ENGINE UNIT INSTALLATION


  1. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. Install the engine mounting bracket with the 4 bolts.

      Torque:
      51 N*m  { 520 kgf*cm, 38 ft.*lbf }

  2. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. Install the engine mounting bracket with the 4 bolts.

      Torque:
      51 N*m  { 520 kgf*cm, 38 ft.*lbf }

  3. INSTALL FRONT ENGINE MOUNTING INSULATOR


    1. Install the 2 mounting insulators with the 2 nuts.

      Torque:
      46 N*m  { 469 kgf*cm, 34 ft.*lbf }

  4. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Install the oil level dipstick guide with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  5. INSTALL NO. 1 WATER BY-PASS PIPE


    1. Install a new gasket and the water by-pass pipe with the 2 nuts.

      Torque:
      18 N*m  { 178 kgf*cm, 13 ft.*lbf }

  6. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. Install the spacer and idler pulley with the bolt.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  7. 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. A01DQ1I

      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. A01DU4EE01
      Text in Illustration
      *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. A01DQTZE01

      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
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }
      Text in Illustration
      A01DQPB Bolt A
      A01DMKT Bolt C

  8. 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 }

  9. INSTALL INTAKE MANIFOLD


    1. Install the No. 2 fuel vapor feed hose to the intake manifold.

    2. Install the 2 wire harness clamp brackets to the intake manifold with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    3. A01DLT1

      Install a new gasket to the intake manifold.

    4. Install the intake manifold with the 5 bolts and 2 nuts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    5. for Engine Rear Side:

      Attach the No. 2 water by-pass hose and connect the No. 3 ventilation hose to the intake manifold.

    6. for Engine Front Side:

      Attach the 2 wire harness clamps to the 2 wire harness clamp brackets.

  10. INSTALL PURGE VSV


    1. Install the purge VSV with the bolt.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    2. Connect the 2 purge line hoses to the purge VSV.

    3. Connect the purge VSV connector.

  11. INSTALL FUEL DELIVERY PIPE WITH FUEL INJECTOR


    1. Install the fuel delivery pipe with fuel injector Click here.

  12. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY


    1. A01DR8CE02
      Text in Illustration
      *1 Protrusion
      *2 Groove

      Install a new gasket to the intake manifold.

      Tech Tips

      Align the protrusion of the gasket with the groove of the intake manifold.

    2. for Type A:

      Install the throttle body with motor with the 2 bolts and 2 nuts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    3. for Type B:

      Install the throttle body with motor with the 4 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    4. Connect the water by-pass hose.

    5. Connect the No. 2 water by-pass hose.

    6. Connect the throttle position sensor and throttle control motor connector.

  13. INSTALL EXHAUST MANIFOLD


    1. A01DTGE

      Install a new gasket.

    2. A01DRRHE01

      Install the exhaust manifold with 8 new nuts in the order shown in the illustration.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

  14. INSTALL AIR SWITCHING VALVE ASSEMBLY


    1. Set the No. 1 exhaust manifold heat insulator in place.

    2. Install the air switching valve with 2 new nuts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    3. Connect the connector.

    4. w/ Manifold Absolute Pressure Sensor:

      Connect the vacuum hose.

  15. INSTALL NO. 4 INTAKE PIPE


    1. A01DOAHE01

      Install 2 new gaskets and the No. 4 intake pipe with 4 new nuts in the order shown in the illustration. Tighten the nuts labeled 1 and 3 to the torque specification again.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    2. Check that the nuts are tightened to the torque specification.

  16. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 1 exhaust manifold heat insulator with the 5 bolts.

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

  17. INSTALL GENERATOR ASSEMBLY


    1. for 80 A Type:

      Install the generator Click here.

    2. for 100 A Type:

      Install the generator Click here.

  18. INSTALL IGNITION COIL ASSEMBLY


    1. Install the 4 ignition coils with the 4 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    2. Connect the 4 ignition coil connectors.