ENGINE UNIT INSTALLATION


  1. INSTALL DRIVE SHAFT BEARING BRACKET

    A0116XM

    1. Install the drive shaft bearing bracket with the 2 bolts.

      Torque:
      64 N*m  { 650 kgf*cm, 47 ft.*lbf }

  2. INSTALL WIRING HARNESS CLAMP BRACKET

    A0117OI

    1. Install the wiring harness clamp bracket with the bolt.

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

  3. INSTALL WATER FILLER ASSEMBLY

    A011A4E

    1. Install the water filler assembly with the bolt.

      Torque:
      13 N*m  { 127 kgf*cm, 10 ft.*lbf }

  4. INSTALL NO. 2 VENTILATION HOSE

    A0117F5

    1. Install the No. 2 ventilation hose with the clip.

  5. INSTALL OIL LEVEL DIPSTICK GUIDE SUB-ASSEMBLY

    A011739

    1. Install the new O-ring to the oil level dipstick guide sub-assembly.

    2. A0118CO

      Install the oil level dipstick guide sub-assembly with the bolt.

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

  6. INSTALL OIL LEVEL DIPSTICK SUB-ASSEMBLY

  7. INSTALL IDLER PULLEY

    A0119EX

    1. Install the idler pulley with the 3 bolts.

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

  8. INSTALL ENGINE WIRE

    A0119MT

    1. Install the engine wire with the 4 bolts.

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

    2. Connect all the connectors and the harness clamps.

  9. INSTALL VACUUM SWITCHING VALVE ASSEMBLY

    A011ASU

    1. Install the vacuum switching valve assembly with the bolt.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

    2. Connect the vacuum switching valve assembly connector.

  10. INSTALL NO. 2 RADIATOR HOSE

    A0119GDE01

    1. Install the No. 2 radiator hose with the clip.

      Tech Tips

      Install the clip as shown in the illustration.

  11. INSTALL NO. 1 IGNITION COIL

    A011ANA

    1. Install the 3 No. 1 ignition coils with the 3 bolts.

      Torque:
      9.0 N*m  { 91 kgf*cm, 80 in.*lbf }

    2. Connect the 3 No. 1 ignition coil connectors.

  12. INSTALL NO. 1 RADIATOR HOSE

    A0118ZJE01

    1. Install the No. 1 radiator hose with the 2 clips.

      Tech Tips

      Install the clip as shown in the illustration.

  13. INSTALL WATER BY-PASS HOSE ASSEMBLY

    A011BN6E01

    1. Install the water by-pass hose assembly with the 2 clips.

      Tech Tips

      Install the clips as shown in the illustration.

  14. INSTALL INJECTOR VIBRATION INSULATOR


    1. A0118JT

      Install 3 new injector vibration insulators to the cylinder head.

  15. INSTALL FUEL INJECTOR ASSEMBLY


    1. A011B36E03
      Text in Illustration
      *1 O-ring

      Apply a light coat of gasoline or spindle oil to the contact surfaces of a new O-ring, and install it onto the injector.

    2. A0117K9

      While turning the fuel injector assembly left and right, install it onto the fuel delivery pipe.

      Note


      • Do not twist the O-ring.

      • Check that the fuel injector assemblies rotate smoothly after installing it onto the fuel delivery pipe. If the fuel injector assembly does not rotate smoothly, replace the O-ring with a new one and install it again.

  16. INSTALL FUEL PIPE INSULATOR


    1. A0118IV

      Install the 2 fuel pipe insulators onto the fuel delivery pipe.

  17. INSTALL FUEL DELIVERY PIPE


    1. A011AQY

      Install the fuel delivery pipe with the 2 bolts.

      Torque:
      27 N*m  { 275 kgf*cm, 20 ft.*lbf }

      Note


      • Do not drop the fuel injector assembly.

      • After installing, check that the fuel injector assembly is securely connected by turning it by hand.

    2. A0119ZX

      Connect the 3 fuel injector assembly connectors.

    3. A011AOR

      Engage the 3 harness clamps and connect the 3 connectors.

  18. INSTALL EGR VALVE ASSEMBLY


    1. A011BD9

      Install a new gasket to the cylinder head.

    2. Insert the EGR valve into the stud bolt, rotate the EGR valve to avoid contact with the delivery pipe, and temporarily install the EGR valve.

    3. A0117RTE01

      Connect the water by-pass hose.

    4. Connect the EGR valve connector.

  19. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR

    A0117GE

    1. Temporarily install the intake manifold insulator with a new gasket, the 2 bolts and the nut.

  20. INSTALL INTAKE MANIFOLD

    A011BIQ

    1. Install the new gasket onto the intake manifold.

    2. A011B3B

      Install the intake manifold with the 2 bolts and 2 nuts in the order shown in the illustration.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }
    3. A01187W

      Connect the vacuum hose, ventilation hose and install the 2 bolts.

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

    4. Connect the 2 connectors and 4 harness clamps.

  21. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY

    A0118CC

    1. Install the new gasket onto the intake manifold.

    2. A0118WD

      Install the throttle with motor body assembly with the 3 bolts and nut.

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

    3. Connect the throttle with motor body assembly connector.

    4. A0118QG

      Connect the 2 water by-pass hoses with the 2 clips.

      Tech Tips

      Install the clips as shown in the illustration.

    5. Install the 2 water by-pass hoses to the hose clamp.

  22. INSTALL GENERATOR ASSEMBLY


    1. A01182A

      Temporarily install the generator assembly with the bolt.

    2. A0117T0E01

      Temporarily install the fan belt adjusting bar with bolt A and bolt B.

    3. Tighten bolt B with the generator assembly near the cylinder block.

      Torque:
      21 N*m  { 214 kgf*cm, 16 ft.*lbf }
    4. A011736

      Install the 2 brackets with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    5. A0119FE

      Connect the connector and wire harness clamps.

    6. Install the terminal B with the nut.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    7. Install the terminal cap.