INSTALL TIMING CHAIN CASE OIL SEAL

INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)

INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)

INSTALL NO. 1 OIL PIPE

INSTALL NO. 2 OIL PIPE

INSTALL IGNITION COIL ASSEMBLY

INSTALL NO. 2 FUEL PIPE

INSTALL FUEL PUMP ASSEMBLY

CONNECT NO. 2 FUEL PIPE

INSTALL NO. 1 FUEL PIPE

INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY

INSTALL OIL STRAINER SUB-ASSEMBLY

INSTALL OIL PAN SUB-ASSEMBLY

INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

INSTALL CRANKSHAFT PULLEY

INSTALL WATER INLET

INSTALL WATER HOSE JOINT

INSTALL NO. 2 SURGE TANK STAY

INSTALL INTAKE AIR SURGE TANK ASSEMBLY

INSTALL INJECTOR DRIVER

INSTALL ENGINE WIRE

INSTALL WATER PUMP PULLEY

INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

INSTALL ENGINE MOUNTING BRACKET LH

INSTALL ENGINE MOUNTING BRACKET RH

CONNECT COOLER COMPRESSOR ASSEMBLY

INSTALL GENERATOR ASSEMBLY

INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

INSTALL NO. 1 ENGINE COVER

INSTALL NO. 2 ENGINE COVER

INSTALL V-RIBBED BELT

INSTALL ENGINE HANGERS

INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)

INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission)

INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY

INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission)

INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)

INSTALL STARTER ASSEMBLY

INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH

INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH

INSTALL OIL DIPSTICK GUIDE SUB-ASSEMBLY

INSTALL ENGINE AND TRANSMISSION ASSEMBLY

CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY

CONNECT POWER STEERING LINK WIRE HARNESS

INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET SUB-ASSEMBLY (for Automatic Transmission)

INSTALL FRONT LOWER BALL JOINT ASSEMBLY LH

INSTALL FRONT LOWER BALL JOINT ASSEMBLY RH

INSTALL FRONT SHOCK ABSORBER ASSEMBLY LH

INSTALL FRONT SHOCK ABSORBER ASSEMBLY RH

CONNECT HEIGHT CONTROL SENSOR LINK

INSTALL STEERING SLIDING WITH SHAFT YOKE SUB-ASSEMBLY

INSTALL FRONT LOWER SUSPENSION MEMBER PROTECTOR

CONNECT NO. 3 FUEL HOSE

CONNECT FUEL MAIN TUBE

CONNECT ENGINE WIRE

INSTALL ECM COVER

CONNECT DISCHARGE HOSE SUB-ASSEMBLY

CONNECT NO. 1 COOLER REFRIGERANT SUCTION HOSE

CONNECT INLET HEATER WATER HOSE

CONNECT OUTLET HEATER WATER HOSE

CONNECT INLET RADIATOR HOSE

CONNECT OUTLET RADIATOR HOSE

CONNECT RADIATOR RESERVOIR TANK HOSE

CONNECT NO. 2 FUEL VAPOR FEED HOSE

CONNECT UNION TO CHECK VALVE HOSE

INSTALL AIR CLEANER CASE SUB-ASSEMBLY

INSTALL AIR CLEANER CAP WITH AIR CLEANER HOSE

INSTALL NO. 1 INLET AIR CLEANER

INSTALL PROPELLER SHAFT WITH CENTER BEARING ASSEMBLY

INSTALL FRONT EXHAUST PIPE ASSEMBLY

ADD ENGINE OIL

CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

ADD ENGINE COOLANT

CHARGE REFRIGERANT

CHECK FOR FUEL LEAKS

CHECK FOR ENGINE COOLANT LEAKS

CHECK FOR ENGINE OIL LEAKS

CHECK FOR EXHAUST GAS LEAKS

CHECK FOR LEAKAGE OF REFRIGERANT

INSTALL FRONT WHEEL

PLACE FRONT WHEELS FACING STRAIGHT AHEAD

ADJUST SHIFT LEVER POSITION

CHECK SHIFT LEVER POSITION

CHECK AND ADJUST FRONT WHEEL ALIGNMENT

CHECK IGNITION TIMING

CHECK ENGINE IDLE SPEED

CHECK CO/HC

CHECK ENGINE OIL LEVEL

INSTALL ENGINE UNDER COVER REAR LH

INSTALL ENGINE UNDER COVER REAR RH

INSTALL NO. 2 ENGINE UNDER COVER

INSTALL ENGINE UNDER COVER

INSTALL V-BANK COVER SUB-ASSEMBLY

INSTALL ENGINE ROOM SIDE COVER LH

INSTALL ENGINE ROOM COVER SIDE RH

INSTALL COOL AIR INTAKE DUCT SEAL

PERFORM INITIALIZATION

Using SST, tap in a new oil seal until its surface is flush with the timing gear case edge.

• SST
• 09223-22010
  09506-35010

• NOTICE:

Apply seal packing in a continuous line to the engine unit as shown in the following illustration.

• Seal packing:
• Part No. 08826-00080 or equivalent

• Seal diameter:
• 5.0 to 5.5 mm (0.197 to 0.217 in.)

• NOTICE:

Apply seal packing in a continuous line to the timing chain cover as shown in the following illustration.

• Seal packing:
• 08826-00080 or equivalent
• 08826-00100, THREE BOND 1282B or equivalent

• NOTICE:

• Apply seal packing as follows:

• Area	Seal Packing Diameter	Application Position from Inside Seal Line
  Continuous Line Area	3.5 to 4.0 mm (0.138 to 0.158 in.)	3.0 to 4.0 mm (0.118 to 0.158 in.)
  Alternate Long and Dashed Line Area	3.5 to 4.0 mm (0.138 to 0.158 in.)	2.0 to 3.0 mm (0.079 to 0.118 in.)
  Dashed Line Area	6.0 mm (0.236 in.)	-

Install a new gasket.

Align the oil pump's drive rotor spline and the crankshaft as shown in the illustration. Install the spline and chain cover to the crankshaft.

Temporarily tighten the timing chain cover with the 25 bolts and 2 nuts.

• Bolt length:

• Item	Length
  Bolt A	50 mm (1.97 in.)
  Bolt B	25 mm (0.98 in.)
  Bolt C	55 mm (2.17 in.)

• NOTICE:

• Make sure that there is no oil on the bolt threads.

Fully tighten the 3 bolts as shown in the illustration.

• Torque:
• 43 N*m{ 438 kgf*cm, 32 ft.*lbf}for bolt A
• 21 N*m{ 214 kgf*cm, 15 ft.*lbf}for bolts except A

Fully tighten the 3 bolts as shown in the illustration.

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

Fully tighten the 7 bolts and 2 nuts as shown in the illustration.

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

• HINT:

• Tighten the bolts and nuts in the order of upper to lower as shown in the illustration.

Fully tighten the 12 bolts as shown in the illustration.

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

• HINT:

• Tighten the bolts in the order of lower to upper as shown in the illustration.

Install the bolt and wiring harness bracket.

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

Apply seal packing as shown in the illustration.

• Seal packing:
• 08826-00080 or equivalent

• NOTICE:

Install 3 new gaskets as shown in the illustration.

Install a new gasket to the head cover.

Install a head cover with the 14 bolts.

• Torque:
• 21 N*m{ 214 kgf*cm, 15 ft.*lbf}for bolt A
• 10 N*m{ 102 kgf*cm, 7 ft.*lbf}for bolts except A

Apply seal packing as shown in the illustration.

• Seal packing:
• 08826-00080 or equivalent

• NOTICE:

Install 3 new gaskets as shown in the illustration.

Install a new gasket to the head cover.

Install the head cover with the 12 bolts.

• Torque:
• 21 N*m{ 214 kgf*cm, 15 ft.*lbf}for bolt A
• 10 N*m{ 102 kgf*cm, 7 ft.*lbf}for bolts except A

Make sure that there is no foreign matter on the mesh of the oil control valve filter LH.

• NOTICE:

• Do not touch the mesh when installing the oil control valve filter.

Install the oil control valve filter LH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side).

Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.

Tighten the oil pipe union (on the head cover side).

• Torque:
• 60 N*m{ 612 kgf*cm, 44 ft.*lbf}

Tighten the oil check valve bolt (on the cylinder head side).

• Torque:
• 60 N*m{ 612 kgf*cm, 44 ft.*lbf}

• NOTICE:

• If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.

Make sure that there is no foreign matter on the mesh of the oil control valve filter RH.

• NOTICE:

• Do not touch the mesh when installing the oil control valve filter.

Install the oil control valve filter RH to the oil pipe union. Install new gaskets and temporarily install the oil pipe (on the head cover side).

Install a new gasket and temporarily install the oil pipe (on the cylinder head side) with the oil check valve bolt.

Tighten the oil pipe union (on the head cover side).

• Torque:
• 60 N*m{ 612 kgf*cm, 44 ft.*lbf}

Tighten the oil check valve bolt (on the cylinder head side).

• Torque:
• 60 N*m{ 612 kgf*cm, 44 ft.*lbf}

• NOTICE:

• If the link that connects the gaskets is broken, remove the connecting link by using nippers or similar tools.

Install the 6 ignition coils with the 6 bolts.

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

Install a new O-ring, new backup rings (No. 1 and No. 2) and new E-ring to the fuel injector as shown in the illustration.

• NOTICE:

Apply gasoline to the O-ring and connect the fuel pipe to the delivery pipe.

• NOTICE:

Turn the crankshaft until the flat of the cam is facing the cylinder head cover's fuel pump attachment hole, as shown in the illustration.

• HINT:

• When installing the fuel pump by following the procedure described above: By not using the crankshaft pointed side to push up the pump activation surface, it is easier to install the fuel pump and No. 2 fuel pipe later.

Pour 30 cc of engine oil through the cylinder head cover's fuel pump attachment hole into the cylinder head oil collector.

Apply a coat of engine oil to the pump activation cam and pump lifter part.

Install a new fuel pump insulator to the cylinder head cover. Then pass the 2 stud bolts through the holes of the fuel pump and set them on the insulator.

• NOTICE:

• Install the insulator so that the open sides of the metal eyelets are facing outward, as shown in the illustration.

Temporarily install the No.2 fuel pipe sub-assembly to the fuel pump assembly.

• NOTICE:

• Be careful not to damage the sealing surface of the fuel pipe when temporarily installing the fuel pipe.

Install the 2 nuts and tighten them in several passes.

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

Connect the fuel hose.

Install the No. 2 fuel pipe to the delivery pipe with the 2 bolts.

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

Using a 19 mm union nut wrench, connect the fuel pipe.

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

• HINT:

• The torque shown above should be used for tightening without using union nut wrench. When the union nut wrench is used for tightening, the torque should be calculated based on the length of the union nut wrench .

Connect the connector to the fuel pump.

Install the fuel pipe with the 2 bolts.

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

Connect the 2 fuel hoses.

Using SST, install a new gasket and the fuel pulsation damper to the fuel pump.

• Torque:
• 40 N*m{ 408 kgf*cm, 28 ft.*lbf}

• HINT:

• The torque shown above should be used for tightening without using SST. When the SST is used for tightening, the torque should be calculated based on the length of the SST .

Using an E6 "torx" socket, install the stud bolts as shown in the illustration.

• Torque:
• 4.0 N*m{ 41 kgf*cm, 35 in.*lbf}

Install the baffle plate with the 8 bolts.

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

• HINT:

• Temporarily tighten the 8 bolts. Fully tighten 2 bolts A as shown in the illustration before tightening the other bolts.

Install a new gasket and the oil strainer with the 3 nuts.

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

Install 2 new O-rings.

When replacing a stud bolt, install it by using an E6 "torx" socket wrench.

• Torque:
• 4.0 N*m{ 41 kgf*cm, 35 in.*lbf}

Apply seal packing in a continuous line as shown in the illustration.

• Seal packing:
• Part No. 08826-00080 or equivalent

• Seal diameter:
• 3.0 to 4.0 mm (0.118 to 0.156 in.)

• NOTICE:

Install the oil pan with the 16 bolts and 2 nuts.

• Torque:
• 10 N*m{ 102 kgf*cm, 7 ft.*lbf}for bolt A
• 21 N*m{ 214 kgf*cm, 15 ft.*lbf}for bolts except A

Apply seal packing in a continuous line as shown in the illustration.

• Seal packing:
• Part No. 08826-00080 or equivalent

• Seal diameter:
• 3.0 to 4.0 mm (0.118 to 0.156 in.)

• NOTICE:

Install the oil pan with the 15 bolts and 2 nuts.

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

Install the pulley set key to the key groove.

Align the pulley set key with the key groove of the pulley, and slide on the pulley.

Using SST, install the crankshaft pulley bolt.

• SST
• 09213-70011(09213-70020)
  09330-00021

• Torque:
• 250 N*m{ 2,550 kgf*cm, 184 ft.*lbf}

Install a new water inlet housing gasket No.1 and water outlet pipe O-ring.

Install the water inlet with the 4 bolts and nut.

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

• NOTICE:

• Be careful not to allow the O-ring to get caught between parts.

Connect the 5 hoses.

Connect the 2 hoses, and install the bolt and water hose joint.

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

Install the bolt and No. 2 surge tank stay.

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

Install the injector driver with the bolt and 2 nuts.

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

Install the engine wire to the engine assembly.

Temporarily install the pulley with the 4 bolts.

Using SST, hold the pulley and tighten the 4 bolts.

• SST
• 09960-10010(09962-01000,09963-00700)

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

Temporarily install the V-ribbed belt tensioner with the 5 bolts.

• Each bolt length is as follows:

• Mark	Specified Length
  A	70 mm (2.76 in.)
  B	35 mm (1.38 in.)

Install the V-ribbed belt tensioner by tightening the bolt 1 and bolt 2 in the order shown in the illustration.

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

Tighten the other bolts.

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

Install the mounting bracket with the 4 bolts.

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

Connect the 2 clamps.

Install the mounting bracket with the 4 bolts.

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

Temporarily install the compressor and magnetic clutch onto the stud bolt.

Install the compressor and magnetic clutch with the 3 bolts and nut.

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

• NOTICE:

• Tighten the bolts in the order shown in the illustration to install the compressor and magnetic clutch.

Install the 2 generator brackets with the 2 bolts.

• Torque:
• 20 N*m{ 204 kgf*cm, 15 ft.*lbf}

Install the generator assembly with the 2 bolts.

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

Install the bracket with the nut.

• Torque:
• 20 N*m{ 204 kgf*cm, 15 ft.*lbf}

Install the generator wire to terminal B with the nut (A).

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

Install the terminal cap.

Install the clamp bracket with the bolt (B).

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

Attach the 2 clamps, and connect the generator connector to the generator.

Install the plate and idler pulley with the bolt.

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

Install the No. 1 engine cover with the 3 clips.

Install the No. 2 engine cover with the 3 clips.

Connect the clamp.

Install the V-ribbed belt.

While turning the belt tensioner counterclockwise, remove the bar.

• NOTICE:

If it is difficult to install the V-ribbed belt, perform the following procedure.

Hold the crankshaft with SST.

• SST
• 09213-70011(09213-70020)
  09330-00021

Using several steps, install and tighten 8 new bolts uniformly in the sequence shown in the illustration.

• Torque:
• 73 N*m{ 741 kgf*cm, 54 ft.*lbf}

• NOTICE:

Using SST, hold the crankshaft.

• SST
• 09213-70011(09213-70020)
  09330-00021

Apply adhesive to 2 or 3 threads of the mounting bolts ends.

• Adhesive:
• Part No. 08833-00070, THREE BOND 1324 or equivalent

Install the front spacer, drive plate and rear spacer on the crankshaft.

Install and tighten the 8 mounting bolts uniformly in several steps.

• Torque:
• 83 N*m{ 846 kgf*cm, 61 ft.*lbf}

• NOTICE:

• Do not start the engine for at least 1 hour after installing.

Install the front suspension crossmember sub-assembly with the 2 bolts.

• Torque:
• 35 N*m{ 357 kgf*cm, 26 ft.*lbf}

Install the starter with the 2 bolts.

• Torque:
• 58 N*m{ 591 kgf*cm, 43 ft.*lbf}

Connect the wire harness to terminal 30 and install the nut, and then attach the terminal cap.

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

Connect the terminal 50 connector to the starter assembly.

Install a new gasket as shown in the illustration.

Install the exhaust manifold with 6 new nuts.

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

• NOTICE:

Install a new gasket as shown in the illustration.

Install the exhaust manifold with 6 new nuts.

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

• NOTICE:

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

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

Push in the oil dipstick guide end into the guide hole.

Install the No. 1 oil dipstick guide with the bolt.

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

Connect the clamp.

Install the No. 2 oil dipstick guide with the bolt.

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

Install the oil dipstick.

Set the engine lifter.

Operate the engine lifter, then install the engine to the vehicle.

Install the engine and transmission assembly with crossmember with the 12 bolts.

• Torque:
• 167 N*m{ 1,700 kgf*cm, 123 ft.*lbf}for Nut
• 204 N*m{ 2,080 kgf*cm, 150 ft.*lbf}for bolt A
• 50 N*m{ 510 kgf*cm, 37 ft.*lbf}for bolt B
• 49 N*m{ 500 kgf*cm, 36 ft.*lbf}for bolt C

Install the engine rear mounting member with the 4 bolts.

• Torque:
• 26 N*m{ 265 kgf*cm, 19 ft.*lbf}

Temporarily tighten the floor shift gear shifting rod sub-assembly with the nut.

Install the power steering earth wire to the power steering link assembly with bolt (B).

• Torque:
• 13 N*m{ 130 kgf*cm, 10 ft.*lbf}

Connect the wire harness connector (E) to the power steering link assembly and securely lock the connector.

Connect the 2 wire harness connectors (C) and (D) to the power steering link assembly.

Install the 2 wire harness clamps to the power steering link assembly.

Connect the earth wire to the bracket with bolt (A).

• Torque:
• 5.0 N*m{ 51 kgf*cm, 44 in.*lbf}

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

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

Install the front lower ball joint with the 2 bolts.

• Torque:
• 120 N*m{ 1,224 kgf*cm, 89 ft.*lbf}

Install the bolt on the lower side of the front shock absorber while holding the nut.

• Torque:
• 157 N*m{ 1,600 kgf*cm, 116 ft.*lbf}

Connect the height control sensor link and install it with the nut.

• Torque:
• 5.4 N*m{ 55 kgf*cm, 48 in.*lbf}

Align the matchmarks on the steering sliding yoke sub-assembly and the power steering gear assembly.

Install bolt (A) and tighten the 2 bolts.

• Torque:
• 35 N*m{ 360 kgf*cm, 26 ft.*lbf}

Install the protector with the 4 bolts.

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

Connect the No. 3 fuel hose and clamp.

Install the bolt, clamp and engine wire No. 3.

• Torque:
• 8.5 N*m{ 87 kgf*cm, 75 in.*lbf}

Connect the ground cable and install it with the bolt.

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

Connect the connector and install the 4 clamps to the body.

Connect the wire to the engine room No. 1 junction block. Then, install it with the nut.

• Torque:
• 12 N*m{ 124 kgf*cm, 9 ft.*lbf}

Install the engine room No. 1 relay block cover.

Connect the battery positive (+) cable and install it with the nut.

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

Connect the ECM connectors.

Connect the connector holder.

Install the ECM cover with the 3 bolts.

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

• NOTICE:

• Make sure that the wire harness does not get caught between the parts.

Remove the attached vinyl tape from the hose.

Apply sufficient compressor oil (ND-OIL 8) to a new O-ring and the fitting surface of the compressor and magnetic clutch.

• Compressor oil:
• ND-OIL 8 or equivalent

Install the O-ring onto the discharge hose sub-assembly.

Install the discharge hose sub-assembly onto the compressor and magnetic clutch with the bolt.

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

Remove the attached vinyl tape from the hose.

Apply sufficient compressor oil to a new O-ring and the fitting surface of the compressor and magnetic clutch.

• Compressor oil:
• ND-OIL 8 or equivalent

Install the O-ring onto the No.1 cooler refrigerant suction hose.

Install the No. 1 cooler refrigerant suction hose onto the compressor and magnetic clutch with the bolt.

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

Connect the inlet heater water hose.

Connect the outlet heater water hose.

Install the clamp and connect the inlet radiator hose.

Install the clamp and connect the outlet radiator hose.

Install the clamp and connect the reservoir tank hose.

Install the clamp and connect the No. 2 fuel vapor feed hose.

Connect the hose to the surge tank.

Install the air cleaner case, clamp and 2 bolts.

• Torque:
• 5.0 N*m{ 51 kgf*cm, 44 in.*lbf}

Install the air cleaner cap with air cleaner hose assembly with the 4 clamps and hose clamp.

• HINT:

• Be sure to install the air cleaner assembly so that the screw part of the hose clamp is as shown in the illustration.

Install the VSV hose to the air cleaner hose.

Connect the MAF meter connector and clamp to the air cleaner.

Install the inlet air cleaner with the bolt.

• Torque:
• 5.0 N*m{ 51 kgf*cm, 44 in.*lbf}

Add new oil.

• Specification:

• Item	Capacity
  Drain and refill with oil filter change	6.3 liters (6.7 US qts, 5.5 Imp. qts)
  Drain and refill without oil filter change	5.9 liters (6.2 US qts, 5.2 Imp. qts)
  Dry fill	7.2 liters (7.6 US qts, 6.3 Imp. qts)

Install the oil filter cap.

Tighten all the plugs and fill the radiator with TOYOTA Super Long Life Coolant (SLLC).

• Torque:
• 13 N*m{ 130 kgf*cm, 9 ft.*lbf}for cylinder block drain cock plug

Add engine coolant.

• Specified capacity:
• 9.1 liters (9.6 US qts, 8.0 lmp. qts)

• HINT:

Slowly pour coolant into the radiator reservoir until it reaches the FULL line.

Press the inlet and outlet radiator hoses several times by hand, and then check the level of the coolant.

If the coolant level is low, add coolant.

Install the radiator cap and reservoir cap.

Bleed air from the cooling system.

• NOTICE:

• Before starting the engine to warm up the engine, turn the A/C switch OFF.

Stop the engine, and wait until the engine coolant cools down to ambient temperature.

• NOTICE:

• Do not remove the radiator cap while the engine and radiator are still hot. Pressurized, hot engine coolant and steam may be released and cause serious burns.

Check the coolant level in the radiator reservoir.

If the coolant level is low, add SLLC to the radiator reservoir FULL line.

Perform vacuum purging using a vacuum pump.

Charge refrigerant HFC-134a (R134a).

• Standard:
• 430 +- 30 g (15.17 +- 1.06 oz.)

• SST
• 07110-58060(07117-58060,07117-58070,07117-58080,07117-58090,07117-78050,07117-88060,07117-88070,07117-88080)

• NOTICE:

Connect the intelligent tester to the DLC3.

Check the fuel pump operation.

Check for fuel leaks.

Fill the radiator with coolant and attach a radiator cap tester.

Warm up the engine.

Using a radiator cap tester, increase the pressure inside the radiator to 118 kPa (1.2 kgf*cm², 17 psi), and check that the pressure does not drop.

If the pressure drops, check the hoses, radiator and water pump for leaks. If no external leaks are found, check the heater core, cylinder block and cylinder head.

After recharging the refrigerant gas, check for refrigerant gas leakage using a halogen leak detector.

Perform the operation under the following conditions:

Using a gas leak detector, check the refrigerant line for leakage.

If a gas leak is not detected on the drain hose, remove the blower motor control (blower resistor) from the cooling unit. Insert the gas leak detector sensor into the unit and perform the test.

Disconnect the connector and leave the pressure switch on for approximately 20 minutes. Bring the gas leak detector close to the pressure switch and perform the test.

Remove the nut and disconnect the shifting rod.

Turn the control shaft lever of the park/neutral position switch counterclockwise until it stops, and turn it clockwise 2 notches to set it to the N position.

Move the shift lever to the N position and tighten the nut while lightly pushing the lever toward the R position.

• NOTICE:

• Do not push the shift lever too hard.

After adjustment, check that the shift lever moves smoothly and the shift lever and gear operate correctly.

When shifting from the P to R position with the engine switch on (IG) and the brake pedal depressed, make sure that the shift lever moves smoothly and moves correctly into the position.

Start the engine and make sure that the vehicle moves forward when shifting from the N to D position and moves rearward when shifting to the R position.

If operation cannot be done as specified, inspect the park/neutral position switch assembly and check the shift lever assembly installation condition.

Warm up the engine and stop the engine.

• NOTICE:

• A warmed up engine should have an engine coolant temperature of over 80°C (176°F), have an engine oil temperature of 60°C (140°F), and the engine rpm should be stabilized.

When using the intelligent tester:

When not using the intelligent tester:

Remove the V-bank cover sub-assembly.

Connect the tester probe of a timing light to the wire of the ignition connector for No. 1 cylinder.

• NOTICE:

• Use a timing light which can detect the primary current.

Using SST, connect terminals TC and CG of the DLC3.

• SST
• 09843-18040

• NOTICE:

Confirm the terminal numbers before connecting them. Connecting the wrong terminals can damage the engine.

When checking the ignition timing, the transmission should be in neutral.

Using a timing light, check the ignition timing.

• Ignition timing:
• 8 to 12 BTDC at idle

Remove the SST from the DLC3.

Check the ignition timing.

• Ignition timing:
• 5 to 15° BTDC at idle

Check that the ignition timing advances immediately when the engine speed is increased.

Disconnect the timing light from the engine.

Install the V-bank cover sub-assembly.

Warm up and stop the engine.

• NOTICE:

• A warmed up engine should have an engine coolant temperature of over 80°C (176°F) and an engine oil temperature of 60°C (140°F), and the engine rpm should be stabilized.

When using the intelligent tester:

When not using the intelligent tester:

Start the engine.

Keep the engine speed at 2,500 rpm for approx. 180 seconds.

Insert the CO / HC meter testing probe at least 40 cm (1.3 ft) into the tailpipe during idling.

Immediately check CO / HC concentration at idle and / or 2,500 rpm.

• HINT:

Warm up the engine, stop the engine and wait 5 minutes. The oil level should be between the dipstick's low level mark and full level mark.

If low, check for leakage and add oil up to the full level mark.

• NOTICE:

• Do not fill with engine oil above the full level mark.

Install the engine under cover rear LH with the bolt.

Engage the 2 clips on the front of the cover, and then engage the clip on the rear to install the V-bank cover.

• NOTICE:

Install the side cover with the 5 clips.

Install the side cover with the 2 clips.

Install the intake duct seal with the 11 clips.

Perform initialization .

• NOTICE:

• Certain systems need to be initialized after reconnecting the cable to the negative (-) battery terminal.