ENGINE UNIT INSTALLATION

INSTALL IGNITION COIL ASSEMBLY

1. Install the 4 ignition coil assemblies to the cylinder head cover sub-assembly with the 4 bolts.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

   Note

   If an ignition coil assembly has been struck or dropped, replace it.

   Tech Tips

   Install the same parts to their original positions.

2. Connect the 4 ignition coil assembly connectors.

INSTALL ENGINE OIL TEMPERATURE SENSOR

INSTALL OIL COOLER ASSEMBLY

INSTALL THERMOSTAT

1. Install a new gasket to the thermostat.

2. 

   Text in Illustration

   *a	Jiggle Valve
   *b	10°

   Install the thermostat to the water inlet housing.

   Note

   The jiggle valve may be set within 10° on either side of the prescribed position.

INSTALL WATER INLET

1. Install the water inlet with the 2 nuts.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

INSTALL ENGINE WATER PUMP ASSEMBLY

1. Install a new water pump gasket and the engine water pump assembly with the 7 bolts.

   Torque:

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

INSTALL FUEL INJECTOR SEAL

1. 

   Text in Illustration

   *a	Area to be Cleaned

   Apply engine conditioner to the area shown in the illustration. Using a piece of cloth, clean carbon deposits from the direct fuel injector assembly and its grooves.

   Note

   
   

   • Do not clean the tip of the direct fuel injector assembly.

   
   

   • Do not use a wire brush to clean the direct fuel injector assembly.

   
   

   • If a direct fuel injector assembly is dropped or the tip of a direct fuel injector assembly is struck, replace it with a new one.

2. 

   Text in Illustration

   *a	SST (Guide)
   *b	Chamfer

   Apply engine oil to the direct fuel injector assembly contact surface of SST (guide), then attach SST (guide) to the direct fuel injector assembly with the chamfer facing the tip of the direct fuel injector assembly as shown in the illustration.

   SST

   09260-39021   ( 09261-03020 )

3. 

   Text in Illustration

   *1	Fuel Injector Seal
   *a	SST (Holder)
   *b	Correct
   *c	Incorrect

   Install a new fuel injector seal to SST (holder).

   SST

   09260-39021   ( 09261-03011 )

   Note

   Be careful not to install the fuel injector seal to SST (holder) at an angle. Doing so will stretch the fuel injector seal.

4. 

   Text in Illustration

   *a	SST (Holder)
   *b	SST (Guide)

   Install SST (holder) with the fuel injector seal to the tip of the direct fuel injector assembly. Slide the fuel injector seal downward into the direct fuel injector assembly groove with your fingers as shown in the illustration.

   SST

   09260-39021   ( 09261-03011, 09261-03020 )

   Note

   Check that the fuel injector seal is seated in the direct fuel injector assembly groove as shown in the illustration.

5. 

   Text in Illustration

   *a	SST (Guide)

   Slowly slide SST (guide) toward the tip of the direct fuel injector assembly. When the direct fuel injector assembly contact surface of SST (guide) aligns with the fuel injector seal as shown in the illustration, hold the position for 5 seconds or more to fully seat the fuel injector seal into the direct fuel injector assembly groove.

   SST

   09260-39021   ( 09261-03020 )

   Note

   Make sure the fuel injector seal is not pinched between SST (guide) and the edge of the direct fuel injector assembly groove. Replace the fuel injector seal if it becomes damaged.

   Tech Tips

   
   

   • Set SST (guide) so that its bottom surface is flush with the fuel injector seal.

   
   

   • If it is difficult to slide SST (guide) upward, slowly wiggle it from side to side while sliding it up the direct fuel injector assembly little by little.

6. 

   Text in Illustration

   *a	Normal
   *b	Protruding
   *c	Deformed
   *d	Correct
   *e	Incorrect

   After installing the fuel injector seals, check that they are not scratched, deformed or protruding from the direct fuel injector assembly groove.

   Note

   If a fuel injector seal is scratched, deformed or protruding from the groove, replace it with a new one.

INSTALL DIRECT FUEL INJECTOR ASSEMBLY

1. 

   Text in Illustration

   *1	Direct Fuel Injector Assembly
   *2	C-ring
   *3	Injector Vibration Insulator
   *a	Taper

   Install a new injector vibration insulator and a new C-ring to the direct fuel injector assembly.

   Note

   
   

   • Install the taper of the injector vibration insulator by aligning it with the taper of the direct fuel injector assembly.

   
   

   • Check that the C-ring is securely seated in the groove of the direct fuel injector assembly.

2. Install a new O-ring and a new No. 1 fuel injector back-up ring to the direct fuel injector assembly as shown in the illustration.

   

   Text in Illustration

   *1	No. 1 Fuel Injector Back-up Ring	*2	O-ring
   *a	No. 1 Fuel Injector Back-up Ring Opening	*b	Overlapped
   *c	Stretched	*d	Correct
   *e	Incorrect	-	-

   Note

   
   

   • Check that there is no foreign matter or damage on the O-ring groove of the direct fuel injector assembly.

   
   

   • Make sure that the No. 1 fuel injector back-up ring is installed in the correct orientation.

   
   

   • Make sure that the No. 1 fuel injector back-up ring and O-ring are installed in the correct order.

   
   

   • Check that the opening of the No. 1 fuel injector back-up ring is not overlapped or stretched as shown in the illustration.

   
   

   • After installing the O-ring, check that it is not contaminated with foreign matter and is not damaged.

3. 

   Text in Illustration

   *1	Direct Fuel Injector Assembly
   *2	No. 3 Fuel Injector Back-up Ring
   *a	Notch

   With the notch of a new No. 3 fuel injector back-up ring facing downward, install the direct fuel injector assembly to the No. 3 fuel injector back-up ring as shown in the illustration.

   Note

   
   

   • Make sure that the No. 3 fuel injector back-up ring is installed in the correct orientation.

   
   

   • After installing the No. 3 fuel injector back-up ring, make sure there is no damage or foreign matter.

4. Install the nozzle holder clamp to each direct fuel injector assembly.

5. 

   Text in Illustration

   *a	Protrusion
   *b	Positioning Hole
   	No Gap

   Align the protrusion of the nozzle holder clamp with the positioning hole of the fuel delivery pipe sub-assembly and insert the direct direct fuel injector assembly.

   Note

   
   

   • Make sure that there is no foreign matter or damage inside the direct fuel injector assembly installation holes (fuel delivery pipe sub-assembly).

   
   

   • Do not allow gasoline to get on the O-rings or inside the installation holes.

   
   

   • If it is difficult to insert the direct fuel injector assembly, apply new engine oil to the chamfer of the direct fuel injector assembly installation hole of the fuel delivery pipe sub-assembly. Be careful not to allow the direct fuel injector assembly to fall out of the fuel delivery pipe sub-assembly.

   
   

   • Do not tilt the direct fuel injector assembly when inserting it into the fuel delivery pipe sub-assembly.

   
   

   • Check that there is no gap between the fuel delivery pipe sub-assembly and the nozzle holder clamp.

   
   

   • 

     Make sure the 4 direct fuel injector assemblies have the same flow classification number 1, 2 or 3 (the number to the left of the QR code).

     Text in Illustration

     *a	QR Code
     *b	Flow Classification Number

INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

CONNECT NO. 2 VENTILATION HOSE

1. Connect the No. 2 ventilation hose to the PCV valve (ventilation valve sub-assembly) and slide the clip to secure it.

INSTALL THROTTLE BODY GASKET

1. 

   Text in Illustration

   *a	Protrusion

   Install a new throttle body gasket to the intake manifold with the protrusion of the throttle body gasket oriented as shown in the illustration.

INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

1. Connect the No. 2 water by-pass hose and No. 3 water by-pass hose to the throttle body with motor assembly and slide the 2 clips to secure them.

2. Install the throttle body with motor assembly to the intake manifold with the 4 bolts.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

   Note

   If the throttle body with motor assembly has been struck or dropped, replace it.

3. Connect the throttle body with motor assembly connector.

INSTALL PORT FUEL INJECTOR ASSEMBLY

1. Apply a light coat of spindle oil or gasoline to a new O-ring, and install one to each port fuel injector assembly.

   Note

   Check that there is no damage or foreign matter on the groove of the port fuel injector assembly when installing each O-ring to the port fuel injector assembly.

2. 

   Text in Illustration

   *a	Claw
   *b	Stopper

   Install the 4 port fuel injector assemblies to the fuel delivery pipe.

   Note

   
   

   • Make sure that the port fuel injector assembly is located within the stopper as shown in the illustration.

   
   

   • Check that there is no damage or foreign matter on the port fuel injector assembly installation holes.

   
   

   • When installing the O-rings, make sure they do not become pinched or cut.

INSTALL INJECTOR VIBRATION INSULATOR

1. Install 4 new injector vibration insulators to the cylinder head sub-assembly.

INSTALL FUEL DELIVERY SPACER

1. Install the 2 fuel delivery spacers to the cylinder head sub-assembly.

INSTALL FUEL DELIVERY PIPE

1. Place the fuel delivery pipe with the port fuel injector assemblies onto the cylinder head sub-assembly.

   Note

   Be careful not to drop the port fuel injector assemblies when installing the fuel delivery pipe.

2. Install the fuel delivery pipe with the port fuel injector assemblies with the 2 bolts.

   Torque:

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

CONNECT FUEL TUBE SUB-ASSEMBLY (for Port Injection)

1. Connect the fuel tube sub-assembly to the fuel delivery pipe.

   
   
   1. 

      Text in Illustration

      *a	Retainer
      *b	Fuel Tube Connector
      *c	Nylon Tube
      *d	O-ring
      *e	Fuel Pipe
      	Push

      Align the fuel tube connector with the fuel pipe, and push them together until the fuel tube connector makes a "click" sound. 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 pipes, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

   3. Push in the fuel tube connector cover.

TEMPORARILY INSTALL FUEL PUMP WITH SEAL SUB-ASSEMBLY

1. 

   Text in Illustration

   *1	Fuel Pump Lifter Guide
   *2	Fuel Pump Lifter Assembly
   *3	Camshaft
   *a	Correct
   *b	Incorrect

   Turn the crankshaft pulley until the flat of the camshaft faces the fuel pump with seal sub- assembly installation hole of the cylinder head cover sub-assembly.

   Tech Tips

   This prevent the camshaft nose from pushing up the fuel pump lifter assembly when installing the fuel pump with seal sub-assembly.

2. 

   Text in Illustration

   *1	Fuel Pump with Seal Sub-assembly
   *2	O-ring
   *3	Fuel Pump Insulator
   *4	Fuel Pump Lifter Assembly
   *5	Fuel Pump Lifter Guide
   	Engine Oil Application Area

   Apply engine oil to a new O-ring and install it to the fuel pump sub-assembly.

3. Apply engine oil to the inside of the fuel pump lifter guide and the outside of the fuel pump lifter assembly.

4. Install the fuel pump lifter assembly to the fuel pump lifter guide.

5. Install the fuel pump insulator to the fuel pump lifter guide.

6. Install the fuel pump with seal sub-assembly to the fuel pump lifter guide.

7. 

   Text in Illustration

   *1	Cylinder Head Cover Sub-assembly
   *2	O-ring
   *3	Fuel Pump Spacer Gasket
   *4	No. 4 Camshaft Bearing Cap
   *a	Pump Drive Cam (Engine Oil Application Area)
   *b	Pump Lifter (Engine Oil Application Area)
   *c	Knock Pin
   *d	Pin Hole

   Apply 30 cc (1.8 cu. in.) of engine oil to the pump drive cam.

8. Apply engine oil to the fuel pump lifter assembly.

9. Apply engine oil to 2 new O-rings and install them to the No. 4 camshaft bearing cap.

10. Install a new fuel pump spacer gasket to the cylinder head cover sub-assembly.

11. Set the fuel pump with seal sub-assembly on the cylinder head cover sub-assembly.

12. Temporarily install the fuel pump with seal sub-assembly with the 2 bolts, leaving some allowance for left and right movement.

TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

1. Connect the No. 1 fuel pipe sub-assembly to the fuel delivery pipe sub-assembly and tighten the union nut by hand.

2. Connect the No. 1 fuel pipe sub-assembly to the fuel pump with seal sub-assembly and tighten the union nut by hand.

   Note

   Do not damage the seals of the union nuts of the No. 1 fuel pipe sub-assembly when installing.

INSTALL FUEL PUMP WITH SEAL SUB-ASSEMBLY

INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

1. 

   Text in Illustration

   *a	17 mm Union Nut Wrench
   *b	Torque Wrench Fulcrum Length

   Using a 17 mm union nut wrench, tighten the union nuts on the fuel pump with seal sub-assembly side of the No. 1 fuel pipe sub-assembly.

   Torque:

   35 N*m  { 357 kgf*cm, 26 ft.*lbf }

   Tech Tips

   
   

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

   
   

   • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)

2. Using a 17 mm union nut wrench, tighten the union nuts on the fuel delivery pipe sub-assembly side of the No. 1 fuel pipe sub-assembly.

   Torque:

   35 N*m  { 357 kgf*cm, 26 ft.*lbf }

   Tech Tips

   
   

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

   
   

   • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)

INSTALL NO. 1 FUEL PIPE

1. Install the No. 1 fuel pipe and a new gasket to the fuel pump with seal sub-assembly.

   Torque:

   40 N*m  { 408 kgf*cm, 30 ft.*lbf }

CONNECT FUEL TUBE SUB-ASSEMBLY (for Direct Injection)

1. Connect the fuel tube sub-assembly to the No. 1 fuel pipe.

   
   
   1. 

      Text in Illustration

      *a	Retainer
      *b	Fuel Tube Connector
      *c	Nylon Tube
      *d	O-ring
      *e	Fuel Pipe
      	Push

      Align the fuel tube connector with the fuel pipe, and push them together until the fuel tube connector makes a "click" sound. 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 pipes, check that the fuel pipe and fuel tube connector are securely connected by pulling on them.

   3. Push in the fuel tube connector cover.

INSTALL NO. 2 MANIFOLD STAY

1. Install the No. 2 manifold stay to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and stiffening crankcase assembly with the bolt and nut.

   Torque:

   43 N*m  { 438 kgf*cm, 32 ft.*lbf }

INSTALL MANIFOLD STAY

1. Install the manifold stay to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and stiffening crankcase assembly with the bolt and nut.

   Torque:

   43 N*m  { 438 kgf*cm, 32 ft.*lbf }

INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

1. Install the No. 1 exhaust manifold heat insulator to the exhaust manifold converter sub-assembly (TWC: Front Catalyst) with the 4 bolts.

   Torque:

   12 N*m  { 122 kgf*cm, 9 ft.*lbf }

INSTALL EGR VALVE WITH COOLER ASSEMBLY

INSTALL FUEL PUMP PROTECTOR

1. Install the fuel pump protector to the cylinder head cover sub-assembly with the 2 bolts.

   Torque:

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }