ENGINE UNIT INSTALLATION


  1. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. When replacing the V-ribbed belt tensioner assembly with a new one.


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

        Note

        Make sure to install a new V-ribbed belt tensioner assembly with the pin and white cover installed to it.

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

      2. Remove the white cover.

      3. Rotate the V-ribbed belt tensioner assembly slightly clockwise and remove the pin that is used to keep the spring compressed.

        Note


        • Do not forcibly rotate the V-ribbed belt tensioner assembly to the V-ribbed belt installation position with the pin installed.

        • Do not apply or add any oil or grease to the V-ribbed belt tensioner assembly.

        Tech Tips

        When installing the V-ribbed belt, rotate the V-ribbed belt tensioner assembly clockwise again with the pin removed, and secure the V-ribbed belt tensioner assembly using a 5 mm hexagon wrench.

    2. When reusing the V-ribbed belt tensioner assembly.


      1. Check that the 3 mm hexagon wrench is installed to the V-ribbed belt tensioner assembly.

      2. Install the V-ribbed belt tensioner assembly to the engine assembly with the 2 bolts.

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

      3. Rotate the V-ribbed belt tensioner assembly slightly clockwise and remove the 3 mm hexagon wrench that is used to keep the spring compressed.

        Note

        Do not forcibly rotate the V-ribbed belt tensioner assembly to the V-ribbed belt installation position with the 3 mm hexagon wrench installed.

        Tech Tips

        When installing the V-ribbed belt, rotate the V-ribbed belt tensioner assembly clockwise again with the 3 mm hexagon wrench removed, and secure the V-ribbed belt tensioner assembly using a 5 mm hexagon wrench.

  2. INSTALL ENGINE OIL TEMPERATURE SENSOR


    1. Install a new gasket to the engine oil temperature sensor.

    2. Using a 19 mm deep socket wrench, install the engine oil temperature sensor to the timing chain cover sub-assembly.

      Torque:
      20 N*m  { 200 kgf*cm, 14 ft.*lbf }

      Note

      If the engine oil temperature sensor has been struck or dropped, replace it.

    3. Connect the engine oil temperature sensor connector.

  3. INSTALL NO. 1 VACUUM PUMP BRACKET


    1. A01IPRW

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

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

  4. INSTALL VACUUM PUMP ASSEMBLY


    1. Apply engine oil to 2 new O-rings.

    2. A01IS1I

      Install the 2 O-rings to the vacuum pump.

    3. A01IS3HE01
      Text in Illustration
      *1 Engine oil

      Apply engine oil to the cylinder hollow.

    4. A01IQ91E03

      Install the vacuum pump so that the coupling teeth of the vacuum pump (labeled A) and the grooves of the camshaft (labeled B) engage.

      Note

      Be careful not to damage the O-ring.

    5. A01IRM2

      Install the vacuum pump with the 3 bolts.

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

      Note

      Confirm that the vacuum pump is not at an angle, and that there is no clearance between the fitting surfaces.

  5. INSTALL IGNITION COIL ASSEMBLY


    1. A01IRN7E01
      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.

      Tech Tips

      Perform "Inspection After Repairs" after replacing the ignition coil assembly Click here.

    2. A01IO82

      Connect the 4 ignition coil connectors.

  6. INSTALL THERMOSTAT


    1. Install a new gasket to the thermostat.

    2. A01IO3SE05

      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.

  7. INSTALL WATER INLET


    1. A01IR3Q

      Install the water inlet with the 2 nuts.

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

  8. INSTALL WATER INLET HOSE


    1. A01IQ5S

      Install the water inlet hose with the 2 clamps.

  9. INSTALL WATER BY-PASS HOSE


    1. A01IS6N

      Install the water by-pass hose with the clamp.

  10. INSTALL NO. 1 WATER BY-PASS PIPE


    1. A01IPEK

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

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

  11. CONNECT NO. 3 WATER BY-PASS HOSE


    1. A01IS6M

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

  12. INSTALL VENTILATION HOSE


    1. Install the ventilation hose to the ventilation valve.

  13. INSTALL IDLER PULLEY BRACKET (w/o Air Conditioning System)


    1. A01IRZA

      Install the idler pulley bracket with the 2 nuts and bolt.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  14. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY (w/o Air Conditioning System)


    1. A01IPAEE01
      Text in Illustration
      *1 Idler Pulley Cover Plate
      *2 No. 1 Idler Pulley Sub-assembly
      *3 Idler Pulley Bracket

      Install the 2 idler pulley cover plates and bolt to the No. 1 idler pulley sub-assembly as shown in the illustration.

    2. Tighten the bolt by hand until the flange of the bolt contacts the idler pulley cover plate and the No. 1 idler pulley sub-assembly is fixed in place.

      Note

      Do not use any tools.

    3. Tighten the bolt.

      Torque:
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }

  15. INSTALL EXHAUST MANIFOLD


    1. Install a new exhaust manifold gasket.

    2. Install the exhaust manifold with 5 new nuts.

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

  16. INSTALL MANIFOLD STAY


    1. A01IUFSE01

      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 }

  17. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY


    1. Install the drive shaft heat insulator sub-assembly with the 2 nuts.

      Torque:
      18 N*m  { 179 kgf*cm, 13 ft.*lbf }

  18. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. Install the No. 1 exhaust manifold heat insulator with the 4 bolts.

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

  19. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A01IU0I

      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.

  20. INSTALL FUEL INJECTOR ASSEMBLY

    Tech Tips

    Perform "Inspection After Repairs" after replacing the fuel injector assembly Click here.


    1. A01IPJEE06
      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. A01IU3A

      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.

  21. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. A01IP4K

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

      Note

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

    2. A01IUIW

      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.

    3. A01IUIW

      Tighten the 2 bolts to the specified torque.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    4. A01IPXR

      Install the bolt to secure the fuel delivery pipe.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    5. A01ISYL

      Install the wire harness bracket with the bolt.

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

  22. INSTALL FUEL TUBE SUB-ASSEMBLY


    1. A01IRMYE01
      Text in Illustration
      *1 Retainer
      *2 Pipe
      *3 O-Ring

      Push the fuel tube 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. A01IURWE01
      Text in Illustration
      *1 Claw

      Install a new No. 2 fuel pipe clamp.

  23. INSTALL WIRE HARNESS CLAMP BRACKET


    1. A01IU5T

      Install the wire harness clamp bracket with the 2 nuts.

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

  24. INSTALL AIR TUBE


    1. A01IN4RE01

      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.

      Text in Illustration
      *1 Union To Connector Tube Hose
      *2 Vacuum Hose
      *3 No. 2 Air Hose
      *4 No. 1 Fuel Vapor Feed Hose

    3. Connect the union to connector tube hose and vacuum hose.

    4. A01IONW

      Connect the fuel vapor feed hose to the purge VSV.

  25. INSTALL INTAKE MANIFOLD


    1. w/ Stud Bolt:

      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. Install a new gasket to the intake manifold.

    4. 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. Connect the fuel vapor feed hose and ventilation hose.

    6. 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 }

  26. INSTALL THROTTLE BODY ASSEMBLY

    Tech Tips

    Perform "Inspection After Repairs" after replacing the throttle body assembly Click here.


    1. Install a new gasket to the intake manifold.

    2. A01IQHEE01
      Text in Illustration
      *a for Type A
      *b for Type B

      for Type A:

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

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

    3. for Type B:

      Install the throttle body with the 4 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    4. A01IUOW

      Connect the throttle body connector and 2 water hoses.