Part 3
With A/T:
With M/T:
With A/T:
With M/T:
Except PZEV:
PARTIAL ENGINE ASSY
REPLACEMENT
81. REMOVE ENGINE OIL PRESSURE SWITCH ASSY
82. REMOVE KNOCK SENSOR
a) Remove 2 nuts and 2 sensor.
83. REPLACE PARTIAL ENGINE ASSY
84. INSTALL KNOCK SENSOR
a) Install the 2 knock sensors with the 2 nuts, as shown in the illustration.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
85. 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 pressure switch.
Adhesive: Part No. 08833-00080 THREE BOND 1344, LOCTITE 242 or equivalent
b) Install the oil pressure switch.
Torque: 15 Nm (152 kgf-cm, 11 ft. lbs.)
86. INSTALL THERMOSTAT
87. INSTALL WATER INLET
88. INSTALL WATER INLET PIPE
89. INSTALL COMPRESSOR MOUNTING BRACKET NO.1
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
90. INSTALL GENERATOR BRACKET NO.1
Torque: 58 Nm (591 kgf-cm, 43 ft. lbs.)
91. INSTALL PUMP BRACKET
Torque: 32 Nm (326 kgf-cm, 24 ft. lbs.)
92. INSTALL DRIVE SHAFT BEARING BRACKET
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
93. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSY NO.2
a) Install a new gasket and the converser with the 7 nuts. Uniformly, tighten the 7 nuts in the sequence shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
b) Retighten nuts 1 and 2 as shown in the illustration.
94. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)
95. INSTALL MANIFOLD STAY NO.2
Torque: 34 Nm (347 kgf-cm, 25 ft. lbs.)
96. INSTALL EXHAUST MANIFOLD SUB-ASSY RH
a) Install a new gasket and the exhaust manifold with the 5 nuts. Uniformly tighten the 5 nuts in the sequence shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
b) Retighten nuts 1 and 2 shown in the illustration.
97. INSTALL WATER OUTLET
98. INSTALL INTAKE MANIFOLD
a) Install the intake manifold with the 9 bolts, 2 nuts and 2 washers. Uniformly tighten the bolts and nuts in the sequence shown in the illustration.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
b) Retighten the water outlet mounting bolts and nuts.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
c) Install the ground cable with the nut.
Torque: 8.4 Nm (86 kgf-cm, 74 inch lbs.)
d) Connect the heater inlet water hose.
99. INSTALL IGNITION COIL ASSY
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
100. INSTALL INTAKE AIR SURGE TANK
a) Install a new gasket to the intake air surge tank.
b) Install the intake air surge tank and emission control valve bracket with the 2 nuts.
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
c) Using an 8 mm socket hexagon wrench, tighten the 4 bolts.
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
d) Install the surge tank stay No. 2 with the 2 bolts.
Torque: 20 Nm (199 kgf-cm, 15 ft. lbs.)
e) Install the surge tank stay No. 1 with the 2 bolts.
Torque: 20 Nm (199 kgf-cm, 15 ft. lbs.)
f) Install the engine hanger No. 1 with the 2 bolts.
Torque: 20 Nm (199 kgf-cm, 15 ft. lbs.)
g) Install the pressure feed tube with the 3 nuts.
Torque: 7.8 Nm (80 kgf-cm, 69 inch lbs.)
h) Connect the ventilation hose.
i) Connect the union to check valve hose.
j) Connect the water by-pass hose No. 2.
k) Connect the water by-pass hose No. 3.
l) Connect the throttle motor connector.
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
32Nm (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 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.
119. INSTALL TIE ROD ASSY RH
HINT: Use the same procedures described for the LH side.
120. INSTALL SPEED SENSOR FRONT LH