Part 3

With A/T:

With M/T:

With A/T:

With M/T:

Except PZEV:

PARTIAL ENGINE ASSY
REPLACEMENT
81. REMOVE KNOCK SENSOR
a) Disconnect the sensor connector.
b) Remove the nut and sensor.
82. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
83. REPLACE PARTIAL ENGINE ASSY
84. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
a) Install a new gasket to the sensor.
b) Install the sensor.
Torque: 20 Nm (204 kgf-cm. 15 ft. lbs.)
85. INSTALL KNOCK SENSOR

a) Install the sensor with the nut as shown in the illustration.
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
86. INSTALL ENGINE OIL PRESSURE SWITCH ASSY
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) Install the oil pressure switch.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
87. INSTALL WATER BY-PASS PIPE NO.1
a) Install a new gasket and the by-pass pipe with the bolt and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
88. INSTALL FUEL DELIVERY PIPE W/INJECTOR
89. INSTALL ENGINE MOUNTING BRACKET RH
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)
90. INSTALL DRIVE SHAFT BEARING BRACKET
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
91. INSTALL V-RIBBED BELT TENSIONER ASSY

a) Install the belt tensioner with the bolt and nut.
Torque: 59.5 Nm (607 kgf-cm, 44 ft. lbs.)
92. INSTALL IGNITION COIL ASSY
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
93. INSTALL THERMOSTAT
94. INSTALL WATER INLET
95. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSY

a) Install a new gasket and the exhaust manifold converter with the 5 nuts. Uniformly tighten the 5 nuts in the sequence shown in the illustration.
Torque: 37 Nm (378 kgf-cm, 27 ft. lbs.)

b) Install the No.1 and No.2 exhaust manifold stays with the 3 bolts and 2 nuts.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)
96. INSTALL MANIFOLD CONVERTER INSULATOR NO.1
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
97. INSTALL OIL LEVEL GAGE GUIDE
a) Apply a light coat of engine oil to the O-ring and install it to the guide.
b) Install the oil level gage and guide with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
98. INSTALL INTAKE MANIFOLD

a) Install a new gasket and the intake manifold with the 5 bolts and 2 nuts.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
99. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY (A/T)

a) Using SST, fix the crankshaft.
SST 09960-10010 (09962-01000, 09963-01000)
b) Clean the bolt and the bolt hole.
c) Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive: Part No. 08833-00070, THREE BOND or equivalent.

d) Install the front spacer, drive plate and rear spacer with the 8 bolts. Uniformly tighten the 8 bolts in the sequence shown in the illustration.
Torque: 98 Nm (1,000 kgf-cm, 72 ft. lbs.)
100. INSTALL FLYWHEEL SUB-ASSY

d) Install the flywheel with the 8 bolts. Uniformly tighten the 8 bolts in the sequence shown in the illustration.
Torque: 130 Nm (1,330 kgf-cm, 96 ft. lbs.)
101. INSTALL CLUTCH DISC ASSY (A/T)
102. INSTALL CLUTCH COVER ASSY (M/T)
103. INSTALL AUTOMATIC TRANSAXLE ASSY (A/T)
104. INSTALL MANUAL TRANSAXLE ASSY (M/T)
105. INSTALL STARTER ASSY
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
106. INSTALL FRONT DRIVE SHAFT ASSY RH
107. INSTALL FRONT DRIVE SHAFT ASSY LH
108. INSTALL FRONT FRAME ASSY

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.)

c) Install the engine mounting insulator RH with the nut.
Torque: 95 Nm (969 kgf-cm, 70 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.)
109. INSTALL VANE PUMP ASSY

a) Install the vane pump to the engine with the 2 bolts.
Torque: 43 Nm (439 kgf-cm, 32 ft. lbs.)
b) Connect the PS oil pressure switch connector.
110. 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: 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
111. INSTALL STEERING INTERMEDIATE SHAFT ASSY

a) Align the matchmarks on the intermediate shaft and control valve shaft.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)

b) Tighten the bolt.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)
112. INSTALL DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT (A/T)

a) Fix the crankshaft, and install the 6 setting bolts.
Torque: 41 Nm (418 kgf-cm, 30 ft. lbs.)
113. 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 (765 kgf-cm, 55 ft. lbs.)
114. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH

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

115. INSTALL TIE ROD ASSY LH
a) Connect the tie rod end to the steering knuckle with the castle nut.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)

NOTICE:
^ Prevent lubricants from contacting the thread and taper portions.
^ After tightening the castle nut, tighten it an additional 60° so that a cotter pin can be inserted.

b) Insert a new cotter pin.
116. INSTALL TIE ROD ASSY RH

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

117. INSTALL SPEED SENSOR FRONT LH (W/ABS)
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
118. INSTALL SPEED SENSOR FRONT RH (W/ABS)
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
119. INSTALL FRONT AXLE HUB LH NUT

a) Using a 30 mm socket wrench, install a new hub nut.
Torque: 294 Nm (3,000 kgf-cm, 217 ft. lbs.)
b) Using a chisel and hammer, tapped the hub LH nut.
120. INSTALL FRONT AXLE HUB RH NUT

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