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.

        Note

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

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

      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. A002OHW

      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 IGNITION COIL ASSEMBLY

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  6. INSTALL THERMOSTAT

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  7. INSTALL WATER INLET

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  8. INSTALL WATER INLET HOSE


    1. A002NKE

      Install the water inlet hose with the 2 clamps.

  9. INSTALL WATER BY-PASS HOSE


    1. A002LMS

      Install the water by-pass hose with the clamp.

  10. INSTALL NO. 1 WATER BY-PASS PIPE


    1. A002P6C

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

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

  11. CONNECT NO. 3 WATER BY-PASS HOSE

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  12. INSTALL VENTILATION HOSE


    1. Install the ventilation hose to the ventilation valve.

  13. INSTALL IDLER PULLEY BRACKET (w/o Air Conditioning System)


    1. A002MSU

      Install the idler pulley bracket with the 2 nuts and bolt.

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

  14. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY (w/o Air Conditioning System)


    1. A002N7UE02
      Text in Illustration
      *1 Idler Pulley Cover Plate
      *2 No. 1 Idler Pulley Sub-assembly
      *3 Idler Pulley Bracket

      Install the 2 idler pulley cover plates and bolt to the No. 1 idler pulley sub-assembly as shown in the illustration.

    2. Tighten the bolt by hand until the flange of the bolt contacts the idler pulley cover plate and the No. 1 idler pulley sub-assembly is fixed in place.

      Note

      Do not use any tools.

    3. Tighten the bolt.

      Torque:
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

  15. INSTALL EXHAUST MANIFOLD

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  16. INSTALL MANIFOLD STAY

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  17. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

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  18. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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  19. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A002LOQ

      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 FUEL DELIVERY PIPE SUB-ASSEMBLY

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  22. INSTALL FUEL TUBE SUB-ASSEMBLY

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  23. INSTALL WIRE HARNESS CLAMP BRACKET

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  24. INSTALL AIR TUBE

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  25. INSTALL INTAKE MANIFOLD

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  26. INSTALL THROTTLE BODY ASSEMBLY

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