ENGINE UNIT INSTALLATION

PROCEDURE

  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.

        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.

        Tip:

        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.

        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.

        Tip:

        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

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  3. INSTALL NO. 1 VACUUM PUMP BRACKET

    1. A172102

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

      21 N*m

      214 kgf*cm

      15 ft.*lbf

  4. INSTALL VACUUM PUMP ASSEMBLY

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  5. INSTALL IGNITION COIL ASSEMBLY

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  6. INSTALL THERMOSTAT

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  7. INSTALL WATER INLET

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  8. INSTALL WATER INLET HOSE

    1. A154919

      Install the water inlet hose with the 2 clamps.

  9. INSTALL WATER BY-PASS HOSE

    1. A206175

      Install the water by-pass hose with the clamp.

  10. INSTALL NO. 1 WATER BY-PASS PIPE

    1. A154918

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

      21 N*m

      214 kgf*cm

      15 ft.*lbf

  11. CONNECT NO. 3 WATER BY-PASS HOSE

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  12. INSTALL VENTILATION HOSE

    1. Install the ventilation hose to the ventilation valve.

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

    1. A346741

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

      25 N*m

      255 kgf*cm

      18 ft.*lbf

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

    1. A346742E02

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

      Table 1. Text in Illustration

      *1

      Idler Pulley Cover Plate

      *2

      No. 1 Idler Pulley Sub-assembly

      *3

      Idler Pulley Bracket

    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.

      60 N*m

      612 kgf*cm

      44 ft.*lbf

  15. INSTALL EXHAUST MANIFOLD

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  16. INSTALL MANIFOLD STAY

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  17. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

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  18. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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  19. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    1. A154921

      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.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

    4. Install the engine oil level dipstick.

  20. INSTALL FUEL INJECTOR ASSEMBLY

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  21. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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  22. INSTALL FUEL TUBE SUB-ASSEMBLY

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  23. INSTALL WIRE HARNESS CLAMP BRACKET

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  24. INSTALL AIR TUBE

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  25. INSTALL INTAKE MANIFOLD

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  26. INSTALL THROTTLE BODY ASSEMBLY

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