ENGINE UNIT INSTALLATION


  1. 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.

  2. INSTALL VENTILATION HOSE


    1. Install the ventilation hose to the ventilation valve.

  3. INSTALL EXHAUST MANIFOLD


    1. A003SA1E01
      Text in Illustration
      *A Nut Type A
      *B Nut Type B

      Install 2 new gaskets and the exhaust manifold with the 7 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  { 439 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. A003TI9E06
      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. A003TTV

      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.

  7. INSTALL NO. 1 DELIVERY PIPE SPACER


    1. A003U9V

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

  10. 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. A003SLWE01

      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. A003SBT

      Connect the 2 wire harness clamps and 3 connectors.

  11. INSTALL EGR WITH COOLER PIPE SUB-ASSEMBLY


    1. A003TH3E01
      Text in Illustration
      *A Nut (C), Type A
      *B Nut (C), Type B
      *1 Bolt
      *2 Stud Bolt and Nut

      Temporarily install a new gasket and the EGR cooler sub-assembly with the 2 nuts (A).

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

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

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

    4. Temporarily install the 4 nuts (B and C) and bolt.

    5. Tighten the 2 nuts (A).

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

    6. Tighten the 2 nuts (B) 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. Tighten the 2 nuts (C).

      Torque:
      Type A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Type B
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
    8. A003SPT

      Connect the connector, wire harness clamp and 4 water hoses.

  12. INSTALL EGR VALVE ASSEMBLY


    1. A003T48E01
      Text in Illustration
      *A Nut (C), Type A
      *B Nut (C), Type B
      *1 Bolt
      *2 Stud Bolt and Nut

      Temporarily install a new gasket and the EGR valve assembly with the 2 nuts (A).

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

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

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

    4. Temporarily install the 4 nuts (B and C) and bolt.

    5. Tighten the 2 nuts (A).

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

    6. Tighten the 2 nuts (B) 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. Tighten the 2 nuts (C).

      Torque:
      Type A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Type B
      37 N*m  { 377 kgf*cm, 27 ft.*lbf }
    8. A003SPT

      Connect the connector, wire harness clamp and 4 water hoses.

  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 with the installation surfaces.

    2. Install the wire harness support with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    3. A003SHC

      Connect the 2 wire harness clamps.

  14. 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. A003UU4E01

      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.

  15. 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.

  16. INSTALL ENGINE HANGERS


    1. A003RGQ

      Install the 2 engine hangers with the 2 bolts.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }
      Part Name Part No.
      No. 1 engine hanger 12281-37021
      No. 2 engine hanger 12282-37011
      Bolt 91552-81050

  17. REMOVE ENGINE STAND


    1. Remove the bolts and engine from the engine stand.