Engine mechanism - Engine assembly

64.

Install temperature regulator assembly.

(a) Check temperature regulator assembly o-ring.

(b)  Install temperature regulator assembly as shown in the

diagram.

(c) Install engine water inlet pipe joint components.

Torque:  

65.

Install oil level gauge tube components.

66.

Install ignition coil mounting components.

Torque:  

m

67.

Install fuel rail injector assembly.

(a) Install isolator on cylinder head.

(b) Install fuel rail injector assembly.

Torque: 

(c) Install fuel pipe retaining clip.

68.

Install exhaust manifold gasket and exhaust

     manifold assembly.

Torque: 

69.

Install exhaust manifold upper heat shield

     components.

Torque:  

70.

Install intake manifold assembly.

Install new gasket and intake manifold assembly.

Torque:  

m

71.

Install throttle supporting plate.

Torque:  

72.

Install flywheel components and clutch assembly.

(a) Fix crankshaft with special tool.

(b) Clean bolts and bolt holes.

(c) Coat bolts with adhesive.

Adhesive:  thread locking sealant 1234 (Kesaixin 1234).

(d) Install flywheel components.

As sequences shown in the diagram, tighten bolts at

several times.

Torque:  88

5N

m

(e) Install clutch assembly.

Special

tool

 41 

Engine mechanism - Engine assembly

73.

Install transmission assembly.

(a) Install transmission assembly.

Torque:  bolt A: 

             Bolt B: 

             Bolt C:  

(b) Install 6 bolts.

Torque:  

74.

nstall starter mounting components.

Torque:  bolt:  

             Nut: 

75.

Install sub frame together with side member.

Install front mounting assembly and rear mounting

assembly.

Torque:  front:  

             Rear:  

76.

Install power steering pump assembly.

Torque:  

77.

Install engine assembly together with

    transmission assembly.

(a) Erect engine together with transmission assembly on

engine crane.

(b) Install engine assembly to vehicle.

(c) Temporarily install side member and 6 bolts.

(d) Install left engine mounting assembly.

Torque:  

(e) Install right engine mounting assembly.

(f) Insert special tool into location hole on right side of sub

frame and vehicle.

(g) Temporarily lock bolt A at first, and then lock bolt B.

(h) Insert special tool into location hole on left side of sub

frame and vehicle.

(i) Temporarily lock bolt A at first, and then lock bolt B.

(j) Insert special tool into location hole on right side of sub

frame and vehicle, and then tighten bolts up to speci-

fied torque.

Torque:  bolt A:  

m

             Bolt B:  

Special

tool

Special tool

42 

(k) Insert special tool into location hole on left side of sub

frame and vehicle, and then tighten bolts up to speci-

fied torque.

Torque:  bolt A: 

             Bolt B:  

m

(l) As shown in the diagram, tighten 2 bolts.

Torque:  

Note: after installing sub frame, check the sub

frame is aligned with location hole on

vehicle.

78.

Install compressor.

Torque: 

79.

Install lower left control arm assembly.

(a) Install drive shaft to steering knucle.

(b) Install lower left control arm.

Torque:  

Hint:  perform the same steps at another side.

80.

Install front left shaft hub nut.

(a) Install fixed nut with socket wrench (39mm).

Torque:  

(b) Drive the cutout part of hub nut into groove with chisel.

Hint:  perform the same steps at another side.

81.

Install left end front stabilizer link assembly.

Fix bolts with hex socket wrench.

Torque:  

Hint:  perform the same steps at another side.

82.

Install left side transversal lever assembly.

(a) Connect transversal lever assembly to steering knucle

and install new nuts.

Torque:  

Note:

Do not coat lubricant on thread and conical surface.

After tightening nuts up to specified torque, con-

tinue turning nuts for 60¡ãand insert open pin.

(b) Insert new open pin.

83.

Connect fuel hose assembly.

84.

Install battery tray.

Torque:  

Engine mechanism - Engine assembly

 43 

Engine mechanism - Engine assembly

85.

Install alternator mounting components.

Torque:  12mm bolt head A:  

        14mm bolt head B:  

86.

Install drive belt.

87.

Install engine wire harness and all hoses

     not connected.

(a) Check and connect all joints of engine wire harness.

(b) Check and connect all hoses.

88.

Install transmission control pull cable assembly

     and valve control pull cable.

89.

Install air filter assembly and its hose.

90.

Install steering middle shaft assembly.

(a) Align alignment mark on steering middle shaft.

(b) Install 2 bolts.

Torque: 

m

(c) Install steering column cover.

91.

Install front exhaust pipe assembly.

92.

Install front chassis bracket.

Torque: 

93.

Install battery and connect wire.

94.

Install engine plastic hood components.

95.

Install front wheel and engine bottom shield.

96.

Refill transmission lubricant.

97.

Refill engine oil.

98.

Refill coolant.

99.

Check there is oil leakage.

100. Check there is coolant leakage.

101. Check idle speed and ignition timing.

102. Check CO/HC.

Alignment

mark

Sliding in

Pulling

 44