ENGINE UNIT INSTALLATION

PROCEDURE


  1. INSTALL IDLER PULLEY SUB-ASSEMBLY


    1. B007ZBS

      Install the idler pulley sub-assembly to the timing chain cover assembly with the bolt.

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

  2. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. B007XFSN01

      Temporarily install the V-ribbed belt tensioner assembly to the timing chain cover assembly with the 2 bolts.

    2. Tighten the bolt (A).

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

    3. Tighten the bolt (B).

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

  3. INSTALL OIL FILLER CAP GASKET


    1. Install the oil filler cap gasket to the oil filler cap sub-assembly.

  4. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.

  5. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the 2 wire harness clamp brackets to the cylinder head cover sub-assembly with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    2. B007XMZN02

      Install the 3 wire harness clamp brackets to the cylinder head sub-assembly with the 3 bolts.

      Torque:
      Bolt (A)
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      Bolt (B)
      12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }

  6. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine assembly with transaxle.

  7. INSTALL TURBOCHARGER SUB-ASSEMBLY

    Click here

  8. CONNECT INLET TURBO OIL PIPE SUB-ASSEMBLY

    Click here

  9. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    Click here

  10. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  11. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  12. INSTALL NO. 1 VACUUM PIPE (w/ Differential Pressure Sensor)

    Click here

  13. INSTALL IGNITION COIL ASSEMBLY

    Click here

  14. INSTALL INTAKE MANIFOLD WITH INTERCOOLER ASSEMBLY AND THROTTLE WITH MOTOR BODY ASSEMBLY


    1. Install 2 new No. 1 intake manifold to head gaskets to the intake manifold.

    2. B007XMMN01

      Temporarily install the intake manifold with intercooler assembly and throttle with motor body assembly with the 4 bolts and 2 nuts.

    3. Tighten the 4 bolts and 2 nuts in the order shown in the illustration.

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

  15. INSTALL STUD BOLT


    1. Using E8 "TORX" socket wrenches, install the stud bolt.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  16. INSTALL FUEL PUMP PROTECTOR

    Click here

  17. INSTALL NO. 2 VENTILATION HOSE

    Click here

  18. CONNECT NO. 1 WATER BY-PASS HOSE AND NO. 2 WATER BY-PASS HOSE


    1. Connect the No. 1 water by-pass hose to the cylinder head sub-assembly and slide the clamp to secure it.

    2. Connect the No. 2 water by-pass hose to the No. 1 water by-pass pipe and slide the clamp to secure it.

  19. CONNECT VACUUM TRANSMITTING HOSE ASSEMBLY

    Click here

  20. CONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY

    Click here

  21. INSTALL PURGE VALVE (PURGE VSV)

    Click here

  22. CONNECT ENGINE WIRE

    Click here

  23. INSTALL NO. 2 WATER BY-PASS PIPE

    Click here

  24. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET


    1. Install the 2 stud bolts to the cylinder block sub-assembly and stiffening crankcase assembly.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    2. Install the No. 1 compressor mounting bracket with the 2 bolts and 2 nuts.

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

  25. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY

    Click here

  26. INSTALL GENERATOR ASSEMBLY

    Click here

  27. INSTALL V-RIBBED BELT

    Click here

  28. INSTALL DRIVE SHAFT BEARING BRACKET (for 2WD)


    1. Install the drive shaft bearing bracket to the cylinder block sub-assembly and stiffening crankcase assembly with the 3 bolts.

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

      Note

      Make sure that the bolts and bolt holes are free of oil. Clean them if necessary.

  29. INSTALL NO. 2 TRANSFER STIFFENER PLATE (for AWD)


    1. Install the No. 2 transfer stiffener plate to the cylinder block sub-assembly and stiffening crankcase assembly with the 3 bolts.

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }