Part 3
PARTIAL ENGINE ASSEMBLYREPLACEMENT
101. INSTALL GENERATOR ASSEMBLY
102. INSTALL STARTER ASSEMBLY
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.
f. 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 fastener with the bolt.
Torque: 7.5 Nm (77 kgf-cm, 66 inch lbs.)
h. Install the V-bank cover bracket No. 1 with the bolt.
Torque: 7.5 Nm (77 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 (77 kgf-cm, 66 inch lbs.)
k. Install the V-bank cover bracket No. 2 with the bolt.
Torque: 7.5 Nm (77 kgf-cm, 66 inch lbs.)
l. Connect the VSV for EVAP to the intake manifold with the bolt.
Torque: 7.5 Nm (77 kgf-cm, 66 inch lbs.)
m. Connect the EVAP hose to the VSV for EVAP.
n. Connect the VSV connector for EVAP.
104. INSTALL THROTTLE BODY ASSEMBLY
105. REMOVE ENGINE STAND 1
06. INSTALL DRIVE PLATE & RING GEAR SUB-ASSEMBLY
HINT: The mounting bolts are tightened in 2 progressive steps (step (c) and (e)). If any one of the mounting bolts is broken or deformed, replace 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 in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
If any one of the mounting bolts does not 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 bolts evenly.
Torque: 48 Nm (490 kgf-cm, 35 ft. lbs.)
HINT: First install the black colored bolt, and then install the other bolts.
3. Install the flywheel housing undercover 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 FILTER 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 bolt
13.5 Nm (138 kgf-cm, 10 ft. lbs.) for nut
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 (663 kgf-cm, 48 ft. lbs.)
c. Install the 2 PS oil tubes with the bolts.
114. INSTALL HEIGHT CONTROL SENSOR LINK SUB-ASSEMBLY FRONT
115. INSTALL PNEUMATIC FRONT RH W/SHOCK ABSORBER CYLINDER ASSEMBLY
116. INSTALL PNEUMATIC FRONT LH W/SHOCK ABSORBER CYLINDER ASSEMBLY
117. INSTALL FRONT SUSPENSION UPPER ARM ASSEMBLY RH
118. INSTALL FRONT SUSPENSION UPPER ARM ASSEMBLY LH
119. INSTALL FRONT DISC BRAKE CYLINDER ASSEMBLY RH
120. INSTALL DISC BRAKE CYLINDER ASSEMBLY LH
121. INSTALL STEERING SLIDING W/ SHAFT YOKE SUB-ASSEMBLY
a. Tighten the 2 bolts for sliding yoke.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)
122. INSTALL FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY
123. INSTALL PROPELLER W/ CENTER BEARING SHAFT ASSEMBLY
124. INSTALL PARKING BRAKE CABLE HEAT INSULATOR
125. INSTALL FRONT FLOOR HEAT INSULATOR NO.1
126. INSTALL W/ CATALYST CONVERTER ASSEMBLY
127. INSTALL EXHAUST PIPE ASSEMBLY
128. INSTALL FRONT FLOOR BRACE CENTER
129. 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 bolt
29 Nm (296 kgf-cm, 21 ft. lbs.) for nut
b. Connect the compressor connector.
c. Install the wire clamp.
130. 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 bolt
43.1 Nm (440 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.
131. INSTALL VANE PUMP OIL RESERVOIR ASSEMBLY
132. CONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)
133. CONNECT HEATER WATER INLET HOSE A
134. CONNECT FUEL VAPOR FEED HOSE NO.2
135. CONNECT AIR HOSE NO.5
136. 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. Connect the ground strap to the body with the 2 bolts.
137. INSTALL FAN AND GENERATOR V BELT
138. CONNECT FUEL PIPE SUB-ASSEMBLY NO.2
139. INSTALL RADIATOR ASSEMBLY
140. INSTALL ENGINE UNDER COVER NO.2
141. INSTALL ENGINE UNDER COVER NO.1
142. INSTALL FRONT WHEEL
143. INSTALL AIR CLEANER ASSEMBLY
144. INSTALL INTAKE AIR CONNECTOR PIPE
145. INSTALL AIR CLEANER INLET NO.1
146. INSTALL V-BANK COVER
147. INSTALL HOOD SUB-ASSEMBLY
148. CONNECT BATTERY NEGATIVE TERMINAL
NOTICE: When disconnecting the negative (-) battery terminal, initialize the following systems after the terminal is reconnected.
149. ADD AUTOMATIC TRANSMISSION FLUID
150. ADD ENGINE COOLANT
151. ADD ENGINE OIL
152. ADD POWER STEERING FLUID
153. BLEED POWER STEERING FLUID
154. INSPECT AUTOMATIC TRANSMISSION FLUID
155. INSPECT ENGINE OIL LEAKS
156. CHECK FOR ENGINE COOLANT LEAKS
157. INSPECT FOR FUEL LEAKS
158. CHECK FOR EXHAUST GAS LEAKS
159. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT
160. INSPECT IGNITION TIMING
161. INSPECT ENGINE IDLE SPEED
162. INSPECT CO/HC
163. ADJUST ENGINE
164. CHECK ABS SPEED SENSOR SIGNAL