ENGINE UNIT INSTALLATION

PROCEDURE


  1. INSTALL NO. 1 WATER BY-PASS PIPE


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

      Torque:
      17.5 N*m  { 178 kgf*cm, 13 ft.*lbf }
  2. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY

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  3. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET

    Note

    Install the No. 1 compressor mounting bracket exactly as described in the procedures below to properly secure and prevent damage to the fan and generator V belt.


    1. A01WARP

      Temporarily install the No. 1 compressor mounting bracket with the 3 bolts.

      Tech Tips

      Temporarily install the No. 1 compressor mounting bracket with the 3 bolts so that the bracket can be moved by hand.

    2. A01W9WRC01
      *a No Clearance
      *b Push
      *c Front

      Push the No. 1 compressor mounting bracket toward the cylinder block as shown in the illustration and tighten bolt B.

      Torque:
      for bolt B
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

      Tech Tips

      Make sure there is no clearance between the cylinder block and No. 1 compressor mounting bracket as shown in the illustration.

    3. A01W8ZFC01
      B0068HS Bolt A
      B006964 Bolt C

      Uniformly tighten the 4 bolts in the order shown in the illustration.

      Torque:
      for bolt A
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }
      for bolt C
      24.5 N*m  { 250 kgf*cm, 18 ft.*lbf }
  4. INSTALL IDLE PULLEY ASSEMBLY


    1. Temporarily install the idle pulley assembly with the bolt.

      Note

      Do not use any tools.

    2. Tighten the bolt.

      Torque:
      44 N*m  { 449 kgf*cm, 32 ft.*lbf }
  5. INSTALL GENERATOR ASSEMBLY

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  6. INSTALL IGNITION COIL ASSEMBLY

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  7. INSTALL EXHAUST MANIFOLD

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  8. INSTALL AIR SWITCHING VALVE ASSEMBLY (w/ Secondary Air Injection System)

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  9. INSTALL NO. 4 INTAKE PIPE (w/ Secondary Air Injection System)

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  10. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (w/ Secondary Air Injection System)

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  11. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (w/o Secondary Air Injection System)

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  12. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. Install the front No. 1 engine mounting bracket RH with the 4 bolts.

      Torque:
      51 N*m  { 520 kgf*cm, 38 ft.*lbf }
  13. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. Install the front No. 1 engine mounting bracket LH with the 4 bolts.

      Torque:
      51 N*m  { 520 kgf*cm, 38 ft.*lbf }
  14. INSTALL NO. 1 WATER BY-PASS HOSE


    1. Connect the No. 1 water by-pass hose to the cylinder head sub-assembly, and slide the clamp to secure the hose.

  15. INSTALL HEATER HOSE


    1. Connect the heater hose to the cylinder head sub-assembly and No. 1 water by-pass pipe, and slide the clamp to secure the hoses.

  16. INSTALL ENGINE WIRE


    1. A01W8JEC01
      *a INCORRECT
      *b Do not Allow Wires to Overlap

      Connect the engine wire (engine ground wire) to the rear side of the engine assembly with the 2 bolts so that it is within the specified range shown in the illustration.

      Torque:
      for bolt A
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
    2. Connect the engine wire to the rear side of the engine assembly with the bolt.

      Torque:
      for bolt B
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
    3. Connect the connectors and clamps of the engine wire.

  17. INSTALL INTAKE MANIFOLD

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  18. INSTALL PCV PIPE


    1. Install the PCV pipe with the bolt.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
    2. Connect the PCV hose to the PCV valve sub-assembly and intake manifold.

  19. INSTALL PURGE VSV

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  20. INSTALL FUEL DELIVERY PIPE WITH FUEL INJECTOR

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  21. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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