ENGINE UNIT INSTALLATION

PROCEDURE


  1. INSTALL NO. 2 VENTILATION HOSE


    1. Install the No. 2 ventilation hose to the cylinder head cover.

  2. INSTALL FUEL INJECTOR ASSEMBLY

    Click here

  3. INSTALL FUEL DELIVERY PIPE


    1. Install 3 new fuel injector vibration insulators to the cylinder head.

      Note

      Do not drop the fuel injectors when installing the fuel delivery pipe.

    2. Provisionally install the 2 bolts which are used to hold the fuel delivery pipe to the cylinder head.

      Note

      Check that the fuel injector turns smoothly after installing it. If it does not, reinstall it with a new O-ring.

    3. Tighten the 2 bolts which are used to hold the fuel delivery pipe to the cylinder head.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

  4. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    Click here

  5. INSTALL MANIFOLD STAY

    Click here

  6. INSTALL EGR INLET EXHAUST MANIFOLD PLATE

    Click here

  7. INSTALL NO. 1 IGNITION COIL

    Click here

  8. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Apply a small amount of engine oil to a new O-ring.

    2. Install the O-ring to the engine oil level dipstick guide.

    3. Install the engine oil level dipstick guide with the bolt.

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

  9. INSTALL ENGINE OIL LEVEL DIPSTICK SUB-ASSEMBLY

  10. TEMPORARILY INSTALL EGR VALVE ASSEMBLY


    1. Install a new EGR valve gasket to the cylinder head.

    2. A01VFKA

      Insert the EGR valve into the stud bolt, rotate the EGR valve to avoid contact with the delivery pipe, and temporarily install the EGR valve.

  11. TEMPORARILY INSTALL NO. 1 INTAKE MANIFOLD INSULATOR

    Click here

  12. INSTALL INTAKE MANIFOLD


    1. Install a new No. 2 intake manifold to head gasket onto the intake manifold.

    2. Temporarily install the intake manifold onto the No. 1 intake manifold insulator with the 2 bolts and 2 nuts.

    3. A01VGH2E02
      Text in Illustration
      *1 No. 2 Fuel Vapor Feed Hose
      *2 Ventilation Hose

      Tighten the 4 bolts and 3 nuts in the order shown in the illustration.

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

    4. Connect the ventilation hose to the ventilation valve.

    5. Connect the No. 2 fuel vapor feed hose to the duty vacuum switching valve.

    6. Install the wire harness clamp bracket to the intake manifold with the bolt.

      Torque:
      8.0 N*m  { 85 kgf*cm, 73 in.*lbf }

  13. INSTALL INTAKE MANIFOLD STAY

    Click here

  14. INSTALL FUEL TUBE SUB-ASSEMBLY


    1. Install the fuel tube to the fuel pipe Click here.

    2. Connect the fuel earth line to the cylinder head.

  15. INSTALL EFI FUEL PIPE CLAMP


    1. Install the EFI fuel pipe clamp to the fuel tube.

  16. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY

    Click here

  17. INSTALL AIR CLEANER CAP SUPPORT

    Click here

  18. INSTALL WATER BY-PASS HOSE ASSEMBLY


    1. Connect the 3 water by-pass hoses to the cylinder head and EGR valve.

    2. Connect the 2 water by-pass hoses to the throttle body.

    3. Engage the 2 water by-pass hoses to the hose clamps.

  19. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

    Click here

  20. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here