ENGINE UNIT > INSTALLATION

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1. INSTALL IGNITION COIL ASSEMBLY

  1. Install the 4 ignition coils with the 4 bolts.

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

    NOTICE:
    When installing each ignition coil, do not damage the plug cap on the engine head cover opening or the upper edge of the spark plug tube.

  1. Connect the 4 ignition coil connectors.



2. INSTALL VENTILATION HOSE

  1. Install the ventilation hose to the ventilation valve.



3. INSTALL EXHAUST MANIFOLD


    A237555E01

  1. Install 2 new gaskets and the exhaust manifold with the 7 nuts.
    Text in Illustration 
    *A
    		Nut Type A
    *B
    		Nut Type B

    Torque:
    Type A:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }
    Type B:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }



4. INSTALL MANIFOLD STAY

  1. Install the manifold stay with the 3 bolts.

    Torque:
    43 N*m{ 439 kgf*cm , 32 ft.*lbf }



5. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

  1. Install the No. 1 exhaust manifold heat insulator with the 3 bolts.

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



6. INSTALL FUEL INJECTOR ASSEMBLY


    A153011E06

  1. Install a new insulator and O-ring to each fuel injector assembly.
    Text in Illustration 
    *1
    		O-ring
    *2
    		Insulator

  1. Apply a light coat of gasoline or spindle oil to the contact surfaces of the new O-ring on each fuel injector assembly.



    A173350

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

    NOTICE:
    1. Do not damage the fuel injector assembly or O-ring.
    2. Do not twist the O-ring.
    3. After installing each fuel injector, check that it turns smoothly. If not, replace the O-ring with a new one.



7. INSTALL NO. 1 DELIVERY PIPE SPACER


    A245591E01

  1. Install the 2 No. 1 delivery pipe spacers onto the cylinder head.
    Text in Illustration 
    *a
    		Delivery Pipe Side
    *b
    		Cylinder Head Side

    NOTICE:
    Install the No. 1 delivery pipe spacers in the correct direction.



8. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

  1. Install the fuel delivery pipe sub-assembly with the 4 fuel injector assemblies and install the 2 bolts.

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

    NOTICE:
    1. Do not drop the fuel injectors when installing the fuel delivery pipe sub-assembly.
    2. Check that the fuel injector assemblies rotate smoothly after installing the fuel delivery pipe sub-assembly.

  1. Install the bolt to secure the fuel delivery pipe sub-assembly.

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



9. INSTALL FUEL VAPOR FEED PIPE

  1. Install the fuel vapor feed pipe with the bolt.

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



10. INSTALL INTAKE MANIFOLD

  1. Install a new No. 1 intake manifold to head gasket to the intake manifold.

  1. Install the intake manifold with the 2 bolts and 2 nuts.

    Torque:
    28 N*m{ 285 kgf*cm , 21 ft.*lbf }

  1. Connect the fuel vapor feed hose and ventilation hose.

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

  1. Apply a light coat of engine oil to the O-ring.



    A212681E01

  1. Install the engine oil level dipstick guide sub-assembly with the 2 bolts and connect the wire harness clamp.

    Torque:
    Bolt (A):
    28 N*m{ 285 kgf*cm , 21 ft.*lbf }
    Bolt (B):
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }

  1. Install the engine oil level dipstick.



    A212682

  1. Connect the 2 wire harness clamps and 3 connectors.



11. INSTALL EGR WITH COOLER PIPE SUB-ASSEMBLY


    A237553E01

  1. Temporarily install a new gasket and the EGR cooler sub-assembly with the 2 nuts (A).
    Text in Illustration 
    *A
    		Nut (C), Type A
    *B
    		Nut (C), Type B
    *1
    		Bolt
    *2
    		Stud Bolt and Nut

  1. Install 2 new gaskets and set the EGR valve with cooler assembly in place.

  1. Using an E8 "TORX" socket wrench, install the 4 stud bolts.

    Torque:
    Stud Bolt (B):
    9.5 N*m{ 97 kgf*cm , 84 in.*lbf }
    Stud Bolt (C):
    5.0 N*m{ 51 kgf*cm , 44 in.*lbf }

  1. Temporarily install the 4 nuts (B and C) and bolt.

  1. Tighten the 2 nuts (A).

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

  1. Tighten the 2 nuts (B) and bolt.

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

    NOTICE:
    Make sure that all installation surfaces of the EGR valve with cooler assembly are in even contact when tightening the bolts and nuts.

  1. Tighten the 2 nuts (C).

    Torque:
    Type A:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }
    Type B:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }



    A212666

  1. Connect the connector, wire harness clamp and 4 water hoses.



12. INSTALL EGR VALVE ASSEMBLY


    A237552E01

  1. Temporarily install a new gasket and the EGR valve assembly with the 2 nuts (A).
    Text in Illustration 
    *A
    		Nut (C), Type A
    *B
    		Nut (C), Type B
    *1
    		Bolt
    *2
    		Stud Bolt and Nut

  1. Install 2 new gaskets and set the EGR valve with cooler assembly in place.

  1. Using an E8 "TORX" socket wrench, install the 4 stud bolts.

    Torque:
    Stud Bolt (B):
    9.5 N*m{ 97 kgf*cm , 84 in.*lbf }
    Stud Bolt (C):
    5.0 N*m{ 51 kgf*cm , 44 in.*lbf }

  1. Temporarily install the 4 nuts (B and C) and bolt.

  1. Tighten the 2 nuts (A).

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

  1. Tighten the 2 nuts (B) and bolt.

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

    NOTICE:
    Make sure that all installation surfaces of the EGR valve with cooler assembly are in even contact when tightening the bolts and nuts.

  1. Tighten the 2 nuts (C).

    Torque:
    Type A:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }
    Type B:
    37 N*m{ 377 kgf*cm , 27 ft.*lbf }



    A212666

  1. Connect the connector, wire harness clamp and 4 water hoses.



13. INSTALL EGR PIPE ASSEMBLY

  1. Install 2 new gaskets and EGR pipe assembly with the 4 bolts.

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

    NOTICE:
    Make sure to tighten the 4 bolts evenly until the flanges of the EGR pipe assembly contact with the installation surfaces.

  1. Install the wire harness support with the bolt.

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



    A212663

  1. Connect the 2 wire harness clamps.



14. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

  1. Apply a light coat of engine oil to a new O-ring.

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



    A213046E01

  1. Install the engine oil level dipstick guide with the 2 bolts.

    Torque:
    Bolt A:
    28 N*m{ 286 kgf*cm , 21 ft.*lbf }
    Bolt B:
    21 N*m{ 214 kgf*cm , 15 ft.*lbf }

  1. Connect the clamp to the engine oil level dipstick guide.

  1. Install the oil dipstick.



15. INSTALL THROTTLE BODY ASSEMBLY

  1. Install a new gasket onto the intake manifold.

  1. Install the throttle body assembly with the 2 bolts and 2 nuts.

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

  1. Connect the 2 water by-pass hoses and throttle body connector.



16. INSTALL ENGINE HANGERS


    A214905

  1. Install the 2 engine hangers with the 2 bolts.

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

    Part Name
    		Part No.
    No. 1 engine hanger
    		12281-37021
    No. 2 engine hanger
    		12282-37011
    Bolt
    		91552-81050



17. REMOVE ENGINE STAND

  1. Remove the engine from the engine stand.