ENGINE UNIT > INSTALLATION

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1. INSTALL DRIVE SHAFT BEARING BRACKET


A191879

  1. Install the drive shaft bearing bracket with the 2 bolts.

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



2. INSTALL WIRING HARNESS CLAMP BRACKET


A191878

  1. Install the wiring harness clamp bracket with the bolt.

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



3. INSTALL WATER FILLER ASSEMBLY


A191877

  1. Install the water filler assembly with the bolt.

    Torque:
    13 N*m{ 127 kgf*cm , 10 ft.*lbf }



4. INSTALL NO. 2 VENTILATION HOSE


A191876

  1. Install the No. 2 ventilation hose with the clip.



5. INSTALL OIL LEVEL DIPSTICK GUIDE SUB-ASSEMBLY


A191874

  1. Install the new O-ring to the oil level dipstick guide sub-assembly.



    A191873

  1. Install the oil level dipstick guide sub-assembly with the bolt.

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



6. INSTALL OIL LEVEL DIPSTICK SUB-ASSEMBLY


7. INSTALL IDLER PULLEY


A191872

  1. Install the idler pulley with the 3 bolts.

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



8. INSTALL ENGINE WIRE


A191871

  1. Install the engine wire with the 4 bolts.

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

  1. Connect all the connectors and the harness clamps.



9. INSTALL VACUUM SWITCHING VALVE ASSEMBLY


A203216

  1. Install the vacuum switching valve assembly with the bolt.

    Torque:
    14 N*m{ 143 kgf*cm , 10 ft.*lbf }

  1. Connect the vacuum switching valve assembly connector.



10. INSTALL NO. 2 RADIATOR HOSE


A191870E01

  1. Install the No. 2 radiator hose with the clip.

    HINT:
    Install the clip as shown in the illustration.



11. INSTALL NO. 1 IGNITION COIL


A191868

  1. Install the 3 No. 1 ignition coils with the 3 bolts.

    Torque:
    9.0 N*m{ 91 kgf*cm , 80 in.*lbf }

  1. Connect the 3 No. 1 ignition coil connectors.



12. INSTALL NO. 1 RADIATOR HOSE


A191869E01

  1. Install the No. 1 radiator hose with the 2 clips.

    HINT:
    Install the clip as shown in the illustration.



13. INSTALL WATER BY-PASS HOSE ASSEMBLY


A191866E01

  1. Install the water by-pass hose assembly with the 2 clips.

    HINT:
    Install the clips as shown in the illustration.



14. INSTALL INJECTOR VIBRATION INSULATOR


    A199573

  1. Install 3 new injector vibration insulators to the cylinder head.



15. INSTALL FUEL INJECTOR ASSEMBLY


    A104648E03

  1. Apply a light coat of gasoline or spindle oil to the contact surfaces of a new O-ring, and install it onto the injector.
    Text in Illustration  
    *1
    		O-ring



    A199576

  1. While turning the fuel injector assembly left and right, install it onto the fuel delivery pipe.

    NOTICE:
    1. Do not twist the O-ring.
    2. Check that the fuel injector assemblies rotate smoothly after installing it onto the fuel delivery pipe. If the fuel injector assembly does not rotate smoothly, replace the O-ring with a new one and install it again.



16. INSTALL FUEL PIPE INSULATOR


    A199574

  1. Install the 2 fuel pipe insulators onto the fuel delivery pipe.



17. INSTALL FUEL DELIVERY PIPE


    A202852

  1. Install the fuel delivery pipe with the 2 bolts.

    Torque:
    27 N*m{ 275 kgf*cm , 20 ft.*lbf }

    NOTICE:
    1. Do not drop the fuel injector assembly.
    2. After installing, check that the fuel injector assembly is securely connected by turning it by hand.



    A202851

  1. Connect the 3 fuel injector assembly connectors.



    A202850

  1. Engage the 3 harness clamps and connect the 3 connectors.



18. INSTALL EGR VALVE ASSEMBLY


    A199580

  1. Install a new gasket to the cylinder head.

  1. Insert the EGR valve into the stud bolt, rotate the EGR valve to avoid contact with the delivery pipe, and temporarily install the EGR valve.



    A202847E01

  1. Connect the water by-pass hose.

  1. Connect the EGR valve connector.



19. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR


A201012

  1. Temporarily install the intake manifold insulator with a new gasket, the 2 bolts and the nut.



20. INSTALL INTAKE MANIFOLD


A191864

  1. Install the new gasket onto the intake manifold.



    A191863

  1. Install the intake manifold with the 2 bolts and 2 nuts in the order shown in the illustration.

    Torque:
    30 N*m{ 306 kgf*cm , 22 ft.*lbf }



    A191862

  1. Connect the vacuum hose, ventilation hose and install the 2 bolts.

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

  1. Connect the 2 connectors and 4 harness clamps.



21. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY


A191861

  1. Install the new gasket onto the intake manifold.



    A191860

  1. Install the throttle with motor body assembly with the 3 bolts and nut.

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

  1. Connect the throttle with motor body assembly connector.



    A191859

  1. Connect the 2 water by-pass hoses with the 2 clips.

    HINT:
    Install the clips as shown in the illustration.

  1. Install the 2 water by-pass hoses to the hose clamp.



22. INSTALL GENERATOR ASSEMBLY


    A198911

  1. Temporarily install the generator assembly with the bolt.



    A198910E01

  1. Temporarily install the fan belt adjusting bar with bolt A and bolt B.

  1. Tighten bolt B with the generator assembly near the cylinder block.

    Torque:
    21 N*m{ 214 kgf*cm , 16 ft.*lbf }



    A201679

  1. Install the 2 brackets with the 2 bolts.

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



    A198909

  1. Connect the connector and wire harness clamps.

  1. Install the terminal B with the nut.

    Torque:
    9.8 N*m{ 100 kgf*cm , 87 in.*lbf }

  1. Install the terminal cap.