ENGINE OIL COOLER INSTALLATION


  1. INSTALL OIL COOLER ASSEMBLY


    1. Install the 2 new gaskets, and the oil cooler with the 4 nuts to the filter bracket.

      Torque:
      16 N*m  { 160 kgf*cm, 11 ft.*lbf }

  2. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY


    1. Install a new gasket and oil filter bracket with the 10 bolts and 2 nuts.

      Torque:
      30 N*m  { 300 kgf*cm, 22 ft.*lbf }

  3. INSTALL VACUUM PUMP OIL INLET HOSE


    1. A01BBQ6E01

      Connect the vacuum pump oil inlet hose with 2 new gaskets and the union bolt.

      Torque:
      14 N*m  { 140 kgf*cm, 10 ft.*lbf }

      CAUTION:

      Catch a stopper-bar of the inlet hose with the oil filter bracket.

  4. INSTALL OIL FILTER SUB-ASSEMBLY


    1. Check and clean the oil filter installation surface.

    2. Apply clean engine oil to the rubber gasket of a new oil filter.

    3. Instal the oil filter, and tighten it by hand until the rubber gasket contacts the installation surface.

    4. A01BDC6E01

      Using SST, tighten it by an additional 3/4 turn to seat the filter.

      SST
      09228-44011

  5. INSTALL EXHAUST MANIFOLD


    1. A01BD1XE01

      Install a new gasket to the cylinder head.

      Tech Tips

      Be sure to install a new gasket in the correct direction as shown in the illustration.

    2. A01BB18

      Install the exhaust manifold with the 6 bolts and 2 new nuts. Uniformly tighten the bolts and nuts in several steps.

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

  6. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1


    1. A01BDOWE01

      Install the heat insulator with the 3 bolts.

      Torque:
      Bolt (A)
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }
      Bolt (B)
      19 N*m  { 195 kgf*cm, 14 ft.*lbf }

  7. INSTALL EXHAUST PIPE ASSEMBLY FRONT

    Click here

  8. INSTALL GENERATOR W/ VACUUM PUMP ASSEMBLY


    1. A01BCCL

      Temporarily tighten the bolt and generator w/ vacuum pump assembly.

    2. A01BFJB

      Install the clip with the hose connected.

    3. Install the bolt with the hose connected.

      Torque:
      14 N*m  { 140 kgf*cm, 10 ft.*lbf }

  9. INSTALL COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning)


    1. Temporarily install the compressor mounting bracket with the 4 bolts.

    2. A01BFW5E01

      Using several steps, uniformly install and tighten the 4 bolts in the sequence shown in the illustration.

      Torque:
      85 N*m  { 870 kgf*cm, 63 ft.*lbf }
    3. A01BDNC

      Temporarily tighten the bolt and spacer.

    4. A01BDQDE01

      Temporarily install the compressor mounting bracket with the 3 bolts.

    5. Using several steps, uniformly install and tighten the 3 bolts in the sequence shown in the illustration.

      Torque:
      47 N*m  { 475 kgf*cm, 36 ft.*lbf }

  10. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)

    Click here

  11. INSTALL FAN & GENERATOR V BELT (w/ Air Conditioning System)


    1. A01BAGHE01

      Install the V belt.

    2. Tightening the bolt C, adjust the tension of the V belt.

    3. Tighten the bolts A and B.

      Torque:
      Bolt A
      75 N*m  { 765 kgf*cm, 55 ft.*lbf }
      Bolt B
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }

    4. Check the tension of the V belt. Click here

  12. INSTALL FAN & GENERATOR V BELT (w/o Air Conditioning)


    1. A01BBR9E01

      Install the V belt.

    2. Using a bar, adjust the tension of the V belt.

    3. Tighten the bolts A and B.

      Torque:
      Bolt A
      75 N*m  { 765 kgf*cm, 55 ft.*lbf }
      Bolt B
      18 N*m  { 185 kgf*cm, 13 ft.*lbf }

    4. Check the tension of the V belt. Click here

  13. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 (w/ Air Conditioning System)


    1. A01BEBYE01

      Install the V belt.

    2. Tightening the bolt B, adjust the tension of the V belt.

    3. Tighten nut A.

      Torque:
      39 N*m  { 400 kgf*cm, 29 ft.*lbf }

    4. Check the tension of the V belt. Click here

  14. INSTALL VANE PUMP V BELT


    1. A01BCBTE01

      Install the V belt.

    2. Using a bar, adjust the tension of the V-ribbed belt.

    3. Tighten the bolt A and nut B.

      Torque:
      Bolt (A)
      48 N*m  { 489 kgf*cm, 35 ft.*lbf }
      Nut (B)
      64 N*m  { 635 kgf*cm, 47 ft.*lbf }

    4. Check the tension of the V belt. Click here

  15. INSTALL OIL LEVEL GAGE GUIDE


    1. Install the level gage guide with the 2 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  16. INSTALL OIL LEVEL GAGE SUB-ASSEMBLY

  17. INSTALL INTAKE AIR CONNECTOR BRACKET


    1. A01BDYM

      Install the 2 bolts and intake air connector bracket.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  18. INSTALL INTAKE AIR CONNECTOR SUB-ASSEMBLY


    1. A01BCJN

      Install a new gasket and intake air connector with the bolt and 3 nuts.

      Torque:
      bolt
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
      Nut
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    2. Connect the turbo pressure sensor connector.

    3. Connect the ventilation hose.

  19. ADD ENGINE OIL

  20. ADD ENGINE COOLANT


    1. Close the engine drain plug.

      Torque:
      57 N*m  { 581 kgf*cm, 42 ft.*lbf }

    2. Close the radiator drain cock plug.

    3. Slowly fill the cooling system with coolant.

      Tech Tips

      The coolant level inside the radiator should be abserved after pressing the radiator hose inlet and radiator hose outlet by hand..

    4. Slowly pour coolant into the radiator reserve tank until it reaches the FULL line.

    5. Install the radiator cap to the radiator reserve tank.

    6. Press the inlet and outlet radiator hoses several times by hand while warming up the engine.

    7. Stop the engine, and wait until the engine coolant cools down.

    8. Add coolant to the FULL line of the radiator reservoir.

  21. CHECK FOR ENGINE OIL LEAKS

  22. CHECK FOR ENGINE COOLANT LEAKS

    CAUTION:

    Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.


    1. Fill the radiator with coolant and attach a radiator cap tester to the radiator.

    2. Warm up the engine.

    3. Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf/cm2, 17.1 psi), and check that the pressure does not drop.

      Tech Tips

      If the pressure drops, check the hoses, radiator or water pump for leaks. If no external leaks are found, check the heater core, cylinder block, and cylinder head.

  23. INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Install the 5 bolts and engine service hole cover.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  24. INSTALL FRONT DOOR SCUFF PLATE RH

  25. INSTALL FRONT SEAT ASSEMBLY RH


    1. A01BBC8

      Connect the front seat inner belt assembly connector and install the front seat assembly.

    2. Align the front seat assembly adjuster pin with the holes in the body.

    3. Move the front seat assembly to the rearmost position.

      Note

      Make sure that the front seat assembly is securely locked.

    4. Temporarily tighten the 2 bolts on the front side of the front seat assembly.

    5. Move the front seat assembly fully forward.

      Note

      Make sure that the front seat assembly is securely locked.

    6. Temporarily tighten the 2 bolts on the rear side of the front seat assembly.

    7. Move the front seat assembly to the rearmost position.

      Note

      Make sure that the front seat assembly is securely locked.

    8. Fully tighten the 2 bolts on the front side of the front seat assembly in the order of outer and inner side.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

    9. Move the front seat assembly fully forward.

      Note

      Make sure that the front seat assembly is securely locked.

    10. Fully tighten the 2 bolts on the rear side of the front seat assembly in the order of outer and inner side.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }