ENGINE UNIT INSTALLATION

PROCEDURE


  1. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the wire harness clamp bracket to the cylinder head cover sub-assembly with the bolt.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }

    2. Install the wire harness clamp bracket to the timing chain cover sub-assembly with the bolt.

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

  2. INSTALL NO. 2 VENTILATION HOSE


    1. Install the No. 2 ventilation hose to the cylinder head cover sub-assembly and slide the hose clip to secure it.

  3. INSTALL VENTILATION HOSE


    1. Install the ventilation hose to the ventilation valve sub-assembly and cylinder head cover sub-assembly and slide the 2 hose clips to secure it.

  4. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. Install the V-ribbed belt tensioner assembly to the timing chain cover sub-assembly with the bolt.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

  5. INSTALL DUTY VACUUM SWITCHING VALVE


    1. Install the duty vacuum switching valve to the cylinder head cover sub-assembly with the bolt.

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

  6. INSTALL FUEL INJECTOR ASSEMBLY

    Click here

  7. INSTALL FUEL PIPE INSULATOR

    Click here

  8. INSTALL INJECTOR VIBRATION INSULATOR

    Click here

  9. INSTALL FUEL DELIVERY PIPE


    1. A004BAVE05

      Temporarily install the fuel delivery pipe with fuel injector assembly to the cylinder head sub-assembly with the 2 bolts.

      Note


      • Do not drop the fuel injector assembly.

      • After installing each fuel injector assembly, check that it turns smoothly. If not, replace the O-ring with a new one.

      Tech Tips

      Because bolt A interferes with the cylinder head cover sub-assembly, temporarily install it together with the fuel delivery pipe.

    2. A004AYCE02
      Text in Illustration
      *a Fulcrum Length of 12 mm Union Nut Wrench
      *b Fulcrum Length of Torque Wrench

      Using a 12 mm union nut wrench, fully tighten bolt A.

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

      Tech Tips


      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.

      • When using a 12 mm union nut wrench (fulcrum length of 20 mm (0.79 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 24 N*m (248 kgf*cm, 18 ft.*lbf).

    3. Fully tighten bolt B.

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

  10. INSTALL NO. 1 IGNITION COIL

    Click here

  11. INSTALL INLET EGR GASKET

    Click here

  12. INSTALL EXHAUST MANIFOLD TO HEAD GASKET

    Click here

  13. INSTALL EXHAUST MANIFOLD

    Click here

  14. INSTALL MANIFOLD STAY

    Click here

  15. INSTALL EGR VALVE GASKET

    Click here

  16. INSTALL EGR VALVE ASSEMBLY


    1. Temporarily install the EGR valve assembly to the cylinder head sub-assembly.

  17. INSTALL NO. 2 INTAKE MANIFOLD TO HEAD GASKET

    Click here

  18. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR

    Click here

  19. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET

    Click here

  20. INSTALL INTAKE MANIFOLD


    1. A0049KSE02

      Temporarily install the intake manifold to the cylinder head sub-assembly with the 2 bolts and 2 nuts.

    2. Fully tighten the 4 bolts and 3 nuts in the order shown in the illustration.

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

    3. Connect the No. 2 fuel vapor feed hose to the duty vacuum switching valve and slide the hose clip to secure it.

  21. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the wire harness clamp bracket to the cylinder head cover sub-assembly with the bolt.

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

  22. INSTALL FUEL TUBE SUB-ASSEMBLY


    1. A00494OE02
      Text in Illustration
      *1 Retainer
      *2 O-ring
      *3 Fuel Tube Connector
      *4 Nylon Tube
      *5 Fuel Pipe
      A0049LZ Push

      Install the fuel tube sub-assembly to the fuel delivery pipe.


      1. Align the fuel tube connector with the fuel pipe, and push them together until the fuel tube connector makes a "click" sound.

        Tech Tips

        If it is difficult to push the fuel pipe into the fuel tube connector, apply a small amount of clean engine oil to the tip of the fuel pipe and reinsert it.

      2. After connecting the fuel lines, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

    2. Engage the clamp to connect the fuel tube sub-assembly to the fuel hose clamp.

  23. INSTALL EFI FUEL PIPE CLAMP

    Click here

  24. INSTALL THROTTLE BODY GASKET

    Click here

  25. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

    Click here

  26. INSTALL AIR CLEANER CAP SUPPORT

    Click here

  27. INSTALL NO. 2 WATER BY-PASS HOSE


    1. Install the No. 2 water by-pass hose to the cylinder head sub-assembly and slide the hose clip to secure it.

  28. INSTALL INLET HEATER WATER HOSE A


    1. Install the inlet heater water hose A to the cylinder head sub-assembly and slide the hose clip to secure it.

  29. INSTALL NO. 2 WATER BY-PASS HOSE


    1. Install the No. 2 water by-pass hose to the throttle body with motor assembly and EGR valve assembly and slide the 2 hose clips to secure it.

    2. Engage the 2 clamps to connect the No. 2 water by-pass hose to the intake manifold.

  30. INSTALL NO. 1 WATER BY-PASS HOSE


    1. Install the No. 1 water by-pass hose to the throttle body with motor assembly and water by-pass hose and slide the 2 hose clips to secure it.

    2. Engage the 3 clamps to connect the No. 1 water by-pass hose to the intake manifold and water by-pass hose clamp.