ENGINE UNIT INSTALLATION


  1. INSTALL WIRING HARNESS CLAMP BRACKET


    1. Install the wiring harness clamp bracket to the cylinder head cover with the bolt.

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

    2. Install the wiring harness clamp bracket to the cylinder head with the bolt.

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

    3. Install the wiring harness clamp bracket to the cylinder block with the bolt.

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

  2. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. Install the V-ribbed belt tensioner with the 2 bolts.

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

  3. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY (w/ No. 1 Engine Cover)

    A011BX4E01
    *1 Stopper

    1. Install the V-ribbed belt tensioner and engine cover bracket with the 2 bolts.

      Note

      Attach stopper of the bracket to the auto tensioner.

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

  4. INSTALL NO. 2 IDLE PULLEY ASSEMBLY (w/ Air Conditioning System)

    A0119MWE01

    1. Temporarily install the No. 2 idle pulley with the 4 bolts.

    2. Fully tighten the 4 bolts in the order shown in the illustration.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

  5. INSTALL NO. 1 WATER BY-PASS PIPE

    A0118TEE01
    Text in Illustration
    *1 Water By-Pass Hose
    *2 No. 1 water by-pass pipe
    *3 No. 2 Water By-Pass Hose
    *4 Protector
    *5 Clip

    1. Connect the water by-pass hose to the water inlet with the clip.

      Note

      Install the clip so that its claws face away from the engine.

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

    3. Fully tighten the 3 bolts in the order shown in the illustration.

      Torque:
      22 N*m  { 224 kgf*cm, 16 ft.*lbf }

    4. Engage the No. 2 water by-pass hose to the 3 clamps as shown in the illustration.

  6. INSTALL NO. 2 VENTILATION HOSE

    A0118CBE01
    Text in Illustration
    *a View A
    *b Upper
    *c Clip center installation range
    *d Paint mark of the hose

    1. Install the ventilation hose to the cylinder head with the clip.

      Note


      • Install the clip so that its claws are within the clip center installation range.

      • The protrusion of the head cover should overlap the paint mark of the hose.

  7. INSTALL VENTILATION HOSE

    A0117Y7E01
    Text in Illustration
    *a View A
    *b Left
    *c Rear
    *d Clip center installation range

    1. Install the ventilation hose to the cylinder head with the clip.

      Note

      Install the clip so that its claws are within the clip center installation range.

  8. INSTALL NO. 1 IGNITION COIL


    1. Install the 4 ignition coils with the 4 bolts.

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

  9. INSTALL INJECTOR VIBRATION INSULATOR


    1. Install 4 new injector vibration insulators onto the cylinder head.

  10. INSTALL NO. 1 DELIVERY PIPE SPACER


    1. A0119LU

      Install the 2 No. 1 delivery pipe spacers onto the cylinder head.

      Note

      Install the No. 1 delivery pipe spacers in the correct direction.

  11. INSTALL FUEL INJECTOR ASSEMBLY


    1. A011ATKE02
      Text in Illustration
      *1 O-Ring

      Apply a light coat of gasoline or spindle oil to new O-rings, then install one onto each fuel injector assembly.

    2. Apply a light coat of gasoline or spindle oil to the contact surfaces of the fuel delivery pipe and the O-ring of the fuel injector assembly.

    3. A011AX9E02
      Text in Illustration
      *a Turn
      *b Push

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

      Note


      • Do not twist the O-ring.

      • After installing the fuel injectors, check that they turn smoothly. If not, replace the O-ring with a new one.

  12. INSTALL FUEL DELIVERY PIPE


    1. Install the fuel delivery pipe with the 4 fuel injectors, and then temporarily install the 2 bolts.

      Note


      • Do not drop the fuel injectors when installing the fuel delivery pipe sub-assembly.

      • Check that the fuel injector assemblies rotate smoothly after installing the fuel delivery pipe sub-assembly.

    2. Tighten the 2 bolts to the specified torque.

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

  13. INSTALL EGR VALVE ASSEMBLY


    1. Install a new EGR valve gaskets onto the cylinder head.

    2. Install the EGR valve with the bolt and 2 new nuts.

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

  14. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


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

      Tech Tips

      Apply engine oil to the O-ring and install the oil level dipstick guide into the oil pan.

    2. A011708E01

      Temporarily install the engine oil level dipstick guide with the 2 bolts.

    3. Fully tighten the 2 bolts in the order shown in the illustration.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  15. INSTALL ENGINE OIL LEVEL DIPSTICK

  16. INSTALL NO. 4 ENGINE WIRE


    1. Engage the 7 clamps and install the No. 4 engine wire.

    2. Install the ground bolt.

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    3. Connect the 4 fuel injector connectors.

    4. Connect the 4 ignition coil connectors.

    5. Connect the 2 camshaft timing oil control valve connectors.

  17. INSTALL INTAKE MANIFOLD ASSEMBLY


    1. Install a new No. 2 intake manifold to head gasket onto the cylinder head.

    2. Install the EGR delivery chamber onto the No. 2 intake manifold to head gasket.

    3. Install a new intake manifold to head gasket onto the EGR delivery chamber.

    4. A011BRYE01

      Temporarily install the intake manifold with the 5 bolts and 2 nuts.

    5. Fully tighten the 5 bolts and 2 nuts in the order shown in the illustration.

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

  18. INSTALL EGR PIPE CONNECTOR


    1. Install 2 new EGR pipe gaskets onto the intake manifold and the EGR valve.

    2. A0118NGE01

      Temporarily install the EGR pipe connector with the 4 nuts.

    3. Fully tighten the A nuts first, and then tighten nut B.

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

  19. INSTALL INTAKE MANIFOLD STAY

    A0117HLE01

    1. Temporarily install the intake manifold stay with the 2 bolts.

    2. Fully tighten the 2 bolts in the order shown in the illustration.

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

  20. CONNECT NO. 4 WATER BY-PASS HOSE

    A0116XFE01
    Text in Illustration
    *a View A
    *b Upper
    *c Clip center installation range

    1. Connect the No. 4 water by-pass hose to the EGR valve with the clip.

      Note

      Install the clip so that its claws are within the clip center installation range.

  21. CONNECT NO. 2 WATER BY-PASS HOSE

    A0117I2E01
    Text in Illustration
    *a View A
    *b Upper
    *c Clip installation range
    *d Paint mark of the hose

    1. Connect the No. 2 water by-pass hose to the throttle body with the clip.

      Note


      • Install the clip so that its claws are within the clip installation range.

      • Line up the rib of the throttle with motor body assembly with the center of the paint mark.

  22. CONNECT VENTILATION HOSE

    A011BXFE01
    Text in Illustration
    *a View A
    *b Upper
    *c Left
    *d Clip center installation range

    1. Connect the ventilation hose to the intake manifold with the clip.

      Note

      Install the clip so that its claws are within the clip center installation range.

  23. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. Install the new exhaust manifold to head gasket and the new inlet EGR gasket onto the cylinder head.

    2. A011B97E01

      Temporarily install the exhaust manifold converter with the 3 bolts and 4 nuts.

    3. Fully tighten the 3 bolts and 4 nuts in the order shown in the illustration.

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

  24. INSTALL MANIFOLD STAY

    A011A6UE01

    1. Temporarily install the manifold stay with the bolt and nut.

    2. Fully tighten the bolt and nut in the order shown in the illustration.

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

  25. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    A011ARDE01

    1. Temporarily install the exhaust manifold heat insulator with the bolt and 2 nuts.

    2. Fully tighten the bolt and 2 nuts in the order shown in the illustration.

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

  26. INSTALL GENERATOR ASSEMBLY

    A011BS7E01

    1. Install the generator with the 2 bolts.

      Torque:
      Bolt A
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }
      Bolt B
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }