ENGINE UNIT INSTALLATION

PROCEDURE


  1. INSTALL STUD BOLT

    Note

    If a stud bolt is deformed or its threads are damaged, replace it.


    1. Using an 8 mm socket wrench, install the stud bolt to the front No. 1 engine mounting bracket LH.

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

  2. INSTALL RADIATOR PIPE CLAMP


    1. Install the radiator pipe clamp to the camshaft housing sub-assembly LH with the bolt.

      Torque:
      5.5 N*m  { 56 kgf*cm, 49 in.*lbf }

  3. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the wire harness clamp bracket to the camshaft housing sub-assembly with the bolt.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  4. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET


    1. Install the No. 1 exhaust pipe support bracket to the oil pan sub-assembly with the 2 bolts.

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

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


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

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

      Note

      Make sure that there is no oil on the threads of the bolts.

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


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

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

  7. INSTALL NO. 5 CYLINDER BLOCK INSULATOR (w/ Oil Cooler)

    B005LKUC01
    *a Fastner Surface

    1. Install the No. 5 cylinder block insulator to the engine assembly.

      Note

      Make sure that the No. 5 cylinder block insulator is not covering any fastener surface.

  8. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Install a new engine oil level dipstick guide O-ring to the engine oil level dipstick guide.

    2. Apply a light coat of engine oil to the engine oil level dipstick guide O-ring.

    3. Insert the engine oil level dipstick guide end into the oil pan sub-assembly.

    4. Install the engine oil level dipstick guide to the camshaft housing sub-assembly LH with the bolt.

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

    5. Install the engine oil level dipstick to the engine oil level dipstick guide.

  9. INSTALL WATER PUMP PULLEY

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  10. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

    Click here

  11. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

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  12. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET


    1. B007YM8N01

      Install the No. 1 compressor mounting bracket to the cylinder block sub-assembly with the 2 bolts.

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

      Note

      Temporarily tighten the bolt (A), and then fully tighten the 2 bolts in the order of (B) and (A).

  13. INSTALL COMPRESSOR AND MAGNETIC CLUTCH

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  14. INSTALL GENERATOR ASSEMBLY

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  15. INSTALL V-RIBBED BELT

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  16. INSTALL NO. 2 VENTILATION HOSE


    1. Install the No. 2 ventilation hose to the cylinder head cover sub-assembly and slide the clip to secure it.

  17. INSTALL VENTILATION HOSE


    1. Install the ventilation hose to the PCV valve (ventilation valve sub-assembly) and slide the clip to secure it.

  18. INSTALL NO. 2 WATER BY-PASS HOSE


    1. Install the No. 2 water by-pass hose to the water outlet and slide the clip to secure it.

  19. INSTALL NO. 3 WATER BY-PASS HOSE


    1. Install the No. 3 water by-pass hose to the water inlet pipe and slide the clip to secure it.

  20. INSTALL VACUUM PUMP ASSEMBLY

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  21. INSTALL IGNITION COIL ASSEMBLY

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  22. INSTALL SENSOR WIRE


    1. Engage the 2 clamps and install the sensor wire to the water inlet pipe with the bolt.

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

  23. INSTALL KNOCK CONTROL SENSOR

    Click here