ENGINE UNIT INSTALLATION

PROCEDURE


  1. INSTALL IGNITION COIL ASSEMBLY

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  2. INSTALL SENSOR WIRE


    1. Install the sensor wire to the cylinder block sub-assembly with the bolt.

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

    2. Connect the knock control sensor connector.

  3. INSTALL FUEL DELIVERY PIPE

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  4. INSTALL INTAKE MANIFOLD

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  5. INSTALL WATER INLET HOUSING


    1. Using an E6 "TORX" socket wrench, install the 4 stud bolts to the water inlet housing.

      A01IEY2C01
      *a 34 mm (1.34 in.) *b 21 mm (0.827 in.)
      *c 9.0 mm (0.354 in.) *d 27 mm (1.06 in.)
      *e 16 mm (0.630 in.) - -
      Torque:
      4.4 N*m  { 45 kgf*cm, 39 in.*lbf }

      Note

      If a stud bolt is deformed or its threads are damaged, replace it.

    2. Install a new gasket to the cylinder block sub-assembly.

    3. Install the water inlet housing to the cylinder block sub-assembly with the 4 bolts and nut.

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

  6. INSTALL THERMOSTAT

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  7. INSTALL WATER INLET

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  8. INSTALL ENGINE WATER PUMP ASSEMBLY

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  9. INSTALL NO. 1 WATER BY-PASS PIPE


    1. B006QQBN01

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

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

      Note

      Temporarily tighten the bolt (A), fully tighten the 2 nuts (B), and then fully tighten the bolt (A).

  10. INSTALL WATER BY-PASS HOSE


    1. Install the water by-pass hose to the cylinder head sub-assembly and slide the clip to secure it.

  11. INSTALL NO. 2 WATER BY-PASS HOSE


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

  12. INSTALL THROTTLE BODY GASKET

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  13. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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  14. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (TWC: Front Catalyst)

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  15. INSTALL MANIFOLD STAY

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  16. INSTALL NO. 2 MANIFOLD STAY

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  17. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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  18. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. Type A:


      1. Install the V-ribbed belt tensioner assembly to the water inlet housing with the bolt.

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

    2. Type B:


      1. Install the V-ribbed belt tensioner assembly to the water inlet housing with the bolt.

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

      2. Install the dust cover to the V-ribbed belt tensioner assembly.

  19. 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 to the water inlet housing with the bolt.

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

    4. Install the engine oil level dipstick.

  20. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET


    1. Install the No. 1 compressor mounting bracket with the 4 bolts.

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

  21. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY

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  22. 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 }

      Note

      Make sure that the bolts and bolt holes are free of oil. Clean them if necessary.