ENGINE UNIT INSTALLATION

INSTALL IGNITION COIL ASSEMBLY
1. 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.
INSTALL VENTILATION HOSE
1. Install the ventilation hose to the ventilation valve.
INSTALL EXHAUST MANIFOLD
1. Install 2 new gaskets and the exhaust manifold with the 7 nuts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL MANIFOLD STAY
1. Install the manifold stay with the 3 bolts.
  
  Torque:
  
  43 N*m { 440 kgf*cm, 32 ft.*lbf }
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 }
INSTALL FUEL INJECTOR ASSEMBLY
1. Text in Illustration
  
  *1 O-ring
  
  *2 Insulator
  
  Install a new 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. While turning the fuel injector assembly left and right, install it onto the fuel delivery pipe sub-assembly.
  Note
  
  Do not damage the fuel injector assembly or O-ring.
  
  Do not twist the O-ring.
  
  After installing each fuel injector, check that it turns smoothly. If not, replace the O-ring with a new one.
INSTALL NO. 1 DELIVERY PIPE SPACER
1. Install the 2 No. 1 delivery pipe spacers onto the cylinder head.
  
  Note
  
  Install the No. 1 delivery pipe spacers in the correct direction.
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 }
INSTALL FUEL VAPOR FEED PIPE
1. Install the fuel vapor feed pipe with the bolt.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL INTAKE MANIFOLD
1. Install a new No. 1 intake manifold to head gasket to the intake manifold.
2. Install the intake manifold with the 2 bolts and 2 nuts.
  
  Torque:
  
  28 N*m { 285 kgf*cm, 21 ft.*lbf }
3. Connect the fuel vapor feed hose and ventilation hose.
4. Install a new O-ring to the engine oil level dipstick guide sub-assembly.
5. Apply a light coat of engine oil to the O-ring.
6. 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 { 285 kgf*cm, 21 ft.*lbf }
  
  Bolt (B)
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
7. Install the engine oil level dipstick.
8. Connect the 2 wire harness clamps and 3 connectors.
INSTALL EGR WITH COOLER PIPE SUB-ASSEMBLY
1. Text in Illustration
  
  *1 Bolt
  
  *2 Stud Bolt and Nut
  
  Temporarily install the EGR cooler sub-assembly with the 2 nuts (A and B).
2. Set a new gasket and EGR valve with cooler assembly.
3. Using an E8 "TORX" wrench, install the 4 stud bolts.
  
  Torque:
  
  9.5 N*m { 97 kgf*cm, 84 in.*lbf }
4. Temporarily install the 2 nuts (C) and bolt.
5. Tighten the nut (A).
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
6. Tighten the 3 nuts (B and C) 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.
7. Connect the connector, wire harness clamp and 4 water hoses.
INSTALL EGR VALVE ASSEMBLY
1. Text in Illustration
  
  *1 Bolt
  
  *2 Stud Bolt and Nut
  
  Temporarily install the EGR valve assembly with the 2 nuts (A and B).
2. Set a new gasket and EGR valve with cooler assembly.
3. Using an E8 "TORX" wrench, install the 4 stud bolts.
  
  Torque:
  
  9.5 N*m { 97 kgf*cm, 84 in.*lbf }
4. Temporarily install the 2 nuts (C) and bolt.
5. Tighten the nut (A).
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
6. Tighten the 3 nuts (B and C) 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.
7. Connect the connector, wire harness clamp and 4 water hoses.
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 with the installation surfaces.
2. Install the wire harness support with the bolt.
3. Connect the 2 wire harness clamps.
INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
1. Apply a light coat of engine oil to a new O-ring.
2. Install the O-ring to the engine oil level dipstick guide.
3. Install the engine oil level dipstick guide with the 2 bolts.
  
  Torque:
  
  Bolt A
  
  28 N*m { 286 kgf*cm, 21 ft.*lbf }
  
  Bolt B
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
4. Connect the clamp to the engine oil level dipstick guide.
5. Install the oil dipstick.
INSTALL THROTTLE BODY ASSEMBLY
1. Install a new gasket onto the intake manifold.
2. Install the throttle body assembly with the 2 bolts and 2 nuts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
3. Connect the 2 water by-pass hoses and throttle body connector.