Engine Assembly, Installation

ENGINE ASSEMBLY

Components:

INSTALLATION
1. 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.)

2. INSTALL KNOCK SENSOR
a. Install the sensor with the nut as shown in the illustration.
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
3. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
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.)
4. INSTALL WATER BY-PASS PIPE NO.1
a. Install anew gasket and the by-pass pipe with the bolt and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
5. INSTALL FUEL DELIVERY PIPE W/INJECTOR
6. INSTALL ENGINE MOUNTING BRACKET RH
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)
7. INSTALL DRIVE SHAFT BEARING BRACKET
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)

8. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
a. Install the belt tensioner with the bolt and nut.
Torque: 59.5 Nm (607 kgf-cm, 44 ft. lbs.)
9. INSTALL IGNITION COIL ASSEMBLY
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
10. INSTALL THERMOSTAT
11. INSTALL WATER INLET
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
12. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

a. Install anew 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.)
13. INSTALL MANIFOLD CONVERTER INSULATOR NO.1
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
14. 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.)

15. INSTALL INTAKE MANIFOLD
a. Install anew gasket and the intake manifold with the 5 bolts and 2 nuts.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
16. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY

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.)
17. INSTALL FLYWHEEL SUB-ASSEMBLY

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.)
18. INSTALL CLUTCH DISC ASSEMBLY
19. INSTALL CLUTCH COVER ASSEMBLY
20. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
21. INSTALL MANUAL TRANSAXLE ASSEMBLY
22. INSTALL STARTER ASSEMBLY
23. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
24. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
25. INSTALL FRONT FRAME ASSEMBLY

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.)

26. INSTALL VANE PUMP ASSEMBLY
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.
27. 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:
Bolt A 85 Nm (867 kgf-cm, 63 ft. lbs.)
Bolt B and nut 32 Nm (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 and nut 32 Nm (326 kgf-cm, 24 ft. lbs.)
28. INSTALL STEERING INTERMEDIATE SHAFT ASSEMBLY

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.)

29. INSTALL DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT
a. Fix the crankshaft, and install the 6 setting bolts.
Torque: 41 Nm (418 kgf-cm, 30 ft. lbs.)

30. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY 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.)
31. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH

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

32. INSTALL TIE ROD ASSEMBLY 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°C so that a cotter pin can be inserted.

b. Insert a new cotter pin.
33. INSTALL TIE ROD ASSEMBLY RH

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

34. INSTALL SPEED SENSOR FRONT LH
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
35. INSTALL SPEED SENSOR FRONT RH
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)

36. 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.
37. INSTALL FRONT AXLE HUB RH NUT

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

38. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
a. Using a 5 mm socket hexagon wrench, fix the stud bolt and install the nut.
Torque: 74 Nm (755 kgf-cm, 55 ft. lbs.)
39. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

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

40. INSTALL FRONT EXHAUST PIPE ASSEMBLY
41. CONNECT FUEL TUBE SUB-ASSEMBLY

42. INSTALL RETURN TUBE SUB-ASSEMBLY
a. Install return tube sub-assembly.

43. INSTALL OIL RESERVOIR TO PUMP HOSE NO.1
a. Install oil reservoir to pump hose No. 1.
44. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
45. INSTALL GENERATOR ASSEMBLY
46. INSTALL FAN AND GENERATOR V BELT
47. CONNECT ENGINE WIRE NO.2
48. CONNECT ENGINE WIRE
49. INSTALL ENGINE MOUNTING BRACKET NO.2 RH
Torque: 52 Nm (531 kgf-cm, 38 ft. lbs.)
50. INSTALL ENGINE MOUNTING STAY NO.2 RH
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)

51. INSTALL ENGINE MOVING CONTROL ROD W/BRACKET
a. Install the engine mounting control rod with the 3 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
52. INSTALL AIR CLEANER ASSEMBLY
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
53. ADD AUTOMATIC TRANSAXLE FLUID
54. ADD MANUAL TRANSAXLE OIL
55. ADD ENGINE OIL
56. ADD ENGINE COOLANT
57. ADD POWER STEERING FLUID
58. BLEED POWER STEERING FLUID
59. CHECK ENGINE OIL LEAKS
60. CHECK ENGINE COOLANT LEAKS
61. INSPECT FUEL LEAKAGE
62. INSTALL FRONT WHEEL
63. ADJUST FRONT WHEEL ALIGNMENT
64. INSPECT IDLE SPEED AND IGNITION TIMING
65. INSPECT CO/HC
66. CHECK ABS SPEED SENSOR SIGNAL (W/ABS)