ENGINE UNIT INSTALLATION


  1. INSTALL FLYWHEEL RING GEAR (for Manual Transmission)


    1. A009AYEE02
      Text in Illustration
      *1 Chamfer
      *2 Ring Gear
      *3 Flywheel

      Using a torch, heat the ring gear evenly to approximately 200°C (392°F).

      Note

      Be careful not to overheat the ring gear.

    2. Using a brass bar, tap the ring gear onto the flywheel with its chamfered gear teeth facing the block.

      Note

      After installing, allow the ring gear to cool before handling.

  2. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH


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

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

  3. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. Install the front No. 1 engine mounting bracket LH with the 3 bolts.

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

  4. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A00XI8OE01
      Text in Illustration
      *1 New O-Ring

      Install a new O-ring to the dipstick guide.

    2. Apply a light coat of engine oil to the O-ring.

    3. Push the dipstick guide end into the guide hole.

    4. Install the dipstick guide with the bolt.

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

    5. Install the dipstick.

  5. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A00XBUFE01

      Temporarily install the V-ribbed belt tensioner with the 5 bolts.

      Standard Bolt
      Item Length
      A 70 mm (2.76 in.)
      B 33 mm (1.30 in.)
      Text in Illustration
      A00XHOQ Bolt A
      A00XFQT Bolt B

    2. Tighten bolts 1 and 2 in numerical order.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

    3. Tighten the other bolts.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

  6. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. for Separate Type:

      Install the 2 idler pulley cover plates, 2 No. 2 idler pulleys and 2 No. 2 idler pulley cover plates with the 2 bolts.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

    2. for Integrated Type:

      Install the 2 No. 2 idler pulleys with the 2 bolts.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

  7. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. A00XGXVE01

      Install the No. 1 idler pulley with the bolt.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

      Tech Tips

      "DOUBLE" is marked on the No. 1 idler pulley to distinguish it from the No. 2 idler pulley.

  8. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY (w/ Oil Cooler)


    1. A00XFBRE01
      Text in Illustration
      *a Upward
      *b Rearward

      Install the water by-pass pipe with the 3 bolts.

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

    2. Connect the 2 hoses.

      Tech Tips

      The direction of the hose clamp is indicated in the illustration.

  9. INSTALL INTAKE MANIFOLD


    1. A00JTQG

      Set a new gasket on each cylinder head.

      Note


      • Align the port holes of the gasket and cylinder head.

      • Be careful of the installation direction.

    2. Set the intake manifold on the cylinder heads.

    3. A00JUYCE01
      Text in Illustration
      *1 Nut

      Install and uniformly tighten the 6 bolts and 4 nuts in several passes.

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

      Tech Tips

      Tighten the inner installation bolts of the intake manifold before tightening the outer bolts.

  10. INSTALL FUEL INJECTOR ASSEMBLY


    1. A00O481E01
      Text in Illustration
      *1 New Insulator
      *2 New O-Ring

      Install a new insulator to each fuel injector.

    2. Apply a light coat of spindle oil or gasoline to new O-rings and install one to each fuel injector.

    3. Install the 6 injectors.


      1. A00OALZE01
        Text in Illustration
        *1 Connector
        A00O9VA Outward
        A00O5SP Turn
        A00O9ZK Push

        While turning each fuel injector left and right, install it to the fuel delivery pipe.

      2. Position the fuel injectors with the connectors facing outward.

  11. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. Place the fuel delivery pipe together with the 6 fuel injectors on the intake manifold.

    2. Temporarily install the 6 bolts, which are used to hold the fuel delivery pipe in place, to the intake manifold.

    3. A00O5G3E01
      Text in Illustration
      *1 Turn

      Check that the fuel injectors rotate smoothly.

      If the fuel injectors do not rotate smoothly, replace the O-ring of any injector that does not rotate smoothly.

    4. Position the fuel injectors with the connectors facing outward.

    5. Tighten the 6 bolts.

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

    6. Connect the 6 fuel injector connectors.

  12. INSTALL FUEL PIPE SUB-ASSEMBLY


    1. Install the No. 1 fuel pipe and No. 2 fuel pipe with the 2 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    2. Connect the 2 fuel pipes Click here.

  13. INSTALL REAR CYLINDER HEAD COVER


    1. Temporarily install the cover with the 3 bolts.

    2. A00O6K9E01

      Tighten the 3 bolts in the sequence shown in the illustration.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  14. INSTALL IGNITION COIL ASSEMBLY


    1. Install the 6 ignition coils with the 6 bolts.

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

  15. INSTALL NO. 2 EMISSION CONTROL VALVE SET (w/ Secondary Air Injection System)


    1. Install the No. 2 emission control valve set with the 3 nuts.

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

  16. INSTALL EMISSION CONTROL VALVE SET (w/ Secondary Air Injection System)


    1. Install the emission control valve set with the 3 nuts.

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

  17. INSTALL HEATER WATER HOSE ASSEMBLY


    1. w/o Warmer:

      Install the heater water hose assembly and connect the 2 hoses.

    2. w/ Warmer:

      Install the heater water hose assembly and connect the 3 hoses.

  18. INSTALL ENGINE WIRE