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Part 9 Of 9:

PARTIAL ENGINE ASSEMBLY
REPLACEMENT





81. REMOVE ENGINE OIL PRESSURE SWITCH ASSEMBLY
a. Remove the oil pressure switch.





82. REMOVE KNOCK SENSOR
a. Remove the nut and the sensor.
83. REMOVE ENGINE COOLANT TEMPERATURE SENSOR
84. REPLACE PARTIAL ENGINE ASSEMBLY
85. 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.)





86. INSTALL KNOCK SENSOR
a. Install the sensor with the nut.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)

HINT: Angling the knock sensor below the horizontal (below 0°) is recommended.

87. 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 pressure switch.
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.)
88. INSTALL OIL COOLER PIPE (W/ OIL COOLER)
a. Install a new gasket and the oil cooler pipe with the bolt and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
89. INSTALL WATER BY-PASS PIPE NO.1
a. Install a new gasket and the by-pass pipe with the bolt and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
90. INSTALL FUEL DELIVERY PIPE W/INJECTOR
91. INSTALL ENGINE MOUNTING BRACKET RH
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
92. INSTALL DRIVE SHAFT BEARING BRACKET (2WD TYPE)
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)





93. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
a. Install the belt tensioner with the bolt and nut.
Torque: 60 Nm (612 kgf-cm, 44 ft. lbs.)
94. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
95. INSTALL IGNITION COIL ASSEMBLY
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
96. INSTALL THERMOSTAT
97. INSTALL WATER INLET
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
98. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY





a. Install a new gasket and the exhaust manifold converter. Uniformly tighten the 5 nuts in the sequence shown in the illustration.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)





b. Install the No. 1 and No. 2 exhaust manifold stays with the 2 bolts and 2 nuts.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)
99. INSTALL MANIFOLD CONVERTER INSULATOR NO.1
100. INSTALL OIL LEVEL GAGE GUIDE
a. Apply a light coat of the 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.)
101. INSTALL GENERATOR ASSEMBLY





102. INSTALL INTAKE MANIFOLD
a. Install a new gasket and the intake manifold with the 5 bolts and 2 nuts. Uniformly tighten the bolts in several passes.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
103. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY





a. Using SST, fix the crankshaft.
SST 09213-54015 (91651-60855), 09330-00021
b. Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive: Part No. 08833-00070, THREE BOND or equivalent.





c. Install the front spacer, drive plate and rear spacer with 8 bolts. Uniformly tighten the 8 bolts in the sequence shown in the illustration.
Torque: 98 Nm (1,000 kgf-cm, 72 ft. lbs.)
104. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
105. INSTALL STARTER ASSEMBLY
Torque: 39 Nm (398 kgf-cm, 29 ft. lbs.)
106. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (2WD TYPE)
107. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
108. INSTALL TRANSFER ASSEMBLY (4WD TYPE)





109. INSTALL ENGINE MOUNTING BRACKET RR (4WD TYPE)
a. Install the mounting bracket with the 6 bolts.
Torque:
34 Nm (347 kgf-cm, 25 ft. lbs.) for bolt A
64 Nm (653 kgf-cm, 47 ft. lbs.) for bolt B
110. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (4WD TYPE)
111. INSTALL FRONT FRAME ASSEMBLY





a. Install the engine mounting insulator LH with the nut.
Torque: 95 Nm (969 kgf-cm, 70 ft. lbs.)





b. Install the engine mounting insulator RH with the nut.
Torque: 95 Nm (969 kgf-cm, 70 ft. lbs.)





c. Install the engine mounting insulator FR with the nut.
Torque: 87 Nm (887 kgf-cm, 64 ft. lbs.)





d. 4WD type: Install the engine mounting insulator RR with 2 nuts.
Torque: 75 Nm (765 kgf-cm, 55 ft. lbs.)
112. INSTALL RACK & PINION POWER STEERING GEAR ASSEMBLY (4WD TYPE)
Torque: 70 Nm (714 kgf-cm, 52 ft. lbs.)
113. INSTALL STABILIZER BAR FRONT (4WD TYPE)
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)





114. INSTALL VANE PUMP ASSEMBLY
a. Install the vane pump to the engine with the 2 bolts.
b. Connect the PS oil pressure switch connector.
Torque: 43 Nm (438 kgf-cm, 31 ft. lbs.)
115. 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 6 bolts.
Torque:
86 Nm (877 kgf-cm, 63 ft. lbs.) for bolt A
32 Nm (326 kgf-cm, 24 ft. lbs.) for bolt B and nut





d. Install the front suspension member brace rear RH and LH with the 6 bolts.
Torque:
86 Nm (877 kgf-cm, 63 ft. lbs.) for bolt C
32 Nm (326 kgf-cm, 24 ft. lbs.) for bolt D and nut
116. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
117. INSTALL STEERING INTERMEDIATE SHAFT SUB-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.)





118. INSTALL BOLT, W/WASHER
a. Fix the crankshaft, and install the 6 setting bolts.
Torque: 41 Nm (418 kgf-cm, 30 ft. lbs.)





119. 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 the 2 nuts.
Torque: 127 Nm (1,295 kgf-cm, 94 ft. lbs.)
120. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO.1 RH

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