Engine Assembly, Installation

ENGINE ASSEMBLY

COMPONENTS:

INSTALLATION
1. 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.)

2. 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.

3. 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.)
4. 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.)
5. 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.)
6. INSTALL FUEL DELIVERY PIPE W/INJECTOR
7. INSTALL ENGINE MOUNTING BRACKET RH
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
8. INSTALL DRIVE SHAFT BEARING BRACKET (for 2WD)
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)

9. 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.)
10. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
11. INSTALL IGNITION COIL ASSEMBLY
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
12. INSTALL THERMOSTAT
13. INSTALL WATER INLET
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)

14. 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.)
15. INSTALL MANIFOLD CONVERTER INSULATOR NO. 1
16. 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.)
17. INSTALL GENERATOR ASSEMBLY

18. 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.)

19. INSTALL DRIVE PLATE AND 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.)
20. INSTALL AUTOMATIC TRANSAXLE ASSEMBLY
21. INSTALL STARTER ASSEMBLY
22. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 2WD)
23. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH
24. INSTALL TRANSFER ASSEMBLY (for 4WD)

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

27. 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.)
28. INSTALL RACK AND PINION POWER STEERING GEAR ASSEMBLY (for 4WD)
Torque: 70 Nm (714 kgf-cm, 52 ft. lbs.)
29. INSTALL STABILIZER BAR FRONT (for 4WD)
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)

30. 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.)

31. 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:
Bolt A 86 Nm (877 kgf-cm, 63 ft. lbs.)
Bolt B and nut 32 Nm (326 kgf-cm, 24 ft. lbs.)

d. Install the front suspension member brace rear RH and LH with the 6 bolts.
Torque:
Bolt C 86 Nm (877 kgf-cm, 63 ft. lbs.)
Bolt D and nut 32 Nm (326 kgf-cm, 24 ft. lbs.)
32. INSTALL COMPRESSOR AND MAGNETIC CLUTCH
a. Install the compressor and magnetic clutch.

33. 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.)

34. INSTALL TRANSAXLE & ENGINE SETTING BOLT
a. Fix the crankshaft, and install the 6 setting bolts.
Torque: 41 Nm (418 kgf-cm, 30 ft. lbs.)

35. 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.)
36. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 RH

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

37. 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 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.
38. INSTALL TIE ROD ASSEMBLY RH

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

39. INSTALL SPEED SENSOR FRONT LH
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
40. INSTALL SPEED SENSOR FRONT RH
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)

41. INSTALL FRONT AXLE HUB LH NUT
a. Using a 30 mm socket wrench, install a new hub nut.
Torque: 294 Nm (3,000 kgf-cm, 217 ft. lbs.)
b. Using a chisel and hammer, tapped the front axle hub LH nut.
42. INSTALL FRONT AXLE HUB RH NUT

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

43. INSTALL FRONT STABILIZER LINK ASSEMBLY LH
a. Using a 5 mm socket hexagon wrench, fix the stud bolt and install the nut.
Torque: 74 Nm (755 kgf-cm, 55 ft. lbs.)
44. INSTALL FRONT STABILIZER LINK ASSEMBLY RH

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

45. INSTALL PROPELLER SHAFT (for 4WD)
a. Align the matchmarks on both the flanges of the front propeller shaft and intermediate shaft, then install and tighten the 4 bolts, 4 washers and 4 nuts.
Torque: 74 Nm (755 kgf-cm, 55 ft. lbs.)
46. INSTALL EXHAUST PIPE ASSEMBLY FRONT
47. CONNECT FUEL TUBE SUB-ASSEMBLY
a. Connect the fuel tube sub-assembly.

48. INSTALL RETURN TUBE SUB-ASSEMBLY
a. Install the return tube with 2 bolts.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
49. INSTALL FAN AND GENERATOR V BELT
50. INSTALL ENGINE MOUNTING BRACKET NO. 2 RH
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)

51. INSTALL ENGINE MOVING CONTROL ROD W/BRACKET
a. Install the engine mounting control rod with the 3 bolts.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)

HINT: First, loosely install bolts (1) and (2) with your hand. Then use a wench to install bolt (3). Finally, tighten bolt (2) and (1), in that order.

52. INSTALL ENGINE MOUNTING STAY NO. 2 RH
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
53. INSTALL AIR CLEANER ASSEMBLY
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
54. ADD TRANSFER OIL
a. Install a new gasket and the filler plug.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
55. ADD AUTOMATIC TRANSAXLE FLUID
56. ADD ENGINE OIL
57. ADD COOLANT
58. CHECK FOR ENGINE OIL LEAKS
59. CHECK FOR ENGINE COOLANT LEAKS
60. INSPECT FOR FUEL LEAKS
a. Inspect for the fuel leaks.
61. INSTALL FRONT WHEEL
62. ADJUST FRONT WHEEL ALIGNMENT
a. Adjust the front wheel alignment.
63. CHECK IDLE SPEED AND IGNITION TIMING
a. Check the idle speed and ignition timing.
64. INSPECT CO/HC
65. CHECK ABS SPEED SENSOR SIGNAL