ENGINE UNIT INSTALLATION


  1. INSTALL IGNITION COIL ASSEMBLY


    1. A0042QC

      Install the 4 ignition coils with the 4 bolts.

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

      Note

      When installing each ignition coil, do not damage the plug cap on the engine head cover opening or the upper edge of the spark plug tube.

    2. Connect the 4 ignition coil connectors.

  2. INSTALL VENTILATION HOSE


    1. Install the ventilation hose to the ventilation valve.

  3. INSTALL EXHAUST MANIFOLD


    1. A0042PJE01
      Text in Illustration
      *A Nut Type A
      *B Nut Type B

      Install a new gasket and the exhaust manifold with the 5 nuts.

      Torque:
      Type A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Type B
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  4. INSTALL MANIFOLD STAY


    1. Install the manifold stay with the 3 bolts.

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

  5. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 1 exhaust manifold heat insulator with the 3 bolts.

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

  6. INSTALL FUEL INJECTOR ASSEMBLY


    1. A0043FXE06
      Text in Illustration
      *1 O-ring
      *2 Injector Vibration Insulator

      Install a new injector vibration insulator and O-ring to each fuel injector assembly.

    2. Apply a light coat of gasoline or spindle oil to the contact surfaces of the new O-ring on each fuel injector assembly.

    3. A0043S2

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

      Note


      • Make sure that the O-ring is not cracked or jammed when installing the fuel injector assembly Click here.

      • If a component has been dropped or subjected to a strong impact, replace it.

      • After installing each fuel injector, check that it turns smoothly. If not, replace the O-ring with a new one.

  7. INSTALL NO. 1 DELIVERY PIPE SPACER


    1. A0042IJE01
      Text in Illustration
      *a Delivery Pipe Side
      *b Cylinder Head Side

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

      Note

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

  8. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. Install the fuel delivery pipe sub-assembly with the 4 fuel injector assemblies and install the 2 bolts.

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

      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. Install the bolt to secure the fuel delivery pipe sub-assembly.

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

  9. INSTALL FUEL VAPOR FEED PIPE


    1. Install the fuel vapor feed pipe with the bolt.

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

  10. INSTALL INTAKE MANIFOLD


    1. w/ Stud Bolt:


      1. Using an E6 "TORX" socket wrench, install the 2 stud bolts to the intake manifold.

        Torque:
        5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

        Tech Tips

        If a stud bolt is deformed or the threads are damaged, replace it.

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

    3. Install the intake manifold with the 2 bolts and 2 nuts.

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

    4. Connect the ventilation hose and slide the clip to secure it.

    5. Connect the fuel vapor feed hose.

    6. Install a new O-ring to the engine oil level dipstick guide sub-assembly.

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

    8. A0041JPE03

      Install the engine oil level dipstick guide sub-assembly with the 2 bolts and connect the wire harness clamp.

      Torque:
      Bolt (A)
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
      Bolt (B)
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    9. Install the engine oil level dipstick.

    10. A00428G

      Connect the 2 wire harness clamps and 3 connectors.

  11. INSTALL VACUUM SWITCHING VALVE ASSEMBLY


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

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

    2. Connect the 2 fuel vapor feed hoses to the intake manifold and fuel vapor feed pipe.

  12. INSTALL EGR VALVE WITH COOLER ASSEMBLY


    1. A0041M6E01
      Text in Illustration
      *A Nut (B), Type A
      *B Nut (B), Type B
      *1 Bolt
      *2 Stud Bolt and Nut

      Install a new gasket and set the EGR valve with cooler assembly in place.

    2. Using an E8 "TORX" socket wrench, install the 4 stud bolts.

      Torque:
      Stud Bolt (A)
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }
      Stud Bolt (B)
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    3. Temporarily install the 4 nuts (A and B) and bolt.

    4. Tighten the 2 nuts (A) and bolt.

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

      Note

      Make sure that all installation surfaces of the EGR valve with cooler assembly are in even contact when tightening the bolts and nuts.

    5. Tighten the 2 nuts (B).

      Torque:
      Type A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Type B
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }

  13. INSTALL EGR PIPE ASSEMBLY


    1. Install 2 new gaskets and EGR pipe assembly with the 4 bolts.

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

      Note

      Make sure to tighten the 4 bolts evenly until the flanges of the EGR pipe assembly contact the installation surfaces.

    2. Install the wire harness support with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    3. A0042P5

      Connect the 2 wire harness clamps.

  14. INSTALL THROTTLE BODY ASSEMBLY


    1. A0041CI

      Install a new gasket to the intake manifold.

    2. w/ Stud Bolt:


      1. Install the throttle body assembly to the intake manifold with the 2 bolts and 2 nuts.

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

      2. Connect the 2 water by-pass hoses to the throttle body assembly and slide the 2 clips to secure them.

      3. Connect the throttle body assembly connector.

    3. w/o Stud Bolt:


      1. Install the throttle body assembly to the intake manifold with the 4 bolts.

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

      2. Connect the 2 water by-pass hoses to the throttle body assembly and slide the 2 clips to secure them.

      3. Connect the throttle body assembly connector.