Engine Unit Installation

Install the front No. 1 engine mounting bracket RH with the 4 bolts.

Torque:

51 N*m{520 kgf*cm, 38 ft.*lbf}

Install the front No. 1 engine mounting bracket LH with the 4 bolts.

Torque:

51 N*m{520 kgf*cm, 38 ft.*lbf}

Install the 2 front mounting insulators with the 2 nuts.

Torque:

46 N*m{469 kgf*cm, 34 ft.*lbf}

Install the engine oil level dipstick guide with the bolt.

Torque:

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

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

Torque:

18 N*m{178 kgf*cm, 13 ft.*lbf}

w/ Engine Oil Cooler:
Connect the No. 6 water by-pass hose to the No. 1 water by-pass pipe and slide the clip to secure the hose.

Install the spacer and No. 1 idler pulley sub-assembly with the bolt.

Torque:

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

Temporarily install the No. 1 compressor mounting bracket with the 3 bolts.

HINT:

Temporarily install the No. 1 compressor mounting bracket with the 3 bolts so that the bracket can be moved by hand.

Push the No. 1 compressor mounting bracket toward the cylinder block as shown in the illustration and tighten bolt B.

Torque:

for bolt B:

45 N*m{459 kgf*cm, 33 ft.*lbf}

HINT:

Make sure there is no clearance between the cylinder block and No. 1 compressor mounting bracket as shown in the illustration.

Uniformly tighten the 4 bolts in the order shown in the illustration.

Torque:

for bolt A:

45 N*m{459 kgf*cm, 33 ft.*lbf}

for bolt C:

25 N*m{250 kgf*cm, 18 ft.*lbf}

Text in Illustration

	Bolt A
	Bolt C

Temporarily install the idle pulley assembly with the bolt.

NOTICE:

Do not use any tools.

Tighten the bolt.

Torque:

44 N*m{449 kgf*cm, 32 ft.*lbf}

Install the ventilation pipe with the bolt.

Torque:

18 N*m{184 kgf*cm, 13 ft.*lbf}

Connect the No. 3 water by-pass hose to the cylinder head sub-assembly, and slide the clip to secure the hose.

Connect the No. 3 ventilation hose to the ventilation pipe, and slide the clip to secure the hose.

Connect the No. 1 ventilation hose to the PCV valve sub-assembly, and slide the clip to secure the hose.

Connect the No. 1 water by-pass hose to throttle body with motor assembly, and slide the clip to secure the hose.

Install the 2 heater hoses to the No. 1 water by-pass pipe and No. 2 water by-pass pipe, and slide the 2 clips to secure the hoses.

Install the purge line hose to the intake manifold, and slide the clip to secure the hose.

Install the 2 wire harness clamp brackets to the intake manifold with the 2 bolts.

Torque:

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

Install the intake manifold insulator to the intake manifold.

HINT:

Insert the protrusions of the intake manifold insulator into the grille of the intake manifold.

NOTICE:

Insert the intake manifold insulator until the position of the line as shown in the illustration.

Install a new gasket to the intake manifold.

Install the intake manifold with the 5 bolts and 2 nuts.

Torque:

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

Install the 2 No. 2 intake manifold insulators to the intake manifold.

Connect the No. 3 ventilation hose to the intake manifold, and slide the clip to secure the hose.

Attach the No. 2 water by-pass hose to the intake manifold.

Attach the 2 wire harness clamps to the 2 wire harness clamp brackets.

Install the purge VSV with the bolt.

Torque:

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

Connect the 2 purge line hoses to the purge VSV.

Connect the purge VSV connector.

Install a new gasket to the intake manifold.

HINT:

Align the protrusion of the gasket with the groove of the intake manifold.

Install the throttle body with motor assembly with the 4 bolts.

Torque:

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

Connect the water by-pass hose to the throttle body with motor assembly, and slide the clip to secure the hose.

Connect the No. 2 water by-pass hose to the throttle body with motor assembly, and slide the clip to secure the hose.

Connect the throttle body with motor connector.

Install a new gasket.

Install the exhaust manifold with 8 new nuts in the order shown in the illustration.

Torque:

36 N*m{367 kgf*cm, 27 ft.*lbf}

Set the No. 1 exhaust manifold heat insulator in place.

Install the air switching valve with 2 new nuts.

Torque:

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

Connect the connector.

Connect the vacuum hose.

Install 2 new gaskets and the No. 4 intake pipe with 4 new nuts in the order shown in the illustration. Tighten the nuts labeled 1 and 3 to the torque specification again.

Torque:

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

Check that the nuts are tightened to the torque specification.

Install the No. 1 exhaust manifold heat insulator with the 5 bolts.

Torque:

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

Install the generator assembly with the 3 bolts.

Torque:

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

Connect the wire harness to terminal B with the nut.

Torque:

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

Install the terminal cap.

Connect the connector to the generator assembly.

Install the 4 ignition coil assemblies with the 4 bolts.

Torque:

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

Connect the 4 ignition coil connectors.