ENGINE UNIT INSTALLATION


  1. INSTALL NO. 1 VACUUM PUMP BRACKET


    1. A005VRQ

      Install a new gasket and the vacuum pump bracket with the 2 bolts.

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

  2. INSTALL VACUUM PUMP ASSEMBLY


    1. A00ON9NE02
      Text in Illustration
      *1 No. 2 O-ring
      *2 No. 3 O-ring

      Apply engine oil to the No. 2 and No. 3 O-rings on the vacuum pump assembly.

      Note

      When removing and installing the vacuum pump assembly, replace the No. 2 and No. 3 O-rings with new ones.

    2. Apply engine oil to the inner surface of the installation hole.

    3. A00OLO5

      Install the vacuum pump assembly so that the oil pipe engages with the hole of the camshaft and the coupling teeth with the grooves on the camshaft tip.

      Note


      • Ensure that the vacuum pump assembly is installed securely.

      • Be careful not to pinch the O-ring.

      Tech Tips

      Apply engine oil to the O-ring.

    4. A00OIZAE01

      Install the vacuum pump assembly with the 3 bolts.

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

      Note


      • After installation, check that there are no gaps between the matching surfaces and that the vacuum pump assembly is not installed at an angle.

      • As 2 different lengths of bolts are used, make sure to check the proper installation positions before installing them.

      • After tightening the bolts, ensure that the contact surface of the vacuum pump assembly is flush with the cylinder head.

      Tech Tips


      • Bolt length

        Bolt A: 25 mm

        Bolt B: 45 mm

  3. INSTALL RADIO SETTING CONDENSER


    1. A005TG3

      Install the setting condenser with the bolt.

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

  4. INSTALL IGNITION COIL ASSEMBLY


    1. A005RTQE01
      Text in Illustration
      *1 Cylinder Head Cover
      *2 Spark Plug Tube
      *3 Plug Cap

      Install the 4 ignition coils with the 4 bolts.

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

      Note

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

    2. A005T4M

      Connect the 4 ignition coil connectors.

  5. INSTALL THERMOSTAT


    1. Install a new gasket to the thermostat.

    2. A00OKDCE05

      Install the thermostat to the water inlet.

      Note

      The jiggle valve must be set within 10° on either side of the position shown in the illustration.

  6. INSTALL WATER INLET


    1. A00OLAP

      Install the water inlet with the 2 nuts.

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

  7. INSTALL WATER INLET HOSE


    1. A005RB5

      Install the water inlet hose with the 2 clamps.

  8. INSTALL WATER BY-PASS HOSE


    1. A005V19

      Install the water by-pass hose with the clamp.

  9. INSTALL NO. 1 WATER BY-PASS PIPE


    1. A005SSP

      Install the water by-pass pipe with the 2 bolts.

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

  10. CONNECT NO. 3 WATER BY-PASS HOSE


    1. A00DS82

      Connect the No. 3 water by-pass hose to the water inlet housing.

  11. INSTALL VENTILATION HOSE


    1. Install the ventilation hose to the ventilation valve.

  12. INSTALL NO. 3 WATER BY-PASS PIPE (for CVT)


    1. A005VAT

      Install a new gasket and the water by-pass pipe with the 2 nuts.

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

  13. INSTALL DRIVE SHAFT BEARING BRACKET


    1. A005U2E

      Install the drive shaft bearing bracket with the 3 bolts.

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

  14. INSTALL EXHAUST MANIFOLD


    1. Install a new exhaust manifold gasket.

    2. for Nut Type A:


      1. A010I2TE01
        Text in Illustration
        *A Nut Type A
        *B Nut Type B

        Install the exhaust manifold with the 5 nuts.

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

    3. for Nut Type B:


      1. Install the exhaust manifold with 5 new nuts.

        Torque:
        26 N*m  { 265 kgf*cm, 19 ft.*lbf }

  15. INSTALL MANIFOLD STAY

    A010HS6E01

    1. Temporarily install the manifold stay with the 3 bolts.

    2. While pushing the manifold stay toward the exhaust manifold, tighten the 2 bolts labeled 1.

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

    3. Tighten the bolt labeled 2.

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

  16. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A010IVS

      Install the heat insulator with the 3 bolts.

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

  17. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A005S94

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

    2. Install the O-ring to the dipstick guide.

    3. Install the dipstick guide with the bolt.

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

    4. Install the engine oil level dipstick.

  18. INSTALL FUEL INJECTOR ASSEMBLY


    1. A00OJOBE06
      Text in Illustration
      *1 O-Ring
      *2 Injector Vibration Insulator

      Install a new injector vibration insulator to the fuel injector.

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

    3. A00ONO6

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

      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.

  19. INSTALL NO. 1 DELIVERY PIPE SPACER


    1. A00OMYZ

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

      Note

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

  20. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. A00OMR1

      Install the fuel delivery pipe with the 4 fuel injector assemblies, and then temporarily install the 2 bolts.

      Note


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

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

    2. A00OMR1

      Tighten the 2 bolts to the specified torque.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    3. A00OJIN

      Install the bolt to secure the fuel delivery pipe.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    4. A00OM0R

      Install the wire harness bracket with the bolt.

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

  21. INSTALL FUEL TUBE SUB-ASSEMBLY


    1. A00OL5UE01
      Text in Illustration
      *1 Retainer
      *2 Pipe
      *3 O-Ring

      Push the fuel tube sub-assembly connector onto the fuel delivery pipe until a "click" sound can be heard.

      Note


      • Check that there are no scratches or foreign matter around the contact surfaces of the fuel tube connector and pipe before performing this step.

      • After connecting the fuel tube, check that the fuel tube connector and pipe are securely connected by pulling on them.

    2. A00OI4GE01
      Text in Illustration
      *1 Claw

      Install a new No. 2 fuel pipe clamp.

  22. INSTALL WIRE HARNESS CLAMP BRACKET


    1. A00OMX5

      Install the wire harness clamp bracket with the 2 nuts.

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

  23. INSTALL AIR TUBE


    1. A00OK27

      Install the air tube with the 2 bolts.

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

    2. Connect the No. 2 air hose and No. 1 fuel vapor feed hose.

    3. Connect the 2 union to connector tube hoses.

    4. Connect the fuel vapor feed hose to the purge VSV.

  24. INSTALL INTAKE MANIFOLD


    1. A00OIZJ

      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 }

    2. Install the wire harness clamp bracket to the intake manifold with the bolt.

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }
    3. A00OL7X

      Install a new gasket to the intake manifold.

    4. A00OKBM

      Install the intake manifold and intake manifold stay with the 5 bolts and 2 nuts.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
    5. A00OLZV

      Connect the fuel vapor feed hose and ventilation hose.

    6. A00OJD4

      Attach the 5 clamps to the intake manifold.

    7. Install the wire harness clamp bracket with the bolt.

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

  25. INSTALL THROTTLE BODY ASSEMBLY


    1. Install a new gasket to the intake manifold.

    2. A00OKFZ

      Install the throttle body with the 2 bolts and 2 nuts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    3. A00ONBL

      Connect the throttle body connector and 2 water hoses.