remove the 5 nuts, exhaust manifold and gasket.
93. REMOVE E.F.I. ENGINE COOLANT TEMPERATURE SENSOR
a. Using SST, remove the E.F.I. engine coolant temperature sensor.
SST 09817-33190
94. REMOVE RADIO SETTING CONDENSER
a. Remove the bolt and condenser.
95. REMOVE WATER BY-PASS HOSE N0. 2
96. REMOVE RADIATOR HOSE INLET
97. REMOVE HEATER INLET WATER HOSE
98. REPLACE ENGINE ASSY, PARTIAL,
.99 INSTALL RADIO SETTING CONDENSER
a. Install the condenser with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
100. INSTALL E.F.I. ENGINE COOLANT TEMPERATURE SENSOR
a. Install a new gasket to the E.F.I. engine coolant temperature sensor.
b. Using SST, install the E.F.I. engine coolant temperature sensor.
SST 09817-33190
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
101. INSTALL EXHAUST MANIFOLD (2WD DRIVE TYPE)
a. Install a new gasket and the exhaust manifold with the 5 nuts.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)
102. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1 (2WD DRIVE TYPE)
a. Install the exhaust manifold heat insulator with the 4 bolts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
103. INSTALL MANIFOLD STAY (2WD DRIVE TYPE)
a. Install the manifold stay with the 3 bolts.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
104. INSTALL V-RIBBED BELT TENSIONER ASSY
a. Install the V-ribbed belt tensioner with the bolt and nut.
Torque:
Nut 29 Nm (296 kgf-cm, 21 ft. lbs.)
Bolt 69 Nm (704 kgf-cm, 51 ft. lbs.)
105. INSTALL KNOCK CONTROL SENSOR
a. Install the knock control sensor with the nut.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
106. INSTALL CRANK POSITION SENSOR
a. Install the crank position sensor with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
107. INSTALL CRANK POSITION SENSOR NO.1
a. Install the cam position sensor with the bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
108. INSTALL ENGINE OIL PRESSURE SWITCH ASSY
Adhesive: Part No.08833-00080, THREE BOND 1344.
SST 09268-46021
109. INSTALL THERMOSTAT
110. INSTALL WATER INLET
a. Install the water inlet with the 2 nuts.
Torque: 11 Nm (112 kgf-cm, 8 ft. lbs.)
111. INSTALL WATER BY-PASS PIPE NO.1
a. Install a new gasket and water by-pass with the 2 nuts and 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
112. INSTALL OIL LEVEL GAGE GUIDE
a. Apply a light coat of a new O-ring and install it to the oil level gage guide.
b. Install the oil level gage guide with the bolt.
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
113. INSTALL INTAKE MANIFOLD
a. Install a new gasket to the intake manifold.
b. Install the intake manifold and throttle body assembly with the 2 brackets, 4 bolts and 2 nuts. Uniformly tighten the bolts and nuts in several passes.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
c. Connect the 2 vacuum hoses to the intake manifold.
d. Connect the 2 water hoses to the throttle body.
114. INSTALL FUEL DELIVERY PIPE SUB-ASSY
115. INSTALL IGNITION COIL ASSY
a. Install the 4 ignition coils with the 4 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
b. Install the engine wire with the bolt and nut.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
116. INSTALL GENERATOR ASSY
117. INSTALL FLYWHEEL SUB-ASSY (M/T TRANSAXLE)
a. Fix the crankshaft with SST.
SST 09960-10010 (09962-01000, 09963-01000)
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.
118. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY (A/T TRANSAXLE)
a. Fix the crankshaft with SST.
SST 09960-10010 (09962-01000, 09963-01000)
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: 88 Nm (897 kgf-cm, 65 ft. lbs.)
119. INSTALL CLUTCH DISC ASSY (M/T TRANSAXLE)
SST 09301-00210
120. INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE)
SST 09301-00210
121. INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE)
122. INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE, 2WD DRIVE TYPE)
123. INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE, 4WD DRIVE TYPE)
124. INSTALL TRANSFER ASSY (4WD DRIVE TYPE)
125. INSTALL TRANSFER STIFFENER PLATE RH (4WD DRIVE TYPE)
126. INSTALL TRANSFER STIFFENER PLATE CENTER (4WD DRIVE TYPE)
127. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (4WD DRIVE TYPE)
128. INSTALL FRONT DRIVE SHAFT ASSY RH (4WD DRIVE TYPE)
129. INSTALL STARTER ASSY
130. INSTALL EXHAUST MANIFOLD (4WD DRIVE TYPE)
a. Install a new gasket and the exhaust manifold with the 5 nuts.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)
131. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 1 (4WD DRIVE TYPE)
a. Install the exhaust manifold heat insulator with the 4 bolts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
132. INSTALL OXYGEN SENSOR (4WD DRIVE TYPE)
a. Using SST, install the oxygen sensor.
SST 09224-00010
Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.)
133. INSTALL MANIFOLD STAY (4WD DRIVE TYPE)
a. Install the manifold stay with the 2 bolts.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
134. INSTALL FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER
a. Attach the engine and transaxle assembly to the suspension crossmember and engine mounting member.
b. Install the bolt holding the rear engine mounting bracket to the mounting insulator.
Torque: 87 Nm (887 kgf-cm, 64 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.)
135. INSTALL RACK & PINION POWER STEERING GEAR ASSY (4WD DRIVE TYPE)
SST 09023-38200
136. INSTALL VANE PUMP ASSY
137. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
a. Set the engine with transaxle on the engine lifter.
b. Install the engine with transaxle 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, 59 ft. lbs.)
e. Install the engine mounting insulator RH.
Torque: 52 Nm (530 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 right-handle of the vehicle, then tighten the bolts with a specified torque.
k. Insert SST to the positioning holes on the right-handle crossmember and 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.)
l. 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 vehicle are aligned with each other.
138. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH
139. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH
HINT: Perform the same procedure on the opposite side.
140. INSTALL FRONT STABILIZER LINK ASSY LH
141. INSTALL FRONT STABILIZER LINK ASSY RH
HINT: Perform the same procedure on the opposite side.
142. INSTALL TIE ROD END SUB-ASSY LH
143. INSTALL TIE ROD END SUB-ASSY RH
HINT: Perform the same procedure on the opposite side.
144. INSTALL FRONT AXLE HUB LH NUT
145. INSTALL FRONT AXLE HUB RH NUT
HINT: Perform the same procedure on the opposite side.
146. TEMPORARY TIGHTEN PROPELLER W/CENTER BEARING SHAFT ASSY (4WD DRIVE TYPE)
147. INSTALL EXHAUST PIPE ASSY FRONT
148. INSTALL EXHAUST PIPE ASSY CENTER (4WD DRIVE TYPE)
149. INSTALL FLOOR PANEL BRACE FRONT
a. Install front floor panel brace with the 2 nuts.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
150. INSTALL FRONT SEAT ASSY RH (4WD DRIVE TYPE)
151. INSTALL STEERING INTERMEDIATE SHAFT
152. INSTALL RETURN TUBE SUB-ASSY
a. 2WD
1 Install the return tube with 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.)
b. 4WD
1 Install the return tube with 3 bolts.
Torque:
Bolt A 5.0 Nm (51 kgf-cm, 44 inch lbs.)
Bolt B 7.8 Nm (80 kgf-cm, 69 inch lbs.)
153. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONER)
154. INSTALL CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE)
155. 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.
156. INSTALL AIR CLEANER ASSEMBLY WITH HOSE
a. Install the air cleaner case with the 3 bolts.
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
b. Connect the wire harness clamp, connector and hose.
c. Install the air filter.
d. Install the air cleaner cap.
e. Connect the air cleaner hose.
f. Connect 3 vacuum hoses, as shown in the illustration.
g. Connect the VSV connector.
h. Connect the intake air flow meter connector.
157. INSTALL BATTERY CARRIER
a. Install the battery carrier with the 4 bolts.
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
158. INSTALL BATTERY
Torque:
Bolt 5.0 Nm (51 kgf-cm, 44 inch lbs.)
Nut 3.0 - 4.0 Nm (31 - 41 kgf-cm, 27 - 35 inch lbs.)
159. INSTALL RADIATOR SUPPORT UPPER (W/AIR CONDITIONER)
a. Install the 2 radiator support uppers with the 2 bolts.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
160. INSTALL CYLINDER HEAD COVER NO.2
a. Install the cylinder head cover with the 2 nuts and 2 clips.
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
161. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
162. ADD TRANSFER OIL (4WD DRIVE TYPE)
a. Install a new gasket and the filler plug.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
163. ADD AUTOMATIC TRANSAXLE FLUID (4WD DRIVE TYPE)
164. ADD ENGINE OIL
165. ADD COOLANT
166. CHECK ENGINE OIL LEAK
167. CHECK ENGINE COOLANT LEAK
168. CHECK FUEL LEAK
169. CHECK EXHAUST GAS LEAK
170. INSPECT CHECK IDLE SPEED AND IGNITION TIMING
SST 09843-18040
171. INSPECT CO/HC
172. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
173. CHECK ABS SPEED SENSOR SIGNAL