ENGINE UNIT INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

Perform "Inspection After Repair" after replacing the engine assembly.

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PROCEDURE


  1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

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  2. INSTALL KNOCK CONTROL SENSOR WIRE


    1. Engage the 3 clamps.

  3. INSTALL KNOCK CONTROL SENSOR

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  4. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

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  5. INSTALL NO. 1 VACUUM SWITCHING VALVE


    1. Install the No. 1 vacuum switching valve with the bolt.

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

  6. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. Install the idler pulley cover plate, No. 2 idler pulley sub-assembly and No. 2 idler pulley cover plate with the bolt.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

  7. INSTALL WATER PUMP PULLEY


    1. Temporarily install the water pump pulley with the 4 bolts.

    2. Using SST, hold the water pump pulley.

      SST
      09960-10010   ( 09962-01000, 09963-00700 )

    3. Tighten the 4 bolts.

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

  8. INSTALL NO. 2 TIMING GEAR COVER


    1. Install the No. 2 timing gear cover with the 2 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  9. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A002BDNN01

      Temporarily install the V-ribbed belt tensioner assembly with the 5 bolts.

      Tech Tips

      Each bolt length is as follows:

      Item Length
      Bolt (A) 70 mm (2.76 in.)
      Bolt (B) 33 mm (1.30 in.)

    2. Install the V-ribbed belt tensioner assembly by tightening the bolt (1) and then the bolt (2).

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

    3. Tighten the other bolts.

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

  10. INSTALL REAR ENGINE MOUNTING BRACKET


    1. Install the rear engine mounting bracket with the 3 bolts.

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

  11. INSTALL ENGINE MOUNTING BRACKET RH


    1. Install the engine mounting bracket RH with the 3 bolts.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

  12. INSTALL EXHAUST MANIFOLD TO HEAD GASKET LH

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  13. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH (TWC: Front Catalyst)

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  14. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

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  15. INSTALL NO. 2 MANIFOLD STAY

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  16. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Install a new O-ring to the No. 2 engine oil level dipstick guide.

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

    3. Push the No. 2 engine oil level dipstick guide end into the engine oil level dipstick guide.

    4. Install the No. 2 engine oil level dipstick guide with the bolt.

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

    5. Install the engine oil level dipstick.

  17. INSTALL EXHAUST MANIFOLD TO HEAD GASKET

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  18. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH (TWC: Front Catalyst)

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  19. INSTALL IGNITION COIL ASSEMBLY

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  20. INSTALL NO. 1 SURGE TANK STAY

    Note

    Do not apply oil to the bolt listed below:

    Oil Application Prohibited Bolt
    Bolt for No. 1 Surge Tank Stay and Cylinder Head Cover

    1. Install the No. 1 surge tank stay with the bolt.

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

  21. INSTALL THROTTLE BODY BRACKET

    Note

    Do not apply oil to the bolt listed below:

    Oil Application Prohibited Bolt
    Bolt for Throttle Body Bracket and Cylinder Head Cover

    1. Install the throttle body bracket with the bolt.

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

  22. INSTALL INTAKE MANIFOLD

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  23. INSTALL GENERATOR ASSEMBLY

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