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 bi-hexagon wrench.

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

      1. Check that the pin with a diameter of 3.0 mm (0.118 in.) 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 pin with a diameter of 3.0 mm (0.118 in.) 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 with a diameter of 3.0 mm (0.118 in.) installed.

        Tip:

        When installing the V-ribbed belt, rotate the V-ribbed belt tensioner assembly clockwise again with the pin with a diameter of 3.0 mm (0.118 in.) removed, and secure the V-ribbed belt tensioner assembly using a 5 mm bi-hexagon wrench.

  2. INSTALL ENGINE OIL TEMPERATURE SENSOR

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  3. INSTALL NO. 1 VACUUM PUMP BRACKET

    1. Install a new gasket and the No. 1 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. CONNECT UNION TO CONNECTOR TUBE HOSE

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  6. INSTALL IGNITION COIL ASSEMBLY

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  7. INSTALL THERMOSTAT

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  8. INSTALL WATER INLET

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  9. INSTALL NO. 1 WATER BY-PASS PIPE

    1. Install the No. 1 water by-pass pipe with the 2 bolts.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

  10. INSTALL WATER INLET HOSE

    1. Install the water inlet hose, and slide the 2 clamps to secure the hose.

  11. INSTALL WATER BY-PASS HOSE

    1. Install the water by-pass hose, and slide the clamp to secure the hose.

  12. CONNECT NO. 3 WATER BY-PASS HOSE

    1. Connect the No. 3 water by-pass hose to the water inlet housing, and slide the clamp to secure the hose.

  13. INSTALL PCV HOSE

    1. Install the PCV hose to the PCV valve and slide the clamp to secure it.

  14. INSTALL NO. 3 WATER BY-PASS PIPE (for CVT)

    1. Install a new gasket and the No. 3 water by-pass pipe with the 2 nuts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  15. INSTALL NO. 1 SEAL PLATE (for Manual Transaxle)

    1. Install the No. 1 seal plate and new gasket with the 2 nuts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  16. INSTALL EXHAUST MANIFOLD

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  17. INSTALL MANIFOLD STAY

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  18. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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  19. 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 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 NO. 1 DELIVERY PIPE SPACER

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  22. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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  23. INSTALL FUEL TUBE SUB-ASSEMBLY

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  24. INSTALL WIRE HARNESS CLAMP BRACKET

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  25. INSTALL INTAKE MANIFOLD

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  26. INSTALL HEATER WATER INLET HOSE

    1. Connect the heater water inlet hose to the cylinder head sub-assembly, and slide the clamp to secure the hose.

  27. INSTALL HEATER WATER OUTLET HOSE

    1. Connect the heater water outlet hose to the No. 1 water by-pass pipe, and slide the clamp to secure the hose.

    2. Attach the 2 hose clamps to connect the heater water outlet hose to the heater water inlet hose.

  28. INSTALL AIR TUBE

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  29. INSTALL THROTTLE BODY ASSEMBLY

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  30. INSTALL ENGINE WIRE