Part 1

ENGINE ASSEMBLY

COMPONENTS:

INSTALLATION (STEPS 1-45)

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.
Torque: 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. REMOVE 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 FUEL TUBE SUB-ASSEMBLY
a. Install the 2 bolts and fuel tube sub-assembly
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
11. INSTALL INTAKE MANIFOLD

12. 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.)
13. 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.)
14. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

15. INSTALL INJECTOR DRIVER
a. Install the injector driver with the bolt and 2 nuts.
Torque: 10 Nm (102 kgf-cm, 7 ft. lbs.)
16. INSTALL ENGINE WIRE
17. INSTALL WATER PUMP PULLEY

18. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
a. Temporarily install the V-ribbed belt tensioner with the 5 bolts.

Bolt Lengths:

b. 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.)
c. 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
22. INSTALL GENERATOR ASSEMBLY

23. 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.)

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

25. INSTALL NO. 2 ENGINE COVER
a. Install the No. 2 engine cover with the 3 clips.
b. Connect the clamp.
26. INSTALL V-RIBBED BELT
27. INSTALL ENGINE HANGERS
Torque: 33 Nm (336 kgf-cm, 24 ft. lbs.)
28. INSTALL DRIVE PLATE AND RING GEAR SUB ASSEMBLY

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.

29. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
a. Install the front suspension crossmember sub assembly with the 2 bolts.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)
30. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
31. INSTALL STARTER ASSEMBLY
32. 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.

34. INSTALL OIL DIPSTICK GUIDE SUB-ASSEMBLY
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.
35. INSTALL ENGINE AND TRANSMISSION ASSEMBLY
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.)
36. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY

37. CONNECT POWER STEERING LINK WIRE HARNESS
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.)

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

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

40. INSTALL FRONT SHOCK ABSORBER ASSEMBLY LH
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.)
41. INSTALL FRONT SHOCK ABSORBER ASSEMBLY RH

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

42. CONNECT HEIGHT CONTROL SENSOR LINK
a. Connect the height control sensor link and install it with the nut.
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
43. CONNECT STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY

44. INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR
a. Install the protector with the 4 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
45. CONNECT FUEL TUBE SUB-ASSEMBLY

a. Connect the connector to the fuel main pipe. Push the two parts together firmly until a click sound is heard. Then attach the lock claws to the connector by pushing down on the connector cover.

HINT:
^ Before installing the fuel main tube's connector to the fuel main pipe, check the connector for damage and foreign matter.
^ Check that the connector and fuel main pipe are securely connected by trying to pull them apart.

b. Install the fuel pipe clamp.