Removal and Installation
REPLACEMENT1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL
CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.
3. REMOVE HOOD SUB-ASSEMBLY
4. REMOVE V-BANK COVER
5. REMOVE AIR CLEANER INLET NO.1
6. REMOVE INTAKE AIR CONNECTOR PIPE
7. REMOVE AIR CLEANER ASSEMBLY
8. REMOVE ENGINE UNDER COVER
9. REMOVE ENGINE UNDER COVER NO.2
10. DRAIN ENGINE OIL
11. DRAIN ENGINE COOLANT
12. DRAIN AUTOMATIC TRANSMISSION FLUID
13. REMOVE RADIATOR ASSEMBLY
14. DISCONNECT FUEL PIPE SUB-ASSEMBLY NO.2
15. REMOVE FAN AND GENERATOR V BELT
16. DISCONNECT ENGINE WIRE
a. Disconnect the engine wire from the ECM box.
b. Remove the nut, and disconnect the wire from the generator.
c. Disconnect the 2 wires from the 2 wire clamps on the generator.
d. Remove the bolt, and disconnect the ground cable from the stay on generator.
e. Remove the 2 bolts, and disconnect the PS oil hose from the No. 1 oil pan. Remove the bolt, and disconnect the ground strap from the body.
17. DISCONNECT AIR HOSE NO.5
18. DISCONNECT FUEL VAPOR FEED HOSE NO.2
19. DISCONNECT HEATER WATER INLET HOSE A
20. DISCONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
21. DISCONNECT VANE PUMP OIL RESERVOIR ASSEMBLY
22. DISCONNECT VANE PUMP ASSEMBLY
a. Disconnect the 2 PS air hoses.
b. Remove the 2 screws and RH engine under cover.
c. Disconnect the PS oil pressure switch connector.
d. Remove the 2 bolts and nut, and disconnect the vane pump from the engine.
e. Support the vane pump securely.
23. DISCONNECT COOLER COMPRESSOR ASSEMBLY
a. Disconnect the compressor connector.
b. Disconnect the wire clamp from the wire bracket on the compressor.
c. Remove the bolt, nut and stay.
d. Remove the bolt, and disconnect the wire bracket from the compressor.
e. Remove the bolt, and disconnect the compressor from the engine.
f. Support the cooler compressor securely.
24. REMOVE FRONT FLOOR BRACE CENTER
a. Remove the 4 bolts and brace center.
25. REMOVE EXHAUST PIPE ASSEMBLY
26. REMOVE FRONT SUSPENSION MEMBER BRACE SUB-ASSEMBLY RH
27. REMOVE W/CATALYST CONVERTER ASSEMBLY
28. REMOVE FRONT FLOOR HEAT INSULATOR NO.1
29. REMOVE PARKING BRAKE CABLE HEAT INSULATOR
30. REMOVE PROPELLER W/CENTER BEARING SHAFT ASSEMBLY
31. REMOVE FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY
32. REMOVE STEERING SLIDING YOKE SUB-ASSEMBLY
a. Check the steering wheel at the center position.
b. Remove the 2 bolts and sliding yoke from the steering intermediate shaft.
33. DISCONNECT POWER STEERING GEAR HOUSING ASSEMBLY
a. Remove the bolt, and disconnect the 2 PS oil tubes from the front frame.
b. Remove the 4 bolts, and disconnect the PS gear housing from the front frame.
c. Suspend the PS gear housing securely.
34. REMOVE ENGINE W/ TRANSMISSION ASSEMBLY
a. Remove the nut and No. 1 V-bank cover bracket from the No. 2 engine hanger.
b. Attach the engine chain hoist to the engine hangers.
c. Remove the 2 hole plugs.
d. Remove the 4 nuts holding the engine mounting insulator to the front suspension crossmember.
e. Remove the 4 bolts, 4 nuts and rear engine mounting member.
f. Lift the engine out of the vehicle slowly and carefully.
HINT: Make sure the engine is clear of all wiring, hoses and cables.
g. Place the engine and transmission assembly onto a stand.
35. DISCONNECT ENGINE WIRE
a. Disconnect the engine wire from the transmission.
1. Disconnect the VSV connector.
2. Disconnect the PNP switch connector.
3. Disconnect the solenoid connector.
4. Disconnect the direct clutch speed sensor connector.
5. Disconnect the engine wire from the 3 wire clamps.
6. Disconnect the oil level sensor connector.
36. REMOVE TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY
37. REMOVE OIL COOLER OUTLET TUBE NO.1
38. REMOVE OIL COOLER INLET TUBE NO.1
39. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY
a. Remove the torque converter clutch bolts.
1. Remove the 2 bolts and flywheel housing under cover.
2. Turn the crankshaft damper bolt to gain access to each bolt.
3. Hold the crankshaft pulley bolt with a wrench, and remove the 6 bolts.
b. Remove the 10 bolts and ground strap.
c. Remove the transmission together with the torque converter clutch from the engine.
40. REMOVE DRIVE PLATE & RING GEAR SUB-ASSEMBLY
a. Remove the 8 bolts, rear spacer, ring gear and front spacer.
41. INSTALL ENGINE STAND
42. REMOVE THROTTLE BODY ASSEMBLY
43. REMOVE INTAKE MANIFOLD ASSEMBLY
a. Disconnect the EVAP VSV connector.
b. Disconnect the EVAP hose from the EVAP VSV.
c. Remove the bolt, and disconnect the EVAP VSV from the upper intake manifold.
d. Remove the bolt and V-bank cover bracket No. 2.
e. Remove the bolt and V-bank cover bracket No. 3.
f. Disconnect the ACIS VSV connector.
g. Remove the bolt and V-bank cover bracket No. 1.
h. Remove the bolt and V-bank cover No. 4.
i. Remove the 4 bolts, and disconnect the engine wire protector (LH side) from the upper intake manifold and camshaft bearing cap.
j. Disconnect the 2 wire clamps on the engine wire (RH side) from the brackets on the RH delivery pipe.
k. Remove the 2 bolts, and disconnect the engine wire protector (rear side) from the rear water by-pass joint and RH cylinder head.
l. Disconnect the 8 injector connectors.
m. Remove the 6 bolts, 4 nuts, intake manifold and 2 gaskets.
44. INSPECT INTAKE MANIFOLD ASSEMBLY
a. Upper intake manifold: Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.
Maximum warpage: 0.15 mm (0.0059 inch)
If the warpage is greater than the maximum, replace the manifold.
b. Lower intake manifold: Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.
Maximum warpage: 0.15 mm (0.0059 inch)
If the warpage is greater than the maximum, replace the manifold.
45. REMOVE STARTER ASSEMBLY
46. REMOVE GENERATOR ASSEMBLY
47. REMOVE TIMING BELT COVER SUB-ASSEMBLY NO.3 LH
a. Remove the cap nut and disconnect the water by-pass pipe No. 3 from the timing belt cover.
b. Disconnect the 2 water by-pass hoses from the water by-pass pipe No. 3.
c. Disconnect the engine wire from the 2 wire clamps.
d. Disconnect the camshaft position sensor connector.
e. Disconnect the camshaft position sensor wire from the wire clamp on the timing belt cover.
f. Remove the wire grommet from the timing belt cover.
g. Remove the 4 bolts.
h. Disconnect the timing belt cover from the timing plate and camshaft bearing cap.
i. Disconnect the wire clamp for the sensor from the timing belt cover.
j. Remove the connector holder from the sensor connector.
k. Remove the timing belt cover.
48. REMOVE TIMING BELT COVER SUB-ASSEMBLY NO.3 RH
a. Disconnect the 2 PS air hoses from the clamp on the timing belt cover No. 3.
b. Remove the cap nut, 3 bolts, timing belt cover No. 3 and gasket.
49. REMOVE WATER INLET HOUSING
a. Remove the 2 bolts and inlet housing.
50. REMOVE FRONT WATER BY-PASS JOINT
a. Disconnect the sensor connector.
b. Remove the 4 nuts, water by-pass joint and 2 gaskets.
51. REMOVE REAR WATER BY-PASS JOINT
a. Disconnect the heater inlet hose from the water by-pass joint.
b. Remove the 4 nuts, water by-pass joint and 2 gaskets.
52. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY
a. Disconnect the heater outlet hose from the water by-pass pipe.
b. Disconnect the wire clamp (for knock sensor 1, 2) from the bracket of the water by-pass pipe.
c. Remove the bolt.
d. Pull out the water by-pass pipe from the water pump.
e. Remove the O-ring from the water by-pass pipe.
53. REMOVE OIL LEVEL GAGE GUIDE
a. Remove the bolt, level gage and O-ring.
54. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (RH BANK)
a. Disconnect the sensor connector.
b. Remove the bolt and oil control valve.
55. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
a. Disconnect the sensor connector.
b. Remove the bolt and oil control valve.
56. REMOVE CAMSHAFT POSITION SENSOR
a. Disconnect the sensor connector.
b. Remove the bolt and sensor.
57. REMOVE VVT SENSOR
a. Disconnect the sensor connector.
b. Remove the bolt and sensor.
58. REMOVE KNOCK SENSOR
a. Disconnect the 2 knock sensor connectors.
b. Remove the 2 knock sensors.
59. REMOVE ENGINE HANGER NO. 1
a. Remove the 2 bolts and engine hanger.
60. REMOVE ENGINE HANGER NO.2
a. Remove the 2 bolts and engine hanger.
61. REMOVE IGNITION COIL ASSEMBLY
a. Remove the bolt and ignition coil.
62. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY
a. Disconnect the oil pressure switch connector.
b. Remove the stud bolt, 2 nuts and oil filter bracket with gasket.
63. REMOVE CRANKSHAFT POSITION SENSOR
a. Disconnect the sensor connector.
b. Remove the bolt and sensor.
64. REMOVE ENGINE OIL LEVEL SENSOR
a. Disconnect the sensor connector.
b. Remove the 4 bolts and sensor and gasket.
65. REMOVE ENGINE WIRE
66. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1
67. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Remove the 8 nuts, exhaust manifold and gasket.
68. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Using a precision straightedge and feeler gauge, mea sure the surface contacting the cylinder head for warpage.
Maximum warpage: 0.50 mm (0.0197 inch)
If the warpage is greater than the maximum, replace the manifold.
69. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2
a. Remove the 4 bolts and heat insulator.
70. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
a. Remove the 8 nuts, exhaust manifold and gasket.
71. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH
a. Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.
Maximum warpage: 0.50 mm (0.0197 inch)
If the warpage is greater than the maximum, replace the manifold.
72. REMOVE WIRING HARNESS HEAT INSULATOR NO.2
73. REMOVE ENGINE MOUNTING BRACKET FRONT NO.1 RH
a. Remove the 4 bolts and mounting bracket.
74. REMOVE ENGINE MOUNTING BRACKET FRONT NO.1 LH
a. Remove the 4 bolts and mounting bracket.
75. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 LH
a. Install the mounting bracket with the 4 bolts
Torque: 36 Nm (370 kgf-cm, 27 ft. lbs.)
HINT: The LH mounting bracket is marked with an L.
76. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 RH
a. Install the mounting bracket with the 4 bolts
Torque: 36 Nm (370 kgf-cm, 27 ft. lbs.)
HINT: The RH mounting bracket is marked with an R.
77. INSTALL WIRING HARNESS HEAT INSULATOR NO.2
78. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH
a. Place a new gasket on the cylinder head with the white mark facing the manifold side.
NOTICE: Be careful of the installation direction.
b. Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)
79. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2
a. Install the heat insulator with the 4 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
80. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Place a new gasket on the cylinder head with the white mark facing the manifold side.
NOTICE: Be careful of the installation direction.
b. Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)
81. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
a. Install the heat insulator with the 4 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
82. INSTALL ENGINE WIRE
83. INSTALL ENGINE OIL LEVEL SENSOR
a. Install the new gasket to the sensor.
b. Install a sensor with the 4 bolts.
c. Connect the sensor connector.
84. INSTALL CRANKSHAFT POSITION SENSOR
85. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY
a. Install a new gasket and the oil filter bracket with the stud bolt and 2 nuts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
b. Connect the oil pressure switch connector.
86. INSTALL IGNITION COIL ASSEMBLY
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
87. INSTALL ENGINE HANGER NO.2
a. Install the engine hanger with the 2 bolts.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)
88. INSTALL ENGINE HANGER NO. 1
a. Install the engine hanger with the 2 bolts.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)
89. INSTALL KNOCK SENSOR
a. Install the 2 knock sensors.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)
b. Connect the 2 knock sensor connectors.
90. INSTALL VVT SENSOR
a. Install the sensor with the bolt.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
91. INSTALL CAMSHAFT POSITION SENSOR
a. Install the sensor with the bolt.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
92. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (RH BANK)
93. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
94. INSTALL OIL LEVEL GAGE GUIDE
a. Install a new O-ring to the guide.
b. Install the guide with the bolt.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
95. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
a. Install a new O-ring to the water by-pass pipe.
b. Apply soapy water to the O-ring.
c. Push in the water by-pass pipe end into the pipe hole of the water pump.
d. Install the water by-pass pipe with the bolt.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
e. Install the wire clamp to the bracket of the water by-pass pipe.
96. INSTALL REAR WATER BY-PASS JOINT
a. Install 2 new gaskets and the water by-pass joint with the 4 nuts. Alternately tighten the nuts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
97. INSTALL FRONT WATER BY-PASS JOINT
a. Install 2 new gaskets and the water by-pass joint with the 4 nuts. Alternately tighten the nuts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
b. Connect the sensor connector.
98. INSTALL WATER INLET HOUSING
a. Install a new O-ring to the inlet housing.
b. Apply soapy water on the O-ring.
c. Apply seal packing to the sealing groove of inlet housing as shown in the illustration.
Seal packing: Part No. 08826-00100 or equivalent
Seal width: 2 to 3 mm (0.08 to 0.12 inch)
NOTICE:
^ Remove any oil from the contact surface.
^ Install the crankcase within 3 minutes after applying seal packing.
^ Do not start the engine for at least 2 hours after installing.
d. Install the water inlet and housing assembly with the 2 bolts. Alternately tighten the bolts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
99. INSTALL TIMING BELT COVER SUB-ASSEMBLY NO.3 RH
a. Install the gasket to the timing belt cover.
b. Install the timing belt cover with the cap nut and 3 bolts.
c. Connect the 2 PS air hoses to the clamp on the timing belt cover.
100. INSTALL GENERATOR ASSEMBLY
101. INSTALL STARTER ASSEMBLY
102. INSTALL TIMING BELT COVER SUB-ASSEMBLY NO.3 LH
a. Install the gasket to the timing belt cover.
b. Run the camshaft position sensor wire through the timing belt cover hole.
c. Install the timing belt cover with the 4 bolts.
d. Install the wire grommet to the timing belt cover.
e. Install the sensor connector to the sensor holder.
f. Connect the sensor connector.
g. Install the sensor wire to the wire clamp on the timing belt cover.
h. Install the engine wire to the 2 wire clamps on the timing belt cover.
i. Connect the 2 water by-pass hoses to the water by-pass pipe No. 3.
j. Install the No. 3 water by-pass pipe to the timing belt cover No. 3 LH with the cap nut.
103. INSTALL INTAKE MANIFOLD ASSEMBLY
a. Place 2 new gaskets on the cylinder heads with the white mark facing outward.
NOTICE: Be careful of the installation direction.
b. Install the intake manifold assembly with the 6 bolts and 4 nuts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
c. Connect the 8 injector connectors.
d. Install the engine wire protector (rear side) with the 2 bolts.
e. Install the engine wire protector (LH side) with the 4 bolts. Install the 2 wire clamps on the engine wire (RH side) to the brackets on the RH delivery pipe.
g. Install the V-bank cover No. 4 with the bolt.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
h. Install the V-bank cover bracket No. 1 with the bolt.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
i. Connect the VSV connector for ACIS.
j. Install the V-bank cover bracket No. 3 with the bolt.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
k. Install the V-bank cover bracket No. 2 with the bolt.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
l. Install the EVAP VSV to the intake manifold with the bolt.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
m. Connect the EVAP hose to the EVAP VSV.
n. Connect the EVAP VSV connector.
104. INSTALL THROTTLE BODY ASSEMBLY
105. REMOVE ENGINE STAND
106. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY
HINT:
^ The mounting bolts are tightened in 2 progressive steps (steps (c) and (e)).
^ If any one of the mounting bolts is broken or deformed, place it.
a. Apply adhesive to 2 or 3 threads of the mounting bolt end.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
b. Install the front spacer, drive plate and rear spacer on the crankshaft.
c. Install and uniformly tighten the 8 mounting bolts in several passes, in the sequence shown.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
If any of the mounting bolts cannot meet the torque specification, replace the mounting bolt.
d. Mark the mounting bolt with paint.
e. Retighten the mounting bolt by 90° in the numerical order shown.
f. Check that the painted mark is now at a 90° angle to step (e)
107. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
a. Check the torque converter clutch installation.
b. Attach the transmission to the engine.
c. Install the ground strap and 10 bolts
Torque:
72 Nm (734 kgf-cm, 53 ft. lbs.) for 17 mm head bolt A
37 Nm (377 kgf-cm, 27 ft. lbs.) for 14 mm head bolt B
d. Install the torque converter clutch bolts.
1. Apply adhesive to 2 or 3 threads of the bolt end.
Adhesive: Part No.08833-00070, THREE BOND 1324 or equivalent
2. Hold the crankshaft pulley bolt with a wrench, and install the 6 bolt evenly.
Torque: 48 Nm (489 kgf-cm, 35 ft. lbs.)
HINT: First install the black colored bolt, and then install the other bolt.
3. Install the flywheel housing under cover with the 2 bolts.
Torque 18 Nm (184 kgf-cm, 13 ft. lbs.)
108. INSTALL OIL COOLER INLET TUBE NO.1
109. INSTALL OIL COOLER OUTLET TUBE NO.1
110. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSEMBLY
111. CONNECT ENGINE WIRE
a. Connect the engine wire to the transmission.
1. Connect the VSV connector.
2. Connect the PNP switch connector.
3. Connect the solenoid connector.
4. Connect the direct clutch speed sensor connector.
5. Connect the engine wire from the 3 wire clamps.
6. Connect the oil level sensor connector.
112. INSTALL ENGINE W/ TRANSMISSION ASSEMBLY
a. Attach the engine chain hoist to the engine hangers.
b. Slowly lower the engine and transmission assembly into the engine compartment.
c. Insert the stud bolts of the front engine mounting brackets into the stud bolt holes of the front suspension crossmember.
d. Keep the engine level.
e. Install the rear engine mounting member with the 4 bolts and 4 nuts.
Torque:
25.5 Nm (260 kgf-cm, 19 ft. lbs.) for bolts
13.5 Nm (137 kgf-cm, 10 ft. lbs.) for nuts
NOTICE: Be careful of installation direction.
f. Install the 4 nuts holding the engine mounting brackets to the front suspension crossmember.
Torque: 68 Nm (693 kgf-cm, 50 ft. lbs.)
g. Install the 2 hole plugs.
h. Remove the engine chain hoist.
i. Install the V-bank cover bracket No.1 to the engine hanger No. 2 with the nut.
113. INSTALL POWER STEERING GEAR HOUSING ASSEMBLY
a. Connect the sliding yoke to the PS gear housing and intermediate shaft.
b. Install the PS gear housing with the 4 bolts.
Torque: 65 Nm (662 kgf-cm, 48 ft. lbs.)
c. Install the 2 PS oil tube with the bolt.
114. INSTALL STEERING SLIDING YOKE SUB-ASSEMBLY
a. Tighten the 2 bolts for sliding yoke.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)
115. INSTALL FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY
116. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSEMBLY
117. INSTALL PARKING BRAKE CABLE HEAT INSULATOR
118. INSTALL FRONT FLOOR HEAT INSULATOR NO.1
119. INSTALL W/CATALYST CONVERTER ASSEMBLY
120. INSTALL FRONT SUSPENSION MEMBER BRACE SUB-ASSEMBLY RH
Torque: 58 Nm (591 kgf-cm, 43 ft. lbs.) for nuts
121. INSTALL EXHAUST PIPE ASSEMBLY
122. INSTALL FRONT FLOOR BRACE CENTER
123. INSTALL COOLER COMPRESSOR ASSEMBLY
a. Install the cooler compressor, stay and wire bracket with the 3 bolts and nut.
Torque:
49 Nm (500 kgf-cm, 36 ft. lbs.) for bolts
29 Nm (296 kgf-cm, 21 ft. lbs.) for nut
b. Connect the compressor connector.
c. Install the wire clamp.
124. INSTALL VANE PUMP ASSEMBLY
a. Install the vane pump with the 2 bolts and nut. Alternately tighten the bolts and nut.
Torque:
39.2 Nm (400 kgf-cm, 29 ft. lbs.) for bolts
43.1 Nm (439 kgf-cm, 32 ft. lbs.) for nut
b. Connect the PS oil pressure switch connector.
c. Install the RH engine under cover with the 2 screws.
d. Connect the 2 PS air hoses to the vane pump.
125. INSTALL VANE PUMP OIL RESERVOIR ASSEMBLY
126. CONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
127. CONNECT HEATER WATER INLET HOSE A
128. CONNECT FUEL VAPOR FEED HOSE NO.2
129. CONNECT AIR HOSE NO.5
130. CONNECT ENGINE WIRE
a. Connect the engine wire from the ECM box.
b. Install the nut, and connect the generator wire to the generator.
c. Connect the wire for generator wire to the wire clamp on generator.
d. Connect the ground cable to the stay on generator with the bolt.
e. Connect the PS oil hose to the No. 1 oil pan with the 2 bolts.
f. Connect the ground strap to the body with the 2 bolts.
131. INSTALL FAN AND GENERATOR V BELT
132. CONNECT FUEL PIPE SUB-ASSEMBLY NO.2
133. INSTALL RADIATOR ASSEMBLY
134. INSTALL ENGINE UNDER COVER NO.2
135. INSTALL ENGINE UNDER COVER
136. INSTALL AIR CLEANER ASSEMBLY
137. INSTALL INTAKE AIR CONNECTOR PIPE
138. INSTALL AIR CLEANER INLET NO.1
139. INSTALL V-BANK COVER
140. INSTALL HOOD SUB-ASSEMBLY
141. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
142. PERFORM INITIALIZATION
NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal. and Initialization
143. ADD AUTOMATIC TRANSMISSION FLUID
144. ADD ENGINE COOLANT
145. ADD ENGINE OIL
146. CHECK FOR ENGINE COOLANT LEAKS
147. CHECK FOR FUEL LEAKS
148. INSPECT AUTOMATIC TRANSMISSION FLUID
149. CHECK FOR ENGINE OIL LEAKS
150. DRIVING TEST
151. ADJUST ENGINE