Part 2

Part 1 Of 10:

Part 2 Of 10:

Part 3 Of 10:

Part 4 Of 10:

Part 5 Of 10:

Part 6 Of 10:

Part 7 Of 10:

Part 8 Of 10:

Part 9 Of 10:

Part 10 Of 10:

REPLACEMENT
55. REPLACE PARTIAL ENGINE ASSY
56. INSTALL VENTILATION VALVE SUB-ASSY

a. Apply adhesive to 2 or 3 threads.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent

b. Install the PCV valve.
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)

HINT: After tightening with the specified turn the rotate PCV valve clockwise with the port faced in the direction indicated in the illustration.

c. Install the PCV valve cover to the PCV valve.
d. Connect the PCV hose to the PCV valve.
57. INSTALL OIL COOLER ASSY
a. Place the new O-ring into the groove of oil pump.
b. Apply a light coat of engine oil on the O-ring.
c. Install the oil cooler assy with the 2 bolts and nut.
Torque:
Bolt 18 Nm (185 kgf-cm, 13 ft. lbs.)
Nut 18 Nm (185 kgf-cm, 13 ft. lbs.)
58. INSTALL WATER BY-PASS JOINT FR

a. With the flat-bottom of each gasket is put downward as shown in the illustration, install the 2 gaskets to the engine front side.
b. Install the water by-pass joint with the 4 nuts. Alternately tighten the nuts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
59. INSTALL WATER INLET HOUSING
60. INSTALL WATER BY-PASS PIPE SUB-ASSY
a. Install a new O-ring to the water by-pass pipe.
b. Apply soapy water to the O-ring.
c. Push in the water by-pass pipe end into the pipe hole of the water pump.
d. Install the water by-pass pipe with the bolt.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
61. INSTALL STARTER ASSY
a. Install the starter assy with 2 bolts.
Torque: 39 Nm (400 kgf-cm, 29 ft. lbs.)
b. Connect the engine wire No.2.
Torque 9.8 Nm (100 kgf-cm, 7.2 ft. lbs.)
62. INSTALL WATER BY-PASS JOINT RR

a. Using a SST, install the 2 knock sensors.
SST 09816-30010
Torque: 45 Nm (450 kgf-cm, 33 ft. lbs.)
64. INSTALL CRANKSHAFT POSITION SENSOR
a. Install the crankshaft position sensor with bolt.
Torque: 6.5 Nm (65 kgf-cm, 58 inch lbs.)
65. INSTALL CAMSHAFT POSITION SENSOR
a. Install the camshaft position sensor with the bolt and the stud bolt.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
66. INSTALL IGNITION COIL ASSY
a. Install the 8 ignition coil assy with 8 bolts.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
67. INSTALL FAN BRACKET SUB-ASSY
a. Install the fan bracket with 2 bolts and 2 nuts.
Torque:
12 mm head 16 Nm (160 kgf-cm, 12 ft. lbs.)
14 mm head 32 Nm (330 kgf-cm, 24 ft. lbs.)
68. INSTALL V-RIBBED BELT TENSIONER ASSY
a. Install the v-ribbed belt tensioner with the bolt and the 2 nuts.
Torque:
Bolt 16 Nm (160 kgf-cm, 12 ft. lbs.)
Nut 16 Nm (160 kgf-cm, 12 ft. lbs.)
69. INSTALL TIMING BELT COVER SUB-ASSY NO.2
a. Install timing belt cover sub-assy No.2 with the 2 bolts.
Torque: 16 Nm (160 kgf-cm, 12 ft. lbs.)
70. INSTALL TIMING CHAIN OR BELT COVER NO.2
a. Install the timing chain or belt cover with the nut and 2 bolts.
Torque:
Bolt 7.5 Nm (80 kgf-cm, 66 inch lbs.)
Nut 7.5 Nm (80 kgf-cm, 66 inch lbs.)
71. INSTALL TIMING BELT COVER SUB-ASSY NO.3 LH
a. Install the timing belt cover sub-assy with 4 bolts.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
b. Install the camshaft position sensor connector and grommet to the timing belt cover.
72. INSTALL PUMP BRACKET
a. Install the pump bracket with 4 bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
73. INSTALL OIL COOLER PIPE
a. Install the oil cooler pipe with bolt and nut.
Torque:
Bolt 7.5 Nm (80 kgf-cm, 66 inch lbs.)
Nut 7.5 Nm (80 kgf-cm, 66 inch lbs.)
b. Connect the 3 hoses.
74. INSTALL DRIVE PLATE & RING GEAR SUB-ASSY

75. INSTALL HARNESS BRACKET
Torque: 8.0 Nm (80 kgf-cm, 71 inch lbs.)
76. INSTALL HEATER HOSE
77. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 LH
a. Install the engine-mounting bracket and engine-mounting insulator with 4 bolts.
Torque: 36 Nm (367 kgf-cm, 27 ft. lbs.)
78. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 RH
a. Install the engine-mounting bracket and engine-mounting insulator with 4 bolts.
Torque: 36 Nm (367 kgf-cm, 27 ft. lbs.)
79. INSTALL ENGINE WIRE NO.2
a. Install engine wire protector with 3 bolts.
b. Connect the ground-cable-wire clamp with the bolt.
80. INSTALL WIRING HARNESS HEAT INSULATOR NO.2
a. Install the wiring harness heat insulator with the 2 bolts.
Torque: 17 Nm (175 kgf-cm, 13 ft. lbs.)
81. INSTALL INTAKE MANIFOLD ASSY

a. Place 2 new gaskets on the cylinder heads with white painted mark facing upward.

NOTICE:
^ Align the port holes of the gasket and cylinder head.
^ Be careful of the installation direction.

b. Place the intake manifold assembly on the cylinder heads.
c. Install and uniformly tighten the 6 bolts and 4 nuts in several passes.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
82. INSTALL ENGINE WIRE
83. INSTALL ENGINE ASSY
a. Attach the engine chain hoist to the engine hangers.
b. Slowly lower the engine assembly into the engine compartment.
c. Attach the engine mounting brackets to the frame brackets.
d. Install the engine mounting brackets and from brackets with the 4 nuts and the 4 bolts.
Torque: 38 Nm (387 kgf-cm, 28 ft. lbs.)
e. Remove the engine chain hoist.
84. INSTALL ENGINE WIRE
85. CONNECT HEATER HOSE
86. INSTALL EXHAUST MANIFOLD SUB-ASSY LH

a. Place a new gasket on the cylinder head with the white painted marks facing the manifold side.

NOTICE: Be careful of the installation direction.

b. Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in diagonally.
Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.)
c. Install the heat insulator with the 4 bolts.
88. INSTALL OIL LEVEL GAGE GUIDE
a. Install a new O-ring to the oil level gage guide.
b. Install the oil level gage guide with the belt.
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
89. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSY
a. Install the transmission oil filler tube sub-assy with the bolt.
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
90. INSTALL FAN W/ FLUID COUPLING
a. Install the fan pulley to the engine.
b. Install the fan w/ fluid coupling with the 4 nuts
Torque: 29 Nm (296 kgf-cm, 21 ft. lbs.)
91. INSTALL COMPRESSOR
a. Install the compressor with the stay, nut and the 3 bolts.
Torque:
Bolt 47 Nm (475 kgf-cm, 34 ft. lbs.)
Nut 25 Nm (255 kgf-cm, 18 ft. lbs.)
92. INSTALL GENERATOR ASSY
93. INSTALL VANE PUMP ASSY
a. Install the vane pump assy with the nut and 2 bolts.
Torque:
Bolt 43 Nm (438 kgf-cm, 32 ft. lbs.)
Nut 43 Nm (438 kgf-cm, 32 ft. lbs.)
94. INSTALL FAN AND GENERATOR V BELT
95. CONNECT FUEL VAPOR FEED HOSE ASSY
96. CONNECT FUEL HOSE
97. CONNECT FUEL HOSE NO.2
98. INSTALL FAN SHROUD
a. Install the fan shroud with the fan into the engine room
b. Clamp the 2 oil cooler hoses to the fan shroud
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
99. INSTALL RADIATOR ASSY
100. ADD ENGINE COOLANT
101. ADD ENGINE OIL
102. INSTALL ENGINE UNDER COVER ASSY REAR
103. INSTALL ENGINE UNDER COVER SUB-ASSY NO.1
104. INSTALL AIR CLEANER ASSY
a. Install the air cleaner assy with the 3 bolts
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
b. Connect the wire harness clamp and the ground cable.
Torque: 8.3 Nm (85 kgf-cm, 73 inch lbs.)
105. INSTALL AIR CLEANER HOSE ASSY
106. INSTALL V-BANK COVER SUB-ASSY
a. Install the V-bank cover sub-assy with the 2 nuts
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
107. INSTALL HOOD SUB-ASSY
a. Install the hood with the 4 bolts
Torque: 13 Nm (133 kgf-cm, 10 ft. lbs.)
b. Connect the windshield washer hose
108. INSTALL AUTOMATIC TRANSMISSION ASSY
109. CHECK FOR ENGINE COOLANT LEAKS
110. CHECK FOR EXHAUST GAS LEAKS
111. INSPECT FOR FUEL LEAKS
112. INSPECT AUTOMATIC TRANSMISSION FLUID
113. INSPECT ENGINE OIL LEAKS