ENGINE UNIT INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

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

PROCEDURE


  1. INSTALL IGNITION COIL ASSEMBLY

    Click here

  2. INSTALL SENSOR WIRE


    1. Install the sensor wire 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

    Click here

  4. INSTALL INTAKE MANIFOLD


    1. Install a new gasket to the intake manifold.

    2. Set the intake manifold on the engine assembly.

    3. Temporarily install the intake manifold with the 6 bolts.

    4. A00099OE03

      Tighten the 6 bolts in the order shown in the illustration.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

    5. Connect the No. 2 ventilation hose to the intake manifold.

  5. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET


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

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

  6. INSTALL WATER INLET HOUSING


    1. Using an E5 "TORX" socket wrench, install the stud bolt to the water inlet housing.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    2. Using an E8 "TORX" socket wrench, install the stud bolt to the cylinder block sub-assembly.

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

    3. Install a new gasket.

    4. A0005HXE04
      Text in Illustration
      *1 Bolt
      *2 Nut

      Install the water inlet housing with the 3 bolts and nut.

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

    5. Install the harness clamp bracket to the water inlet housing with the bolt.

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

    6. Install the harness clamp bracket to the cylinder block sub-assembly with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  7. INSTALL WATER INLET SUB-ASSEMBLY


    1. Install a new gasket and the water inlet sub-assembly with the 2 bolts.

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

  8. INSTALL ENGINE WATER PUMP ASSEMBLY


    1. Install a new gasket and the engine water pump assembly with the 5 bolts.

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

  9. INSTALL NO. 1 WATER BY-PASS PIPE


    1. A000449E04
      Text in Illustration
      *1 Clamp

      Install the No. 1 water by-pass pipe with the 2 bolts.

      Torque:
      Bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Bolt B
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Connect the No. 4 water by-pass hose and No. 6 water by-pass hose with the 2 clamps.

  10. INSTALL NO. 3 WATER BY-PASS PIPE


    1. Install the No. 3 water by-pass pipe with the 2 bolts.

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

    2. Connect the No. 5 water by-pass hose with the clamp.

  11. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    Click here

  12. INSTALL MANIFOLD STAY

    Click here

  13. INSTALL NO. 2 MANIFOLD STAY

    Click here

  14. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  15. INSTALL NO. 1 WATER BY-PASS HOSE


    1. Connect the No. 1 water by-pass hose with the clamp.

  16. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY

    Click here

  17. 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:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    4. Install the engine oil level dipstick.

  18. INSTALL ENGINE HANGERS


    1. A0005ALE08
      Text in Illustration
      *1 No. 1 Engine Hanger
      *2 No. 2 Engine Hanger

      Install the No. 1 engine hanger and No. 2 engine hanger with the 2 bolts as shown in the illustration.

      Part No.
      Item Part No.
      No. 1 Engine Hanger 12281-36020
      No. 2 Engine Hanger 12282-36021
      Bolt 91552-81025 or 91552-81040
      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }