ENGINE UNIT INSTALLATION

PROCEDURE


  1. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. When replacing the V-ribbed belt tensioner assembly with a new one.


      1. Install the V-ribbed belt tensioner assembly to the engine assembly with the 2 bolts.

        Torque:
        21 N*m  { 214 kgf*cm, 15 ft.*lbf }

        Note

        Make sure to install a new V-ribbed belt tensioner assembly with the pin and white cover installed to it.

      2. Remove the white cover.

      3. Rotate the V-ribbed belt tensioner assembly slightly clockwise and remove the pin that is used to keep the spring compressed.

        Note


        • Do not forcibly rotate the V-ribbed belt tensioner assembly to the V-ribbed belt installation position with the pin installed.

        • Do not apply or add any oil or grease to the V-ribbed belt tensioner assembly.

        Tech Tips

        When installing the V-ribbed belt, rotate the V-ribbed belt tensioner assembly clockwise again with the pin removed, and secure the V-ribbed belt tensioner assembly using a 5 mm hexagon wrench.

    2. When reusing the V-ribbed belt tensioner assembly.


      1. Check that the 3 mm hexagon wrench is installed to the V-ribbed belt tensioner assembly.

      2. Install the V-ribbed belt tensioner assembly to the engine assembly with the 2 bolts.

        Torque:
        21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      3. Rotate the V-ribbed belt tensioner assembly slightly clockwise and remove the 3 mm hexagon wrench that is used to keep the spring compressed.

        Note

        Do not forcibly rotate the V-ribbed belt tensioner assembly to the V-ribbed belt installation position with the 3 mm hexagon wrench installed.

        Tech Tips

        When installing the V-ribbed belt, rotate the V-ribbed belt tensioner assembly clockwise again with the 3 mm hexagon wrench removed, and secure the V-ribbed belt tensioner assembly using a 5 mm hexagon wrench.

  2. INSTALL ENGINE OIL TEMPERATURE SENSOR

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  3. INSTALL NO. 1 VACUUM PUMP BRACKET


    1. A0059G9

      Install a new gasket and the vacuum pump bracket with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  4. INSTALL VACUUM PUMP ASSEMBLY

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  5. INSTALL RADIO SETTING CONDENSER


    1. A0058XD

      Install the setting condenser with the bolt.

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

  6. INSTALL IGNITION COIL ASSEMBLY

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  7. INSTALL THERMOSTAT

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  8. INSTALL WATER INLET

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  9. INSTALL WATER INLET HOSE


    1. A0058SA

      Install the water inlet hose with the 2 clamps.

  10. INSTALL WATER BY-PASS HOSE


    1. A0055A9

      Install the water by-pass hose with the clamp.

  11. INSTALL NO. 1 WATER BY-PASS PIPE


    1. A00531A

      Install the water by-pass pipe with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  12. CONNECT NO. 3 WATER BY-PASS HOSE

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  13. INSTALL VENTILATION HOSE


    1. Install the ventilation hose to the ventilation valve.

  14. INSTALL NO. 3 WATER BY-PASS PIPE


    1. A0052LY

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

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

  15. INSTALL DRIVE SHAFT BEARING BRACKET


    1. A0052RD

      Install the drive shaft bearing bracket with the 3 bolts.

      Torque:
      64 N*m  { 650 kgf*cm, 47 ft.*lbf }

  16. INSTALL EXHAUST MANIFOLD

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  17. INSTALL MANIFOLD STAY

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  18. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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  19. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A0057XE

      Apply a light coat of engine oil to a new O-ring.

    2. Install the O-ring to the dipstick guide.

    3. Install the dipstick guide with the bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    4. Install the engine oil level dipstick.

  20. INSTALL FUEL INJECTOR ASSEMBLY

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  21. INSTALL NO. 1 DELIVERY PIPE SPACER

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  22. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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  23. INSTALL FUEL TUBE SUB-ASSEMBLY

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  24. INSTALL WIRE HARNESS CLAMP BRACKET

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  25. INSTALL AIR TUBE

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  26. INSTALL INTAKE MANIFOLD

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  27. INSTALL THROTTLE BODY ASSEMBLY

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