Part 2
REPLACEMENT51. REMOVE ENGINE OIL PRESSURE SWITCH ASSY
a. Using SST, remove the oil pressure switch.
SST 09268-46021
52. REPLACE PARTIAL ENGINE ASSY
53. INSTALL ENGINE OIL PRESSURE SWITCH ASSY
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 SST, install the oil pressure switch.
SST 09268-60210
Torque: 15 Nm (150 kgf-cm, 11 ft. lbs.)
NOTICE: Do no not start the engine within 1 hour of installation.
54. INSTALL KNOCK SENSOR
a. Using SST, install the knock sensor.
SST 09816-30010
Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.)
55. INSTALL ENGINE COOLANT TEMPERATURE SENSOR
a. Install a new gasket to the water temperature sensor.
b. Using SST, fix the water temperature sensor.
SST 09817-33190
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
56. INSTALL WATER BY-PASS PIPE NO.1
a. Install a new gasket and the water by-pass pipe with the 2 bolts and 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
57. INSTALL IGNITION COIL NO.1
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
58. INSTALL EXHAUST MANIFOLD
a. Using several steps, install a new exhaust manifold gasket and exhaust manifold with the 3 bolts and 2 nuts in the sequence shown in the illustration.
Torque: 27 Nm (275 kgf-cm, 20 ft. lbs.)
59. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
a. Install the exhaust manifold heat insulator No 1 with the 4 bolts
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
60. INSTALL MANIFOLD SUPPORT BRACKET
a. Install the manifold support bracket with the 3 bolts.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)
61. INSTALL BOOSTER VACUUM TUBE
a. Install the booster vacuum tube with the 2 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
62. INSTALL INTAKE MANIFOLD
a. Install a new gasket to the intake manifold.
b. Install the intake manifold with the 3 bolts and 2 nuts. Using several steps, tighten the bolts and nuts uniformly in the sequence shown in the illustration.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
63. INSTALL DRIVE PLATE AND RING GEAR OR FLYWHEEL
SST 09213-58012 (91111-50845), 09330-00021
64. INSTALL CLUTCH DISC ASSY (M/T TRANSAXLE)
65. INSTALL CLUTCH COVER ASSY (M/T TRANSAXLE)
66. INSTALL MANUAL TRANSAXLE ASSY (M/T TRANSAXLE)
67. INSTALL AUTOMATIC TRANSAXLE ASSY (A/T TRANSAXLE)
68. INSTALL GENERATOR ASSY
69. INSTALL STARTER ASSY
70. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSY
a. Fasten the bolt to secure the engine and transaxle assembly to the suspension crossmember.
Torque: 64 Nm (653 kgf-cm, 47 ft. lbs.)
71. INSTALL VANE PUMP ASSY
a. Install the vane pump assembly with the 2 bolts.
Torque: 44 Nm (449 kgf-cm, 33 ft. lbs.)
HINT: After adjusting the V-ribbed belt, tighten bolt A.
72. INSTALL VANE PUMP V-BELT
a. Temporarily install the V-ribbed belt on each pulley.
73. ADJUST VANE PUMP V-BELT
74. INSTALL ENGINE ASSEMBLY WITH TRANSAXLE
a. Set the engine with the transaxle on the engine lifter.
b. Install the engine with the transaxle to the engine compartment.
c. Temporarily install the suspension crossmember with the 8 bolts.
d. Install the engine mounting bracket LH to the engine mounting insulator LH with the 2 bolts.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
e. Install the engine mounting insulator RH with the 5 bolts and nut.
Torque:
Bolt A 45 Nm (459 kgf-cm, 33 ft. lbs.)
Bolt B 52 Nm (530 kgf-cm, 38 ft. lbs.)
Nut 52 Nm (530 kgf-cm, 38 ft. lbs.)
f. Install the liquid tube with the bolt.
Torque:
Bolt C 9.8 Nm (100 kgf-cm, 7.2 ft. lbs.)
g. Insert SST to the positioning holes on the right-hand crossmember and on the right-hand of the vehicle.
SST 09670-00010
h. Temporarily tighten bolt A, then tighten bolt B.
i. Insert SST to the positioning holes on the left-hand crossmember and on the left-hand of the vehicle.
SST 09670-00010
j. Temporarily tighten bolt A, then tighten bolt B.
k. Insert SST to the positioning holes on the right-hand crossmember and the right-hand of the vehicle, then tighten the bolts to the specified torque.
SST 09670-00010
Torque:
Bolt A 116 Nm (1,183 kgf-cm, 86 ft. lbs.)
Bolt B 70 Nm (714 kgf-cm, 52 ft. lbs.)
l. Insert SST to the positioning holes on the left-hand crossmember and the left-hand of the vehicle, then tighten the bolts to the specified torque.
SST 09670-00010
Torque:
Bolt A 116 Nm (1,183 kgf-cm, 86 ft. lbs.)
Bolt B 70 Nm (714 kgf-cm, 52 ft. lbs.)
m. Tighten the 4 bolts, shown in the illustration.
Torque: 47 Nm (479 kgf-cm, 35 ft. lbs.)
75. INSTALL FRONT SUSPENSION ARM SUB-ASSY LOWER NO.1 LH
a. Install the front suspension arm lower to the steering knuckle with the nut.
Torque: 98 Nm (999 kgf-cm, 72 ft. lbs.)
b. Install a new clip.
HINT: Perform the same procedure as above on the opposite side.
76. INSTALL TIE ROD END SUB-ASSY LH
a. Connect the tie rod end to the steering knuckle with the nut.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
b. Install a new cotter pin.
NOTICE:
^ Be careful of the threads and taper portions of the tie rod end to prevent contact with oils.
^ After tightening the castle nut, turn it clockwise within 60° to align the pin holes for the cotter pin.
HINT: Perform the same procedure as above on the opposite side.
77. CONNECT SPEED SENSOR FRONT LH (W/ ABS)
a. Install the speed sensor with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
HINT: Perform the same procedure as above on the opposite side.
78. INSTALL FRONT AXLE HUB LH NUT
a. Using a 30 mm socket wrench, install the new hub nut.
Torque: 216 Nm (2,203 kgf-cm, 160 ft. lbs.)
b. Using a chisel, stake the hub nut.
HINT: Perform the same procedure as above on the opposite side.
79. INSTALL STEERING INTERMEDIATE SHAFT ASSY
80. INSTALL EXHAUST PIPE ASSY FRONT
81. INSTALL FLOOR PANEL BRACE FRONT
82. INSTALL A/C COMPRESSOR
83. INSTALL FAN AND GENERATOR V-BELT
a. Temporarily install the V-ribbed belt on each pulley.
84. ADJUST FAN AND GENERATOR V-BELT
85. INSTALL RADIATOR ASSY
86. CONNECT FUEL TUBE SUB-ASSY
87. INSTALL AIR CLEANER ASSY
88. INSTALL CYLINDER HEAD COVER NO.2
a. First tighten nut A, then tighten bolt B.
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
89. ADD ENGINE OIL
90. ADD ENGINE COOLANT
91. CHECK FOR ENGINE OIL LEAKS
92. CHECK FOR ENGINE COOLANT LEAKS
93. CHECK FOR FUEL LEAKS
94. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
95. CHECK IDLE SPEED AND IGNITION TIMING
96. INSPECT CO/HC
97. CHECK ABS SPEED SENSOR SIGNAL (W/ ABS)
Refer to Antilock Brakes / Traction Control Systems; Testing and Inspection.