ENGINE ASSEMBLY INSTALLATION


  1. INSTALL E.F.I. ENGINE COOLANT TEMPERATURE SENSOR

    Note

    Do not use parts that have been dropped or received strong impact.


    1. A013793E01

      Using SST, install a gasket and the E.F.I. engine coolant temperature sensor.

      SST
      09817-33190
      Torque:
      19.6 N*m  { 200 kgf*cm, 14 ft.*lbf }

    2. Connect the water temperature sensor connector.

  2. INSTALL CAMSHAFT POSITION SENSOR

    Note


    • A0138M3

      Do not use parts that have been dropped or received strong impact.

    • Make sure that the O-ring is not damaged before installing it.


    1. Apply a light coat of engine oil to the O-ring.

    2. Install the camshaft position sensor with the bolt.

      Torque:
      7.5 N*m  { 77 kgf*cm, 66 in.*lbf }

    3. Connect the camshaft position sensor connector.

  3. INSTALL KNOCK CONTROL SENSOR


    1. A013670E01

      Install the knock control sensor with the bolt.

      Tech Tips

      Be sure to tilt the knock control sensor by 0 to 45 degrees as shown in the illustration.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    2. Connect the knock control sensor connector.

  4. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY


    1. A013746

      Install the engine oil pressure switch.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

      Note

      Use a wrench with a fulcrum length of 345 mm (13.58 in.)

      Tech Tips

      If a wrench with a fulcrum length of 345 mm (13.58 in.) is used, the torque should be 8.5 N*m (87 kgf*cm, 75 in.*lbf). If not, the torque needs to be calculated based on 15 N*m (153 kgf*cm, 11 ft.*lbf) tightening torque for the oil pressure switch assembly.

    2. Connect the engine oil pressure switch connector.

  5. INSTALL OIL CONTROL VALVE FILTER


    1. A01369E

      Install the oil control valve filter to the straight screw w/ head plug.

    2. Using a hexagon wrench, install a new gasket and the oil control valve filter.

      Torque:
      24.5 N*m  { 250 kgf*cm, 18 ft.*lbf }

  6. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

    Note

    Make sure that the O-ring is not damaged before installing it.


    1. A01379D

      Apply a light coat of engine oil to the O-ring.

    2. Install the camshaft timing oil control valve assembly with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    3. Connect the camshaft timing oil control valve assembly connector.

  7. INSTALL CRANKSHAFT POSITION SENSOR

    Note


    • A0137QZ

      Do not use parts that have been dropped or received strong impact.

    • Make sure that the O-ring is not damaged before installing it.


    1. Apply a light coat of engine oil to the O-ring.

    2. Install the crankshaft position sensor with the bolt.

      Torque:
      7.5 N*m  { 77 kgf*cm, 66 in.*lbf }

    3. Connect the crankshaft position sensor connector.

  8. INSTALL THERMOSTAT

    Note

    Do not use the dropped water inlet.

    A013717

    1. Install the thermostat gasket to the thermostat.

    2. Install the thermostat with the jiggle valve upward.

      Note

      Make sure that the jiggle valve is aligned with the top protrusion of the water inlet.

    3. Install the water inlet with the 2 bolts.

      Torque:
      7 N*m  { 71 kgf*cm, 62 in.*lbf }

      Note

      Make sure that the thermostat gasket does not get caught between the parts after installing the water inlet.

  9. INSTALL INTAKE MANIFOLD


    1. A0138RJE01

      Install the intake manifold gasket to the intake manifold.

    2. Install the intake manifold with the 4 bolts and 2 nuts.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

      Note

      Tighten the bolts and nuts in the order shown in the illustration.

  10. INSTALL VACUUM SENSOR


    1. A01383I

      Install the vacuum sensor with the 2 bolts.

      Torque:
      5 N*m  { 51 kgf*cm, 44 in.*lbf }

    2. Connect the vacuum sensor connector.

  11. INSTALL FUEL INJECTOR


    1. Install the fuel injector Click here.

  12. INSTALL FUEL DELIVERY PIPE


    1. Install the fuel delivery pipe Click here.

  13. INSTALL THROTTLE BODY ASSEMBLY


    1. A0137AM

      Install the throttle body gasket to the intake manifold.

    2. Install the throttle body assembly with the 3 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      Note

      Do not bend the throttle body gasket while installing the throttle body assembly.

    3. Connect the throttle body assembly connector.

  14. INSTALL OIL LEVEL GAUGE GUIDE SUPPORT


    1. A0136CW

      Install the oil level gauge guide support.

      Seal packing
      Part No. 08833-00070 or equivalent

      Note

      Apply seal packing inside the cylinder block.

  15. INSTALL OIL LEVEL GAUGE GUIDE


    1. A0138AI

      Install a new O-ring to the oil level gauge guide.

    2. A0137FF

      Apply a light coat of engine oil to the O-ring.

    3. Install the oil level gauge guide with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    4. Connect the 2 clamps to the oil level gauge guide.

  16. INSTALL OIL LEVEL GAUGE SUB-ASSEMBLY

  17. INSTALL WATER BY-PASS PIPE NO.1


    1. A0137IA

      Install a new water by-pass pipe gasket and water by-pass pipe No.1 with the 2 nuts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

      Note

      Be sure to install the gasket in the direction shown in the illustration.

    2. A013907

      Install the water by-pass hose to the water by-pass pipe with the clip.

      Note


      • Be sure to install the clip as shown in the illustration.

      • Be sure to insert the water by-pass hose to the stay edge of the water by-pass pipe.

    3. Install the water by-pass pipe with the bolt.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  18. INSTALL COMPRESSOR MOUNTING BRACKET NO.1 (W/ AIR CONDITIONER)


    1. A0137BB

      Install the compressor mounting bracket with the 2 bolts.

      Torque:
      24.5 N*m  { 250 kgf*cm, 18 ft.*lbf }

  19. INSTALL EXHAUST MANIFOLD


    1. A0137U7E01

      Install the exhaust manifold gasket.

    2. Install the exhaust manifold with the 3 bolts and 2 nuts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

      Note

      Tighten the bolts and nuts in the order shown in the illustration.

  20. INSTALL FAN BELT ADJUSTING BAR


    1. Install the fan belt adjusting bar Click here.

  21. INSTALL GENERATOR ASSEMBLY


    1. Install the generator assembly Click here.

  22. INSTALL SPARK PLUG


    1. A01360A

      Install the 3 spark plugs.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Note

      Do not use parts that have been dropped or received strong impact.

  23. INSTALL IGNITION COIL NO.1


    1. A0138SF

      Install the 3 ignition coils with the 3 bolts.

      Torque:
      8.9 N*m  { 91 kgf*cm, 79 in.*lbf }

    2. Connect the 3 connectors.

  24. INSTALL FLYWHEEL SUB-ASSEMBLY


    1. A0137XIE01

      Using SST, hold the crankshaft.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )

    2. Clean the bolts and their holes.

    3. A0137IY

      Apply adhesive to the 2 or 3 threads of the bolt end.

      Adhesive
      Part No. 08833-00070, THREE BOND 1324 or equivalent
    4. A0138G0E01

      Install the flywheel sub-assembly with the 6 bolts.

      Torque:
      78 N*m  { 796 kgf*cm, 58 ft.*lbf }

      Note

      Tighten the bolts in the order shown in the illustration.

  25. INSTALL CLUTCH DISC ASSEMBLY

    SST
    09301-00210

    1. Install the clutch disc assembly Click here.

  26. INSTALL CLUTCH COVER ASSEMBLY

    SST
    09301-00210

    1. Install the clutch cover assembly Click here.

  27. INSTALL MANUAL TRANSAXLE ASSEMBLY


    1. Install the manual transaxle assembly Click here.

  28. INSTALL STARTER ASSEMBLY


    1. Install the starter assembly Click here, Click here.

  29. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. A01389H

      Install the engine and transaxle assembly to the crossmember sub-assembly and the engine mounting member with the bolt.

      Torque:
      120 N*m  { 1,224 kgf*cm, 89 ft.*lbf }

  30. INSTALL ENGINE ASSEMBLY W/ TRANSAXLE


    1. A0136Z3

      Set the engine lifter.

    2. Remove the chain block from the engine assembly with transaxle.

    3. Remove the 2 engine hangers and 2 bolts.

    4. Install the engine assembly with transaxle.

    5. A01388ME02

      Tighten the 6 bolts.

      Torque:
      85 N*m  { 867 kgf*cm, 63 ft.*lbf, for A }
      128 N*m  { 1,306 kgf*cm, 95 ft.*lbf, for B }
      48 N*m  { 490 kgf*cm, 35 ft.*lbf, for C }
    6. A0138HJ

      Install the engine mounting insulator LH with the 3 bolts.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }
    7. A01371N

      Tighten the 4 bolts.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }
    8. A0138YS

      Install the engine mounting insulator RH with the nut.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }
    9. A0137YC

      Tighten the 4 bolts.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

    10. Remove the engine lifter.

  31. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH

    SST
    09930-00010

    1. Install the front drive shaft assembly RH Click here.

  32. INSTALL FRONT DRIVE SHAFT ASSEMBLY LH

    SST
    09930-00010

    1. Install the front drive shaft assembly LH Click here.

  33. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER RH


    1. Install the front suspension arm sub-assembly lower RH Click here.

  34. INSTALL FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER LH


    1. Install the front suspension arm sub-assembly lower LH Click here.

  35. INSTALL TIE ROD END SUB-ASSEMBLY RH


    1. Install the tie rod end sub-assembly RH Click here.

  36. INSTALL TIE ROD END SUB-ASSEMBLY LH


    1. Install the tie rod end sub-assembly LH Click here.

  37. INSTALL FRONT AXLE HUB NUT RH


    1. Install the front axle hub nut RH Click here.

  38. INSTALL FRONT AXLE HUB NUT LH


    1. Install the front axle hub nut LH Click here.

  39. INSTALL FRONT WHEELS

  40. INSTALL STEERING INTERMEDIATE SHAFT ASSEMBLY NO.2


    1. Install the steering intermediate shaft assembly No.2 Click here.

  41. INSTALL STEERING COLUMN HOLE COVER PLATE


    1. Install the steering column hole cover plate Click here.

  42. INSTALL CLUTCH RELEASE CABLE ASSEMBLY


    1. Install the clutch release cable assembly Click here.

  43. ADJUST CLUTCH RELEASE CABLE ASSEMBLY


    1. Adjust the clutch release cable assembly Click here.

  44. INSTALL TRANSAXLE CONTROL CABLE ASSEMBLY


    1. Install the transaxle control cable assembly Click here.

  45. CONNECT FUEL TUBE SUB-ASSEMBLY


    1. A0135WC

      Align the connector with the pipe, then push in the connector to the pipe until it makes a click sound to connect the fuel tube sub-assembly to the fuel delivery pipe.

    2. A0137VV

      Install the fuel pipe clamp.

  46. CONNECT HEATER WATER OUTLET HOSE A (FROM HEATER UNIT)


    1. A01372J

      Using pliers, grip the claws of the clip and slide the clip to connect the heater water outlet hose A (from heater unit).

  47. CONNECT HEATER WATER HOSE INLET A

    Tech Tips

    Connection procedure for the heater water inlet hose A is the same as for the heater water outlet hose A.

  48. CONNECT VACUUM HOSE ASSEMBLY


    1. A0138M8

      Align the connector with the pipe, then push in the connector to the pipe until it makes a click sound to connect the vacuum hose to the intake manifold.

  49. INSTALL W/ PULLEY COMPRESSOR ASSEMBLY (W/ AIR CONDITIONER)


    1. Install the w/ pulley compressor assembly Click here.

  50. INSTALL W/ MOTOR FAN ASSEMBLY


    1. Install the w/ motor fan assembly Click here.

  51. INSTALL RADIATOR ASSEMBLY


    1. Install the radiator assembly Click here.

  52. INSTALL FRONT CROSS MEMBER SUB-ASSEMBLY


    1. Install the front cross member sub-assembly Click here.

  53. INSTALL RADIATOR HOSE OUTLET

  54. INSTALL RADIATOR HOSE INLET

  55. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    1. Install the front exhaust pipe assembly Click here.

  56. INSTALL FAN & GENERATOR V BELT


    1. Install the fan and generator V belt Click here.

  57. INSTALL FRONT BUMPER COVER


    1. Install the front bumper cover Click here.

  58. INSTALL FUEL VAPOR FEED HOSE NO.1 AND NO.2


    1. A0137U4

      Connect the VSV connector.

    2. Connect the fuel vapor feed hoses No.1 and No.2.

  59. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. A0138BV

      Connect the throttle control cable to the throttle body.

      Torque:
      13 N*m  { 133 kgf*cm, 9.6 ft.*lbf }
    2. A013637

      Install the air cleaner filter element to the air cleaner case.

    3. Install the air cleaner cap sub-assembly.

    4. Tighten the hose clamp bolt.

    5. Engage the air cleaner cap sub-assembly clamp.

  60. CONNECT ENGINE WIRE


    1. A0136MC

      Connect the battery terminal B with the nut.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }
    2. A0138EF

      Connect the 2 ground terminals with the 2 bolts.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }
    3. A01367S

      Install the ECM with the 3 bolts.

      Torque:
      8 N*m  { 82 kgf*cm, 71 in.*lbf }

    4. Connect the engine wire harness clamp.

    5. Connect the engine wire harness connectors to the ECM.

    6. A0137O3

      Install the engine relay block with the bolt.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    7. Connect the engine wire harness connectors to the engine room relay block.

  61. INSTALL COWL TOP PANEL OUTER


    1. A0138B1

      Install the cowl top panel outer with the 10 bolts.

      Torque:
      9.2 N*m  { 94 kgf*cm, 81 in.*lbf }

  62. INSTALL FRONT WIPER MOTOR & LINK ASSEMBLY


    1. Install the front wiper motor & link assembly Click here.

  63. INSTALL COWL TOP VENTILATOR LOUVER RH


    1. Install the cowl top ventilator louver RH Click here.

  64. INSTALL COWL TOP VENTILATOR LOUVER LH


    1. Install the cowl top ventilator louver LH Click here.

  65. INSTALL HOOD TO COWL TOP SEAL


    1. Install the hood to cowl top seal Click here.

  66. INSTALL FRONT WIPER ARM LH


    1. Install the front wiper arm LH Click here.

  67. INSTALL FRONT WIPER ARM HEAD CAP


    1. Install the front wiper arm head cap Click here.

  68. INSTALL BATTERY


    1. A0136RYE01

      Install the battery carrier with the 4 bolts.

      Torque:
      17.2 N*m  { 175 kgf*cm, 13 ft.*lbf, for A }
      7.4 N*m  { 75 kgf*cm, 65 in.*lbf, for B }
      8.4 N*m  { 86 kgf*cm, 74 ft.*lbf, for C }

      Tech Tips

      Tighten the A bolt from the service hole on the battery carrier.

    2. A0137MN

      Install the battery clamp with the bolt.

      Torque:
      15.1 N*m  { 154 kgf*cm, 11 ft.*lbf }

    3. Connect the positive battery cable.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  69. ADD MANUAL TRANSAXLE OIL


    1. Add the manual transaxle oil Click here.

  70. INSPECT MANUAL TRANSAXLE OIL


    1. Inspect the manual transaxle oil Click here.

  71. ADD ENGINE COOLANT


    1. Add the engine coolant Click here.

  72. INSPECT FOR ENGINE COOLANT LEAKS


    1. Inspect for engine coolant leaks Click here.

  73. INSPECT ENGINE OIL LEAKS

  74. CONNECT BATTERY NEGATIVE TERMINAL


    1. Connect the negative battery cable.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  75. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT


    1. Inspect and adjust the front wheel alignment Click here.

  76. INSPECT CO/HC


    1. Inspect the CO/HC Click here.

  77. INSTALL ENGINE UNDER COVER


    1. A013649

      Install the engine under cover with the 5 screws.

    2. Install the 9 bolts.