Part 2
REPLACEMENT66. REMOVE GENERATOR ASSY
67. REMOVE FUEL DELIVERY PIPE SUB-ASSY
68. REMOVE IGNITION COIL ASSY
a. Remove the 3 bolts, the nut and the 4 ignition coils.
69. REMOVE THERMOSTAT
70. REMOVE WATER BY-PASS PIPE NO.1
a. Remove the 2 bolts, the 2 nuts, the water by-pass pipe No. 1 and the gasket.
71. REMOVE ENGINE OIL PRESSURE SWITCH ASSY
a. Using the SST, remove the oil pressure switch.
SST 09268-46021
72. REMOVE UNION TO CONNECTOR TUBE HOSE
a. Remove the clamp and tube.
73. REMOVE CRANK POSITION SENSOR
74. REMOVE CAM POSITION SENSOR
75. REMOVE KNOCK CONTROL SENSOR
a. Remove the nut and the knock control sensor.
76. REMOVE E.F.I. ENGINE COOLANT TEMPERATURE SENSOR
a. Using a SST, remove the water temperature sensor.
SST 09817-33190
77. REPLACE PARTIAL ENGINE ASSY
78. INSTALL E.F.I. ENGINE COOLANT TEMPERATURE SENSOR
a. Install a new gasket to the water temperature sensor.
b. Using a SST, install the water temperature sensor.
SST 09817-33190
Torque: 20 Nm (208 kgf-cm, 15 ft. lbs.)
79. INSTALL KNOCK CONTROL SENSOR
a. install the nut and the knock control sensor.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
80. INSTALL CAM POSITION SENSOR
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
81. INSTALL CRANK POSITION SENSOR
a. Install the crank position sensor and cord wiring clamp.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
82. INSTALL UNION TO CONNECTOR TUBE HOSE
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
83. INSTALL ENGINE OIL PRESSURE SWITCH ASSY
a. Clean the threads of the oil pressure switch, apply adhesive there.
Adhesive: Part No. 08833-00080, THREE BOND 1344,
b. Using a SST, install the oil pressure switch.
SST 09268-46021
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
84. INSTALL WATER BY-PASS PIPE NO.1
a. Install the 2 bolts, the 2 nuts, the new gasket and the water by-pass pipe.
Torque:
8.5 Nm (87 kgf-cm, 75 inch lbs.) for M6
21 Nm (214 kgf-cm, 15 ft. lbs.) for M8
10 Nm (102 kgf-cm, 7 ft. lbs.) for Nut
85. INSTALL THERMOSTAT
86. INSTALL IGNITION COIL ASSY
a. Install the 3 bolts, the nut and the 4 ignition coils.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
87. INSTALL FUEL DELIVERY PIPE SUB-ASSY
88. INSTALL EXHAUST MANIFOLD
a. Install a new gasket.
b. Install and uniformly tighten the 3 bolts and 2 nuts in several passes and in the sequence shown.
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)
89. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)
90. INSTALL MANIFOLD STAY
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)
91. INSTALL V-RIBBED BELT TENSIONER ASSY
a. Install the bolt, the nut and v-ribbed belt tensioner assy.
Torque:
Nut: 29 Nm (296 kgf-cm, 21 ft. lbs.)
Bolt: 100 Nm (1,020 kgf-cm, 74 ft. lbs.)
92. INSTALL INTAKE MANIFOLD
a. Install the new gasket, the intake manifold with the 4 bolts and 2 nuts.
Torque:
A: 34 Nm (347 kgf-cm, 25 ft. lbs.)
B: 46 Nm (469 kgf-cm, 34 ft. lbs.)
93. INSTALL SURGE TANK STAY NO.1
a. Install the surge tank stay with the 2 bolts and nut.
Torque: 24 Nm (245 kgf-cm, 18 ft. lbs.)
94. INSTALL OIL LEVEL GAGE GUIDE
a. Apply a light coat of engine oil to a new O-ring, install it to the oil level gage guide.
b. Install the oil level gage and guide with the bolt.
Torque: 24 Nm (245 kgf-cm, 18 ft. lbs.)
95. INSTALL FLYWHEEL SUB-ASSY (M/T TRANSAXLE)
a. Fix the crankshaft with SST
SST 09213-70011 (09213-70020), 09330-00021
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.
96. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY (A/T TRANSAXLE)
a. Fix the crankshaft with SST.
SST 09213-70011 (09213-70020), 09330-00021
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.)
97. INSTALL CLUTCH DISC ASSY (M/T TRANSAXLE)
SST 09301-00210
98. INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE)
SST 09301-00210
99. INSTALL FRONT DRIVE SHAFT ASSY LH
100. INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE)
101. INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE)
102. INSTALL STARTER ASSY
103. INSTALL FRONT SUSPENSION CROSSMEMBER W/CENTER MEMBER
a. Attach the engine and transaxle assembly to the suspension crossmember w/center 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.)
104. 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. Temporarily, install the suspension crossmember and 6 bolts.
d. Install the engine mounting insulator LH.
Torque: 80 Nm (816 kgf-cm, 60 ft. lbs.)
e. Install the engine mounting insulator RH
Torque: 52 Nm (531 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 the right-handle of the vehicle, then 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.)
k. Insert SST to the positioning holes on the left-handle crossmember and the 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.)
1 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 the vehicle are aligned with each other.
105. INSTALL FRONT AXLE ASSY LH
106. INSTALL FRONT AXLE ASSY RH
HINT: Perform the same procedure on the opposite side.
107. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH
108. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 RH
HINT: Perform the same procedure on the opposite side.
109. INSTALL FRONT STABILIZER LINK ASSY LH
110. INSTALL FRONT STABILIZER LINK ASSY RH
HINT: Perform the same procedure on the opposite side.
111. INSTALL TIE ROD END SUB-ASSY LH
112. INSTALL TIE ROD END SUB-ASSY RH
HINT: Perform the same procedure on the opposite side.
113. INSTALL FRONT AXLE HUB LH NUT
114. INSTALL FRONT AXLE HUB RH NUT
HINT: Perform the same procedure on the opposite side.
115. INSTALL STEERING INTERMEDIATE SHAFT
116. INSTALL EXHAUST PIPE ASSY FRONT
117. INSTALL FLOOR PANEL BRACE FRONT
118. INSTALL RETURN TUBE SUB-ASSY
a. Install the return tube with the 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.)
119. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONER)
120. INSTALL CLUTCH RELEASE CYLINDER ASSY (M/T TRANSAXLE)
121. INSTALL GENERATOR ASSY
122. INSTALL GENERATOR BRACKET NO.1
123. INSTALL RADIATOR ASSY (W/ AIR CONDITIONER)
124. INSTALL GLOVE COMPARTMENT DOOR ASSY
125. INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (M/T TRANSAXLE)
126. INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SELECT (M/T TRANSAXLE)
127. INSTALL FLOOR SHIFT CABLE TRANSMISSION CONTROL SHIFT (A/T TRANSAXLE)
128. CONNECT FUEL TUBE SUB-ASSY
129. INSTALL EFI FUEL PIPE CLAMP
130. INSTALL SUCTION HOSE SUB-ASSY
Torque: 9.8 Nm (100 kgf-cm, 7 ft. lbs.)
131. INSTALL WIRE HARNESS CLAMP
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
132. INSTALL BATTERY CARRIER
a. Install the battery carrier with the 4 bolts.
Torque: 13 Nm (132 kgf-cm, 10 ft. lbs.)
133. 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.
134. 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. Connect the air cleaner hose to the throttle body.
e. Attach the air cleaner cap to the air cleaner case, and install the 2 clamps.
f. Tighten the air cleaner hose clamp.
g. Connect the 5 vacuum hoses for the air cleaner cap.
h. Connect the MAF meter connector.
135. INSTALL CYLINDER HEAD COVER NO.2
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
136. ADD MANUAL TRANSAXLE OIL (M/T TRANSAXLE)
137. ADD AUTOMATIC TRANSAXLE FLUID (A/T TRANSAXLE)
138. ADD ENGINE OIL
139. ADD COOLANT
140. CHECK ENGINE OIL LEAK
141. CHECK ENGINE COOLANT LEAK
142. CHECK FUEL LEAK
143. INSTALL FRONT WHEELS
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
144. CHECK EXHAUST GAS LEAK
145. INSPECT CHECK IDLE SPEED AND IGNITION TIMING
SST 09843-18040
146. INSPECT CO/HC
147. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
148. CHECK ABS SPEED SENSOR SIGNAL