Part 2
REPLACEMENT70. REMOVE MANIFOLD STAY NO. 2
71. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 2
72. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO. 2
73. REMOVE DRIVE SHAFT BEARING BRACKET
74. REMOVE PUMP BRACKET
a. Remove the 3 bolts and pump bracket.
75. REMOVE GENERATOR BRACKET NO. 1
76. REMOVE COMPRESSOR MOUNTING BRACKET NO. 1
77. REMOVE WATER INLET PIPE
78. REMOVE WATER INLET
79. REMOVE THERMOSTAT
80. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
a. Remove the oil pressure switch.
81. REMOVE KNOCK CONTROL SENSOR
a. Using SST, remove the 2 knock control sensors.
SST 09816-30010
82. REPLACE PARTIAL ENGINE ASSEMBLY
83. INSTALL KNOCK CONTROL SENSOR 3
a. Using SST, install the 2 knock control sensors.
SST 09816-30010
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
84. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
a. Apply adhesive to 2 or 3 threads of the oil pressure switch.
Adhesive: Part No. 08833-00080 THREE BOND 1344, LOCTITE 242 or equivalent.
b. Install the oil pressure switch.
Torque: 15 Nm (152 kgf-cm, 11 ft. lbs.)
85. INSTALL THERMOSTAT
86. INSTALL WATER INLET
87. INSTALL WATER INLET PIPE
88. INSTALL COMPRESSOR MOUNTING BRACKET NO. 1
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
89. INSTALL GENERATOR BRACKET NO. 1
Torque: 58 Nm (591 kgf-cm, 43 ft. lbs.)
90. INSTALL PUMP BRACKET
Torque: 32 Nm (326 kgf-cm, 24 ft. lbs.)
91. INSTALL DRIVE SHAFT BEARING BRACKET
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
92. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO. 2
a. Install a new gasket and the exhaust manifold LH.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
93. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO. 2
Torque: 8.5 Nm (87 kgf-cm, 55 inch lbs.)
94. INSTALL MANIFOLD STAY NO. 2
Torque: 34 Nm (347 kgf-cm, 25 ft. lbs.)
95. INSTALL EGR COOLER NO. 1
a. Install a new gasket and the EGR cooler No. 1.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
96. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Install a new gasket and the exhaust manifold RH. Uniformly tighten the nuts in several passes, in the sequence shown.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
97. INSTALL EGR PIPE SUB-ASSEMBLY NO. 1
a. Install 2 new gaskets and the EGR pipe.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
98. INSTALL EGR PIPE SUB-ASSEMBLY NO. 2
a. Install 2 new gaskets and the EGR pipe.
Torque: 12 Nm (120 kgf-cm, 9 ft. lbs.)
99. INSTALL WATER OUTLET
100. INSTALL INTAKE MANIFOLD
101. INSTALL IGNITION COIL ASSEMBLY
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
102. INSTALL INTAKE AIR SURGE TANK
103. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY
SST 09213-54015 (91651-60855), 09330-00021
104. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
105. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH
106. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
107. INSTALL FRONT FRAME ASSEMBLY
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 kg-cm, 64 ft. lbs.)
108. INSTALL VANE PUMP ASSEMBLY
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 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, 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 ASSEMBLY
114. INSTALL STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY
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 ASSEMBLY
118. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY 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-ASSEMBLY LOWER NO. 1 RH
HINT: Perform the same procedure on the opposite side.
120. INSTALL TIE ROD ASSEMBLY 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 ASSEMBLY RH
HINT: Perform the same procedure on the opposite side.
122. INSTALL SPEED SENSOR FRONT LH
123. INSTALL SPEED SENSOR FRONT RH
HINT: Perform the same procedure 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 on the opposite side.
126. INSTALL FRONT STABILIZER LINK ASSEMBLY 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 ASSEMBLY RH
HINT: Perform the same procedure on the opposite side.
128. INSTALL EXHAUST PIPE ASSEMBLY FRONT
129. INSTALL EXHAUST PIPE NO. 1 SUPPORT BRACKET
130. CONNECT FUEL PIPE SUB-ASSEMBLY 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 pap of the pipe.
- After connecting, check if the pipe and the connector are securely connected by purling them.
b. Install the fuel pipe clamp.
131. INSTALL AIR CLEANER ASSEMBLY WITH HOSE
132. CONNECT VACUUM HOSE
133. INSTALL V-BANK COVER SUB-ASSEMBLY
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 64 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
139. INSTALL FRONT WHEEL
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 ENGINE COOLANT LEAK
147. INSPECT FUEL LEAK
148. CHECK 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