Part 1

ENGINE ASSEMBLY

COMPONENTS:

INSTALLATION (STEPS 1-60)

1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
a. Using a 19 mm deep socket wrench, install the temperature sensor.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
2. INSTALL 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. Using a 24 mm deep socket wrench, install the oil pressure switch.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)

NOTICE: Do not start the engine within 1 hour after installation for prevent oil leaks.

3. INSTALL ENGINE OIL LEVEL SENSOR
a. Install the engine oil level sensor and a new gasket with the 4 bolts.
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
4. INSTALL IGNITION COIL ASSEMBLY
a. Install the 6 ignition coils with the 6 bolts.
Toque: 10 Nm (102 kgf-cm, 7 ft. lbs.)

5. INSTALL V-BANK COVER BRACKET SUB ASSEMBLY
a. Install the V-bank cover bracket with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)

6. INSTALL RADIO SETTING CONDENSER
a. Install the 2 bolts and 2 radio setting condensers.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
7. INSTALL KNOCK SENSOR
8. INSTALL FUEL INJECTOR ASSEMBLY
9. INSTALL FUEL PUMP
10. INSTALL INTAKE MANIFOLD

11. INSTALL WATER HOSE JOINT
a. Connect the 2 hoses, and install the bolt and water hose joint.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
12. INSTALL NO. 2 SURGE TANK STAY
a. Install the bolt and No. 2 surge tank stay.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)
13. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

14. INSTALL INJECTOR DRIVER
a. Install the injector driver with the bolt and 2 nuts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
15. INSTALL ENGINE WIRE
a. Install the engine wire to the engine assembly
16. INSTALL WATER PUMP PULLEY
17. INSTALL FRONT DIFFERENTIAL CARRIER ASSEMBLY (for 4WD)

18. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
a. Temporarily install the V-ribbed belt tensioner with the 5 bolts. (2WD)
b. Temporarily install the V-ribbed belt tensioner with the 4 bolts. (4WD)

Each bolt length is as follows:
c. Install the V-ribbed belt tensioner by tightening the bolt 1 and bolt 2 in the order shown in the illustration.
Torque: 43 Nm (439 kgf-cm, 32 ft. lbs.)
d. Tighten the other bolts.
Torque: 43 Nm (439 kgf-cm, 32 ft. lbs.)

19. INSTALL ENGINE MOUNTING BRACKET LH
a. Install the mounting bracket with the 4 bolts.
Torque: 43 Nm (439 kgf-cm, 32 ft. lbs.)
b. Connect the 2 clamps.

20. INSTALL ENGINE MOUNTING BRACKET RH
a. Install the mounting bracket with the 4 bolts.
Torque: 43 Nm (439 kgf-cm, 32 ft. lbs.)
21. INSTALL COOLER COMPRESSOR ASSEMBLY (for 2WD)
22. TEMPORARILY TIGHTEN COOLER COMPRESSOR ASSEMBLY (for 4WD)
23. INSTALL OIL FILTER BRACKET (for 4WD)
24. INSTALL COOLER COMPRESSOR ASSEMBLY (for 4WD)
25. INSTALL GENERATOR ASSEMBLY

26. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
a. Install the plate and idler pulley with the bolt.
Torque: 43 Nm (439 kgf-cm, 32 ft. lbs.)

27. INSTALL NO. 1 ENGINE COVER
a. Install the No. 1 engine cover with the 3 clips.

28. INSTALL NO. 2 ENGINE COVER
a. Install the No. 2 engine cover with the 3 clips.
b. Connect the clamp.
29. INSTALL V-RIBBED BELT
30. INSTALL ENGINE HANGERS
Torque: 33 Nm (336 kgf-cm, 24 ft. lbs.)
31. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)

a. Hold the crankshaft with SST.
SST 09213-70011 (09213-70020), 09330-00021

b. Using several steps, install and tighten 8 new bolts uniformly in the sequence shown in the illustration.
Torque: 73 Nm (741 kgf-cm, 54 ft. lbs.)

NOTICE:
^ Do not reuse the flywheel installation bolts. Be sure to check the tightening torque within 5 minutes after tightening.
^ Do not impact or damage the flywheel installation bolts. Be sure to handle them carefully.
^ Make sure that the seating surface of the flywheel installation bolts and installation surfaces of the crankshaft and flywheel are free of oil or foreign matter.

32. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission)

a. Using SST, hold the crankshaft.
SST 09213-70011 (09213-70020), 09330-00021
b. Apply adhesive to 2 or 3 threads of the mounting bolts ends.
Adhesive: Part No. 08833-00070, THREE BOND 1324 or equivalent
c. Install the front spacer, drive plate and rear spacer on the crankshaft.

d. Install and tighten the 8 mounting bolts uniformly in several steps.
Torque: 83 Nm (846 kgf-cm, 61 ft. lbs.)

NOTICE: Do not start the engine for at least 1 hour after installing.

33. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY (for 2WD)
a. Install the front suspension crossmember sub assembly with the 2 bolts.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)

34. INSTALL FRONT FRAME ASSEMBLY (for 4WD)
a. Install the front frame assembly with the 2 bolts.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)
35. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH (for 4WD)
36. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (for 4WD)
37. INSTALL MANUAL TRANSMISSION ASSEMBLY (for Manual Transmission)
38. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)
39. INSTALL STARTER ASSEMBLY
40. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

a. Install a new gasket as shown in the illustration.

b. Install the exhaust manifold with 6 new nuts.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)

NOTICE:
^ Do not damage the stud bolt when installing the exhaust manifold.
^ Be sure to tighten either of nuts A first as shown in the illustration.

42. INSTALL OIL DIPSTICK GUIDE SUB-ASSEMBLY (for 2WD)
a. Install a new O-ring to the oil dipstick guide.
b. Apply a light coat of engine oil to the O-ring.
c. Push in the oil dipstick guide end into the guide hole.

d. Install the No. 1 oil dipstick guide with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
e. Connect the clamp.

f. Install the No. 2 oil dipstick guide with the bolt.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)
g. Install the oil dipstick.
43. INSTALL OIL DIPSTICK GUIDE SUB-ASSEMBLY (for 4WD)
a. Install a new O-ring to the oil dipstick guide.
b. Apply a light coat of engine oil to the O-ring.
c. Push in the oil dipstick guide end into the guide hole.

d. Install the No. 1 oil dipstick guide with the bolt.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)

e. Install the No. 2 oil dipstick guide with the bolt.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)
f. Install the oil dipstick.
44. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (for 4WD)
45. INSTALL ENGINE AND TRANSMISSION ASSEMBLY (for 2WD)
a. Set the engine lifter.
b. Operate the engine lifter, then install the engine to the vehicle.

c. Install the engine and transmission assembly with crossmember with the 12 bolts.
Torque:
167 Nm (1,700 kgf-cm, 123 ft. lbs.) for Nut
204 Nm (2,080 kgf-cm, 150 ft. lbs.) for bolt A
50 Nm (510 kgf-cm, 37 ft. lbs.) for bolt B
49 Nm (500 kgf-cm, 36 ft. lbs.) for bolt C

d. Install the engine rear mounting member with the 4 bolts.
Torque: 26 Nm (265 kgf-cm, 19 ft. lbs.)
46. INSTALL ENGINE AND TRANSMISSION ASSEMBLY (for 4WD)
a. Set the engine lifter.
b. Operate the engine lifter, then install the engine to the vehicle.

c. Install the engine and transmission assembly with crossmember with the 6 bolts.
Torque:
167 Nm (1,700 kgf-cm, 123 ft. lbs.) for bolt A
165 Nm (1,680 kgf-cm, 122 ft. lbs.) for bolt B
50 Nm (510 kgf-cm, 37 ft. lbs.) for bolt C

d. Install the engine rear mounting member with the 4 bolts.
Torque: 26 Nm (265 kgf-cm, 19 ft. lbs.)
47. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for 2WD)
48. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY (for 4WD)

49. CONNECT POWER STEERING LINK WIRE HARNESS (for 2WD)
a. Install the power steering earth wire to the power steering link assembly with bolt (B).
Torque: 13 Nm (130 kgf-cm, 10 ft. lbs.)
b. Connect the wire harness connector (E) to the power steering link assembly and securely lock the connector.
c. Connect the 2 wire harness connectors (C) and (D) to the power steering link assembly.
d. Install the 2 wire harness clamps to the power steering link assembly.
e. Connect the earth wire to the bracket with bolt (A).
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)

50. CONNECT POWER STEERING LINK WIRE HARNESS (for 4WD)
a. Install the power steering earth wire to the power steering link assembly with bolt (A).
Torque: 5.0 Nm (51 kgf-cm, 44 inch lbs.)
b. Connect the wire harness connector (E) to the power steering link assembly and securely lock the connector.
c. Connect the 2 wire harness connectors (C) and (D) to the power steering link assembly
d. Install the 2 wire harness clamps to the front frame.
e. Connect the earth wire to the bracket with bolt (B).
Torque: 13 Nm (130 kgf-cm, 10 ft. lbs.)
f. Install the bolt (F) to connect the bracket to the front frame.
Torque: 13 Nm (130 kgf-cm, 10 ft. lbs.)
51. INSTALL FRONT AXLE ASSEMBLY LH (for 4WD)
52. INSTALL FRONT AXLE ASSEMBLY RH (for 4WD)

HINT: Install the RH side following the same procedures as for the LH side.

53. INSTALL FRONT LOWER BALL JOINT ASSEMBLY LH (for 4WD)
a. Install the front lower ball joint with the 2 bolts.
Torque: 120 Nm (1,224 kgf-cm, 89 ft. lbs.)
54. INSTALL FRONT LOWER BALL JOINT ASSEMBLY RH (for 2WD)

HINT: Install the RH side following the same procedures as for the LH side.

55. INSTALL FRONT LOWER BALL JOINT ASSEMBLY LH (for 4WD)
a. Install the front lower ball joint with the 2 bolts.
Torque: 120 Nm (1,224 kgf-cm, 89 ft. lbs.)
56. INSTALL FRONT LOWER BALL JOINT ASSEMBLY RH (for 4WD)

HINT: Install the RH side following the same procedures as for the LH side.

57. INSTALL FRONT SHOCK ABSORBER ASSEMBLY LH (for 2WD)
a. Install the bolt on the lower side of the front shock absorber while holding the nut.
Torque: 157 Nm (1,600 kgf-cm, 116 ft. lbs.)
58. INSTALL FRONT SHOCK ABSORBER ASSEMBLY RH (for 2WD)

HINT: Install the RH side following the same procedures as for the LH side.

59. INSTALL FRONT SHOCK ABSORBER ASSEMBLY LH (for 4WD)
a. Install the bolt on the lower side of the front absorber bracket lower.
Torque: 48 Nm (489 kgf-cm, 35 ft. lbs.)
60. INSTALL FRONT SHOCK ABSORBER ASSEMBLY RH (for 4WD)

HINT: Install the RH side following the same procedures as for the LH side.