Engine Assembly, Installation

ENGINE ASSEMBLY

COMPONENTS:

INSTALLATION

1. INSTALL KNOCK SENSOR
a. Install the 2 knock sensors with the 2 nuts, as shown in the illustration.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
2. 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, LOCTITE 242 or equivalent
b. Install the oil pressure switch.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
3. INSTALL THERMOSTAT
4. INSTALL WATER INLET
5. INSTALL WATER INLET PIPE
6. INSTALL COMPRESSOR MOUNTING BRACKET NO. 1
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
7. INSTALL GENERATOR BRACKET NO. 1
Torque: 58 Nm (591 kgf-cm, 43 ft. lbs.)
8. INSTALL PUMP BRACKET
Torque: 32 Nm (326 kgf-cm, 24 ft. lbs.)
9. INSTALL ENGINE MOUNTING BRACKET RH
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)

10. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO. 2
a. Install the manifold stay with the 2 bolts, as shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)

b. Install a new gasket and the converter subassembly No. 2 with the 7 nuts. Uniformly, tighten the 7 nuts in the sequence shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
c. Retighten nuts 1 and 2 as shown in the illustration.

d. Install the insulator No. 2 with the bolt and nut, as shown in the illustration.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

e. Install the insulator No. 3 with the bolt and nut, as shown in the illustration.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
f. Connect the A/F sensor connector.
11. INSTALL IGNITION COIL ASSEMBLY
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
12. INSTALL WATER OUTLET
a. Install 2 new gaskets to the 2 cylinder heads.
b. Install the water outlet together with the water bypass hose No. 1 and unlock the hose clamp.
c. Tighten the 2 bolts, 2 nuts and 2 washers.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
d. Install the clamp.
e. Connect the engine coolant temperature sensor connector.
f. Connect the radiator hose inlet.

13. INSTALL INTAKE MANIFOLD
a. Install the intake manifold with the 9 bolts, 2 nuts and 2 washers. Uniformly tighten the bolts and nuts in the sequence shown in the illustration.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
b. Retighten the water outlet mounting bolts and nuts.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
c. Install the ground cable with the nut.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
d. Connect the heater inlet water hose.

14. INSTALL INTAKE AIR SURGE TANK
a. Install a new gasket to the intake air surge tank.
b. Install the intake air surge tank and emission control valve bracket with the 2 nuts.
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
c. Using a socket hexagon wrench 8, tighten the 4 bolts.
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)

d. Install the surge tank stay No. 2 with the 2 bolts [D].
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
e. Install the surge tank stay No. 1 with the 2 bolts [E].
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
f. Install the engine hanger No. 1 with the 2 bolts [F].
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)

g. Install the pressure feed tube with the 3 nuts [G].
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)

h. Connect the ventilation hose [H].

i. Connect the union to the check valve hose [I].
j. Connect the water bypass hose No. 2 [J].
k. Connect the water bypass hose No. 3 [K].
l. Connect the throttle motor connector [L].

15. INSTALL EMISSION CONTROL VALVE SET
a. Install the emission control valve set with the 2 nuts [A].
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
b. Install the clamp [B].
c. Connect the 2 vacuum hoses [C].
d. Connect the fuel vapor feed hose No. 2 [D].
e. Connect the fuel vapor feed hose No. 1 [E].

f. Install the wire harness clamp [F].
g. Connect the 2 VSV connectors [G].
16. INSTALL ENGINE HANGER NO. 2
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
17. REMOVE ENGINE STAND
18. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY
19. INSTALL ENGINE MOUNTING BRACKET RR
20. INSTALL AUTOMATIC TRANSAXLE W/TRANSFER (for 4WD)
a. Install the automatic transaxle assembly.
21. INSTALL TRANSFER STIFFENER PLATE RH (for 4WD)
22. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY (for 2WD)
a. Install the automatic transaxle assembly.
23. INSTALL ENGINE MOUNTING BRACKET FR
24. INSTALL STARTER ASSEMBLY
25. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
26. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 2WD)
27. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD)

28. 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 nut.
Torque: 87 Nm (887 kgf-cm, 64 ft. lbs.)

c. Install the engine mounting insulator RR with the 2 bolts.
Torque: 75 Nm (765 kgf-cm, 55 ft. lbs.)
29. INSTALL POWER STEERING LINK ASSEMBLY
a. Install the power steering link assembly.
30. INSTALL STABILIZER BAR FRONT
a. Install the stabilizer bar front.

31. INSTALL VANE PUMP ASSEMBLY
a. Install the vane pump with the 2 bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)

HINT: After adjusting the V-ribbed belt, tighten bolt A.

32. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
a. Install a new gasket and the exhaust manifold RH. Uniformly tighten the 6 nuts in the sequence shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
b. Retighten nuts 1 and 2 shown in the illustration.

c. Install the insulator with the 3 bolts, as shown in the illustration.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
d. Connect the A/F sensor connector.

33. 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 RH and LH with the 6 bolts and 2 nuts.
Torque:
Bolt A 85 Nm (867 kgf-cm, 63 ft. lbs.)
Bolt B and Nut C 32 Nm (326 kgf-cm, 24 ft. lbs.)

d. Install the front suspension member brace rear RH and LH with the 6 bolts and 2 nuts.
Torque:
Bolt A 85 Nm (867 kgf-cm, 63 ft. lbs.)
Bolt B and Nut C 32 Nm (326 kgf-cm, 24 ft. lbs.)

34. CONNECT STEERING INTERMEDIATE SHAFT SUB-ASSEMBLY
a. Align the matchmarks on the intermediate shaft and the 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.)

35. INSTALL DRIVE PLATE & TORQUE CONVERTER CLUTCH SETTING BOLT
a. Using SST, hold the crankshaft.
SST 09213-54015 (91651-60855), 09330-00021
b. 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 the green colored bolt and then tighten the 5 bolts.

e. Install the flywheel housing under cover with the 2 bolts.
Torque: 8.0 Nm (82 kgf-cm, 70 inch lbs.)

36. 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 2 nuts.
Torque: 127 Nm (1,295 kgf-cm, 94 ft. lbs.)
37. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 RH

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

38. INSTALL TIE ROD END SUB-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 contacting 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.
39. INSTALL TIE ROD END SUB-ASSEMBLY RH

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

40. INSTALL SPEED SENSOR FRONT LH
41. INSTALL SPEED SENSOR FRONT RH

42. 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 and hammer, tap the front axle hub LH nut.
43. INSTALL FRONT AXLE HUB RH NUT

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

44. 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.)
45. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

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

46. INSTALL EXHAUST PIPE SUPPORT BRACKET NO. 1
47. CONNECT EXHAUST PIPE ASSEMBLY FRONT
48. CONNECT EXHAUST PIPE SUB-ASSEMBLY FRONT NO. 3
49. INSTALL PROPELLER SHAFT (for 4WD)
50. CONNECT ENGINE WIRE
51. INSTALL GLOVE COMPARTMENT DOOR ASSEMBLY
52. CONNECT STEERING GEAR OUTLET RETURN TUBE
53. CONNECT OIL RESERVOIR TO PUMP HOSE NO. 1
54. CONNECT OIL COOLER OUTLET TUBE NO. 1
55. CONNECT OIL COOLER INLET TUBE NO. 1
56. CONNECT RADIATOR HOSE OUTLET
57. CONNECT RADIATOR HOSE INLET
58. CONNECT HEATER OUTLET WATER HOSE
59. CONNECT HEATER INLET WATER HOSE

60. 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 for damage or contamination on the connected part of the pipe.
^ After having finished the connection, check if the pipe and the connector are securely connected by trying to pull them apart.

b. Install the fuel pipe clamp.
61. CONNECT UNION TO CHECK VALVE HOSE
62. INSTALL TRANSMISSION CONTROL CABLE ASSEMBLY

63. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
a. Install the compressor with the 3 bolts.
Torque: 25 Nm (255 kgf-cm, 18 ft. lbs.)
b. Install the adjusting bar bracket with the bolt and nut.
Torque:
Bolt 25 Nm (255 kgf-cm, 18 ft. lbs.)
Nut 26 Nm (265 kgf-cm, 19 ft. lbs.)

64. INSTALL ENGINE MOUNTING STAY NO. 2 RH
a. Install the mounting stay and mounting bracket with the bolt.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)

65. INSTALL ENGINE MOVING CONTROL ROD
a. Install the 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.)

66. 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.)
67. INSTALL GENERATOR BRACKET NO. 2
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
68. INSTALL GENERATOR ASSEMBLY
69. INSTALL VANE PUMP V BELT
70. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1
71. INSPECT DRIVE BELT TENSION
72. INSTALL AIR CLEANER CASE
73. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
74. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
75. CONNECT VACUUM HOSES

a. Connect the vacuum hoses.
76. INSTALL BATTERY

77. INSTALL V-BANK COVER SUB-ASSEMBLY
a. Fit the 2 retainers and install the V-bank cover.
b. Using a socket hexagon wrench 5, tighten the 3 nuts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
78. INSTALL FRONT SUSPENSION BRACE SUB-ASSEMBLY UPPER CENTER
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)
79. INSTALL COWL PANEL SUB-ASSEMBLY
80. INSTALL WINDSHIELD WIPER LINK ASSEMBLY
81. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
82. INSTALL FR WIPER ARM LH
83. INSTALL FR WIPER ARM RH
84. INSTALL FRONT WHEELS
85. ADD TRANSFER OIL (for 4WD)
86. INSPECT TRANSFER OIL (for 4WD)
87. ADD AUTOMATIC TRANSAXLE FLUID
88. ADD ENGINE OIL
89. ADD ENGINE COOLANT
90. ADD POWER STEERING FLUID
91. BLEED POWER STEERING FLUID
92. INSPECT AUTOMATIC TRANSAXLE FLUID
93. CHECK FOR ENGINE OIL LEAKS
94. CHECK FOR ENGINE COOLANT LEAKS
95. CHECK POWER STEERING FLUID LEAKAGE
96. INSPECT FOR FUEL LEAKS
97. CHECK FOR EXHAUST GAS LEAKS
98. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
a. Inspect and adjust the front wheel alignment.
99. INSPECT IGNITION TIMING
100. INSPECT ENGINE IDLE SPEED
101. INSPECT CO/HC
102. CHECK ABS SPEED SENSOR SIGNAL