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.

         Note

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

         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 bi-hexagon wrench.

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

      
      

      1. Check that the 3 mm bi-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 bi-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 bi-hexagon wrench installed.

         Tech Tips

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

2. INSTALL ENGINE OIL TEMPERATURE SENSOR

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3. INSTALL NO. 1 VACUUM PUMP BRACKET

   
   

   1. Install a new gasket and the No. 1 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. Install the water inlet hose to the water inlet housing and No. 2 water by-pass pipe, and slide the 2 clamps to secure the hose.

9. INSTALL WATER BY-PASS HOSE

   
   

   1. Install the water by-pass hose to the No. 2 water by-pass pipe, and slide the clamp to secure the hose.

10. INSTALL NO. 1 WATER BY-PASS PIPE

    
    

    1. Install the No. 1 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

    
    

    1. Connect the No. 3 water by-pass hose to the water inlet housing, and slide the clamp to secure the hose.

12. INSTALL NO. 2 PCV HOSE

    
    

    1. Install the PCV hose to the PCV valve sub-assembly, and slide the clamp to secure the hose.

13. INSTALL NO. 3 WATER BY-PASS PIPE

    
    

    1. Install a new gasket and the No. 3 water by-pass pipe with the 2 nuts.

       Torque:

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

14. INSTALL NO. 2 GENERATOR BRACKET

    
    

    1. Install the No. 2 generator bracket with the bolt.

       Torque:

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

15. INSTALL DRIVE SHAFT BEARING BRACKET

    
    

    1. Install the drive shaft bearing bracket with the 3 bolts.

       Torque:

       63.7 N*m  { 650 kgf*cm, 47 ft.*lbf }

16. INSTALL EXHAUST MANIFOLD

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17. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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18. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    
    

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

    2. Install the O-ring to the engine oil level dipstick guide.

    3. Install the engine oil level dipstick guide with the bolt.

       Torque:

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

    4. Install the engine oil level dipstick.

19. INSTALL FUEL INJECTOR ASSEMBLY

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20. INSTALL NO. 1 DELIVERY PIPE SPACER

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21. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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22. INSTALL VACUUM SENSOR BRACKET

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23. INSTALL VACUUM SENSOR ASSEMBLY

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24. CONNECT FUEL TUBE SUB-ASSEMBLY

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25. INSTALL WIRE HARNESS CLAMP BRACKET

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26. INSTALL PURGE VSV

    
    

    1. 

       Install the purge VSV with the 2 bolts.

       Torque:

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

       Note

       Make sure that there is no oil on the thread of the bolt A.

27. INSTALL HEATER WATER INLET HOSE

    
    

    1. Install the heater water inlet hose to the cylinder head sub-assembly, and slide the clamp to secure the hose.

28. INSTALL HEATER WATER OUTLET HOSE

    
    

    1. Install the heater water outlet hose to the No. 1 water by-pass pipe, and slide the clamp to secure the hose.

29. INSTALL INTAKE MANIFOLD

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30. INSTALL THROTTLE BODY ASSEMBLY

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