Part 3
REPLACEMENT100. INSTALL INTAKE MANIFOLD
101. INSTALL IGNITION COIL ASSY
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
102. INSTALL INTAKE AIR SURGE TANK
103. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY
SST 09213-54015 (91651-60855), 09330-00021
104. INSTALL AUTOMATIC TRANSAXLE ASSY
105. INSTALL FRONT DRIVE SHAFT ASSY RH
106. INSTALL FRONT DRIVE SHAFT ASSY LH
107. 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.)
108. INSTALL VANE PUMP ASSY
a. Install the vane pump assembly with the 2 bolts.
Torque: 43 Nm (439 kgf-cm, 32 ft. lbs.)
HINT: After adjusting the V-ribbed belt, tighten the bolt A.
109. 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 sub-assembly RH and LH with the 4 bolts and 2 nuts.
Torque:
Bolt A 85 Nm (867 kgf-cm, 63 ft. lbs.)
Bolt B, Nut 32Nm (326 kgf-cm, 24 ft. lbs.)
d. Install the front suspension member brace rear RH and LH with the 4 bolts and 2 nuts.
Torque:
Bolt C 85 Nm (867 kgf-cm, 63 ft. lbs.)
Bolt D, Nut 32 Nm (326 kgf-cm, 24 ft. lbs.).
110. 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:
Bolt 25 Nm (250 kgf-cm, 18 ft. lbs.)
Nut 26 Nm (260 kgf-cm, 19 ft. lbs.)
111. INSTALL GENERATOR BELT ADJUSTING BAR
a. Install the adjusting bar with the 2 bolts and 2 nuts.
Torque:
Nut A 43 Nm (438 kgf-cm, 32 ft. lbs.)
Bolt B 18 Nm (184 kgf-cm, 13 ft. lbs.)
Bolt C 8.0 Nm (82 kgf-cm, 71 inch lbs.)
112. INSTALL GENERATOR BRACKET NO.2
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
113. INSTALL GENERATOR ASSY
114. INSTALL STEERING INTERMEDIATE SHAFT SUB-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.)
115. 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 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.)
116. INSTALL EXHAUST PIPE SUPPORT BRACKET NO.1
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)
117. INSTALL STARTER ASSY
118. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH
a. Install the drive shaft to steering knuckle.
b. Install the suspension lower arm with the bolt and 2 nuts.
Torque: 127 Nm (1,295 kgf-cm, 94 ft. lbs.)
119. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH
HINT: Perform the same procedure as above on the opposite side.
120. 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 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.
121. INSTALL TIE ROD ASSY RH
HINT: Perform the same procedure as above on the opposite side.
122. INSTALL SPEED SENSOR FRONT LH
123. INSTALL SPEED SENSOR FRONT RH
HINT: Perform the same procedure as above on the opposite side.
124. 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, stake the hub nut.
125. INSTALL FRONT AXLE HUB RH NUT
HINT: Perform the same procedure as above on the opposite side.
126. 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.)
127. INSTALL FRONT STABILIZER LINK ASSY RH
HINT: Perform the same procedure as above on the opposite side.
128. INSTALL EXHAUST PIPE ASSY FRONT
129. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET
130. 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 if there is any damage or foreign objects on the connected part of the pipe.
- After connecting, check if the pipe and the connector are securely connected by pulling them.
b. Install the fuel pipe clamp.
131. INSTALL AIR CLEANER ASSEMBLY WITH HOSE
132. CONNECT VACUUM HOSE
133. 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.)
134. INSTALL ENGINE MOUNTING STAY NO.2 RH
a. Install the engine mounting stay No. 2 RH and engine mounting bracket No. 2 RH with the bolt.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
135. INSTALL ENGINE MOVING CONTROL ROD
a. Install the engine moving control rod and bracket with the 4 bolts.
Torque:
Bolt A 614 Nm (653 kgf-cm, 47 ft. lbs.)
Bolt B 23 Nm (235 kgf-cm, 17 ft. lbs.)
136. INSTALL VANE PUMP V BELT
137. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
138. INSPECT DRIVE BELT DEFLECTION AND TENSION (REFERENCE)
139. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
140. ADD AUTOMATIC TRANSAXLE FLUID
141. ADD ENGINE OIL
142. ADD COOLANT
143. ADD POWER STEERING FLUID
144. BLEED POWER STEERING FLUID
145. INSPECT OIL LEAK
146. CHECK FOR ENGINE COOLANT LEAKS
147. INSPECT FOR FUEL LEAKS
148. CHECK FOR EXHAUST GAS LEAK
149. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
150. INSPECT IGNITION TIMING
SST 09843-18040, 09843-18020
151. INSPECT ENGINE IDLE SPEED
SST 09843-18040
152. INSPECT CO/HC
153. CHECK ABS SPEED SENSOR SIGNAL