ENGINE UNIT INSTALLATION

PROCEDURE

INSTALL WIRE HARNESS CLAMP BRACKET
1. Install the wire harness clamp bracket to the intake manifold with the bolt.
  
  Torque:
  
  15 N*m { 153 kgf*cm, 11 ft.*lbf }
2. Install the 2 wire harness clamp brackets to the cylinder head cover sub-assembly with the 2 bolts.
  
  Torque:
  
  Bolt (A)
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
  
  Bolt (B)
  
  8.0 N*m { 82 kgf*cm, 71 in.*lbf }
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.
    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.
INSTALL ENGINE OIL TEMPERATURE SENSOR

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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 }
INSTALL VACUUM PUMP ASSEMBLY

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INSTALL THERMOSTAT

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INSTALL WATER INLET

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INSTALL WATER INLET HOSE
1. Install the water inlet hose and slide the 2 clips to secure it.
CONNECT NO. 3 WATER BY-PASS HOSE
1. Connect the No. 3 water by-pass hose to the water inlet housing and slide the clip to secure it.
INSTALL PCV HOSE
1. Install the PCV hose to the PCV valve sub-assembly and slide the clip to secure it.
INSTALL WATER BY-PASS HOSE
1. Install the water by-pass hose and slide the clip to secure it.
CONNECT 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 }
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 }
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 }
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 }
INSTALL EXHAUST MANIFOLD

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INSTALL MANIFOLD STAY

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INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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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.
INSTALL IGNITION COIL ASSEMBLY

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INSTALL FUEL INJECTOR ASSEMBLY

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INSTALL NO. 1 DELIVERY PIPE SPACER

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INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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CONNECT FUEL TUBE SUB-ASSEMBLY

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INSTALL PURGE VALVE (PURGE VSV)
1. Install the purge valve (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).
INSTALL INTAKE MANIFOLD

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INSTALL THROTTLE BODY ASSEMBLY

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