Engine Assembly, Installation

ENGINE ASSEMBLY

COMPONENTS:

INSTALLATION
1. INSTALL OIL PRESSURE SWITCH
2. INSTALL KNOCK SENSOR

3. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
a) Install a new gasket onto the sensor.
b) Using SST, install the temperature sensor in place.
SST 09817-33190
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
4. INSTALL NO. 1 WATER BY-PASS PIPE
a) Install a new gasket and the water by-pass pipe with the 2 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

5. INSTALL IGNITION COIL
a) Install the 4 ignition coils with the 4 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

6. INSTALL EXHAUST MANIFOLD
a) Using several steps, install a new exhaust manifold gasket and the exhaust manifold with the 3 bolts and 2 nuts in the sequence shown in the illustration.
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)
7. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
a) Install the exhaust manifold heat insulator with the 4 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)

8. INSTALL MANIFOLD SUPPORT BRACKET
a) Install the manifold support bracket with the 3 bolts.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)

9. INSTALL BOOSTER VACUUM TUBE
a) Install the booster vacuum tube with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

10. INSTALL INTAKE MANIFOLD
a) Install a new gasket onto the intake manifold.
b) Install the intake manifold with the 3 bolts and 2 nuts. Using several steps, uniformly tighten the bolts and nuts in the sequence shown in the illustration.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
11. CONNECT NO. 2 VENTILATION HOSE
12. CONNECT VENTILATION HOSE

13. INSTALL DRIVE PLATE (for Automatic Transaxle)
a) Hold the crankshaft pulley with SST.
SST 09213-58012 (91111-50845), 09330-00021

b) Install the drive plate.
1) Clean the bolt and bolt hole.
2) Apply adhesive to the bolts.
Adhesive: Part No. 0933-00070, THREE BOND or equivalent
3) Using several steps, uniformly install and tighten the 6 bolts in the sequence shown in the illustration.
Torque: 88 Nm (900 kgf-cm, 65 ft. lbs.)

14. INSTALL FLYWHEEL (for Manual Transaxle)
a) Hold the crankshaft pulley with SST.
SST 09213-58012 (91111-50845), 09330-00021
b) Install the flywheel.
1) Clean the bolt hole.
2) Apply adhesive to the bolts.
Adhesive: Part No. 0933-00070, THREE BOND or equivalent

3) Using several steps, uniformly install and tighten the 6 bolts in the sequence shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)

NOTICE: Do not reuse the flywheel bolt. It may cause breakage of the flywheel bolt.

4) Mark the flywheel bolt with paint.
5) Retighten the flywheel bolts by an additional 90°.
6) Check that the paint mark is at a 90° position from the original location.
15. INSTALL CLUTCH DISC (for Manual Transaxle)
16. INSTALL CLUTCH COVER (for Manual Transaxle)
17. INSTALL MANUAL TRANSAXLE (for Manual Transaxle)
18. INSTALL AUTOMATIC TRANSAXLE (for Automatic Transaxle)
19. INSTALL GENERATOR
20. INSTALL STARTER

21. INSTALL FRONT SUSPENSION CROSSMEMBER
a) Fasten the bolt to secure the engine and transaxle assembly to the suspension crossmember.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)

22. INSTALL VANE PUMP
a) Install the vane pump assembly with the 2 bolts.
Torque: 44 Nm (449 kgf-cm, 33 ft. lbs.)

HINT: Temporarily tighten bolt A so that the V belt can be adjusted in a later step.

23. INSTALL VANE PUMP V BELT
a) Temporarily install the V belt on each pulley.
24. ADJUST VANE PUMP V BELT

25. INSTALL ENGINE AND TRANSAXLE ASSEMBLY
a) Set the engine together with the transaxle on the engine lifter.
b) Install the engine together with the transaxle onto the engine compartment.
c) Temporarily install the suspension crossmember with the 8 bolts.

d) Install the engine mounting bracket LH onto the engine mounting insulator LH with the 2 bolts.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)

e) Install the engine mounting insulator RH with the 5 bolts and nut.
Torque: 45 Nm (459 kgf-cm, 33 ft. lbs.) for bolt A
52 Nm (530 kgf-cm, 38 ft. lbs.) for bolt B
52 Nm (530 kgf-cm, 38 ft. lbs.) for nut
f) Install the liquid tube with the bolt.
Torque: 9.8 Nm (100 kgf-cm, 7.2 ft. lbs.) for bolt C

g) Insert SST to the positioning holes on the right-hand crossmember and on the right-hand of the vehicle.
SST 09670-00010
h) Temporarily tighten bolt A, and then tighten bolt B.

i) Insert SST into the positioning holes on the lefthand crossmember and on the left-hand of the vehicle.
SST 09670-00010
j) Temporarily tighten bolt A, and then tighten bolt B.
k) Insert SST into the positioning holes on the righthand crossmember and the right-hand of the vehicle, and then tighten the bolts to the specified torque.
SST 09670-00010
Torque: 116 Nm (1,183 kgf-cm, 86 ft. lbs.) for bolt A
70 Nm (714 kgf-cm, 52 ft. lbs.) for bolt B
l) Insert SST into the positioning holes on the lefthand crossmember and the left-hand of the vehicle, and then tighten the bolts to the specified torque.
SST 09670-00010
Torque: 116 Nm (1,183 kgf-cm, 86 ft. lbs.) for bolt A
70 Nm (714 kgf-cm, 52 ft. lbs.) for bolt B

m) Tighten the 4 bolts shown in the illustration.
Torque: 47 Nm (479 kgf-cm, 35 ft. lbs.)
26. INSTALL FRONT SUSPENSION ARM LOWER LH
a) Install the front suspension arm lower to the steering knuckle with the nut.
Torque: 98 Nm (999 kgf-cm, 72 ft. lbs.)
b) Install a new clip.

HINT: Perform the same procedure as above on the opposite side.

27. INSTALL TIE ROD END LH
a) Connect the tie rod end to the steering knuckle with the nut.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
b) Install a new cotter pin.

NOTICE:
^ Be careful of the threads and taper portions of the tie rod end to prevent contact with oils.
^ After tightening the castle nut, turn it clockwise less than 60° to align the pin holes for the cotter pin.

HINT: Perform the same procedure as above on the opposite side.

28. CONNECT SPEED SENSOR FRONT LH (w/ABS)
a) Install the speed sensor with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)

HINT: Perform the same procedure as above on the opposite side.

29. INSTALL FRONT AXLE HUB LH NUT
a) Using a 30 mm socket wrench, install the new hub nut.
Torque: 216 Nm (2,203 kgf-cm, 160 ft. lbs.)
b) Using a chisel and hammer, stake the hub nut.

HINT: Perform the same procedure as above on the opposite side.

30. INSTALL STEERING INTERMEDIATE SHAFT
31. INSTALL EXHAUST PIPE FRONT
32. INSTALL FLOOR PANEL BRACE FRONT
33. INSTALL COOLER COMPRESSOR
34. INSTALL GENERATOR V BELT
a) Temporarily install the V belt on each pulley.
35. ADJUST GENERATOR V BELT
36. INSTALL RADIATOR
37. INSTALL CLUTCH RELEASE CYLINDER (for Automatic Transaxle)
38. CONNECT TRANSMISSION CONTROL CABLE (for Automatic Transaxle)
39. CONNECT TRANSMISSION CONTROL CABLE (for Manual Transaxle)
40. CONNECT FUEL TUBE
41. INSTALL AIR CLEANER
42. INSTALL BATTERY

43. INSTALL NO. 2 CYLINDER HEAD COVER
a) First tighten the nuts labeled A, and then tighten the nuts labeled B.
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
44. ADD ENGINE OIL
45. ADD ENGINE COOLANT
46. CHECK FOR ENGINE OIL LEAKS
47. CHECK FOR ENGINE COOLANT LEAKS
48. CHECK FOR FUEL LEAKAGE
49. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT

HINT: Inspect and adjust wheel alignment.

50. INSPECT IGNITION TIMING
51. INSPECT ENGINE IDLE SPEED
52. INSPECT CO/HC
53. INSPECT ABS SPEED SENSOR SIGNAL
54. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
55. PERFORM INITIALIZATION
a) Perform initialization. Testing and Inspection

NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.