ENGINE UNIT INSTALLATION

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PROCEDURE

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   INSTALL NO. 1 WATER BY-PASS PIPE

   
   

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

      17.5 N*m

      178 kgf*cm

      13 ft.*lbf

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   INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY

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   INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)

   Note:

   Install the No. 1 compressor mounting bracket exactly as described in the procedures below to properly secure and prevent damage to the fan and generator V belt.

   
   
   1. 

      Temporarily install the No. 1 compressor mounting bracket with the 3 bolts.

      Tip:

      Temporarily install the No. 1 compressor mounting bracket with the 3 bolts so that the bracket can be moved by hand.

   2. 

      *a	No Clearance
      *b	Push
      *c	Front

      Push the No. 1 compressor mounting bracket toward the cylinder block as shown in the illustration and tighten bolt B.

      for bolt B
      45 N*m	459 kgf*cm	33 ft.*lbf

      Tip:

      Make sure there is no clearance between the cylinder block and No. 1 compressor mounting bracket as shown in the illustration.

   3. 

      	Bolt A
      	Bolt C

      Uniformly tighten the 4 bolts in the order shown in the illustration.

      for bolt A
      45 N*m	459 kgf*cm	33 ft.*lbf
      for bolt C
      24.5 N*m	250 kgf*cm	18 ft.*lbf

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   INSTALL IDLE PULLEY ASSEMBLY (w/ Air Conditioning System)

   
   

   1. Temporarily install the idle pulley assembly with the bolt.

      Note:

      Do not use any tools.

   2. Tighten the bolt.

      44 N*m

      449 kgf*cm

      32 ft.*lbf

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   INSTALL GENERATOR ASSEMBLY

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   INSTALL IGNITION COIL ASSEMBLY

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   INSTALL EXHAUST MANIFOLD

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   INSTALL AIR SWITCHING VALVE ASSEMBLY (w/ Secondary Air Injection System)

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   INSTALL NO. 4 INTAKE PIPE (w/ Secondary Air Injection System)

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    INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (w/ Secondary Air Injection System)

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    INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (w/o Secondary Air Injection System)

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    INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH

    
    

    1. Install the front No. 1 engine mounting bracket RH with the 4 bolts.

       51 N*m

       520 kgf*cm

       38 ft.*lbf

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    INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH

    
    

    1. Install the front No. 1 engine mounting bracket LH with the 4 bolts.

       51 N*m

       520 kgf*cm

       38 ft.*lbf

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    INSTALL NO. 1 WATER BY-PASS HOSE

    
    

    1. Connect the No. 1 water by-pass hose to the cylinder head sub-assembly, and slide the clamp to secure the hose.

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    INSTALL HEATER HOSE

    
    

    1. Connect the heater hose to the cylinder head sub-assembly and No. 1 water by-pass pipe, and slide the clamp to secure the hoses.

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    INSTALL ENGINE WIRE

    
    
    1. 

       *a	INCORRECT
       *b	Do not Allow Wires to Overlap

       Connect the engine wire (engine ground wire) to the rear side of the engine assembly with the 2 bolts so that it is within the specified range shown in the illustration.

       for bolt A
       25 N*m	255 kgf*cm	18 ft.*lbf

    2. Connect the engine wire to the rear side of the engine assembly with the bolt.

       for bolt B
       30 N*m	306 kgf*cm	22 ft.*lbf

    3. Connect the connectors and clamps of the engine wire.

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    INSTALL INTAKE MANIFOLD

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    INSTALL PCV PIPE

    
    

    1. Install the PCV pipe with the bolt.

       18 N*m

       184 kgf*cm

       13 ft.*lbf

    2. Connect the PCV hose to the PCV valve sub-assembly and intake manifold.

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    INSTALL PURGE VSV

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    INSTALL FUEL DELIVERY PIPE WITH FUEL INJECTOR

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    INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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