Engine Unit Installation

Install the radio setting condenser with the bolt.

Torque:

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

Install a new gasket on the thermostat.

Install the thermostat to the water inlet with the jiggle valve upward.

HINT:

The jiggle valve may be set to within 10° on either side of the indicated position.

Install the water inlet with the 2 nuts.

Torque:

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

Install the inlet water hose with the 2 clamps.

Install the water by-pass hose with the clamp.

Install the No. 1 water by-pass pipe with the 2 bolts.

Torque:

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

Connect the No. 3 water by-pass hose to the inlet water housing.

Install the ventilation hose.

Install a new gasket onto the exhaust manifold.

Install the exhaust manifold with the 5 nuts.

Torque:

37 N*m{377 kgf*cm, 27 ft.*lbf}

Install the manifold stay with the 3 bolts.

Torque:

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

Install the 2 drive shaft heat insulator sub-assemblies with the 2 nuts.

Torque:

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

Install the No. 1 exhaust manifold heat insulator with the 4 bolts.

Torque:

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

Apply engine oil to a new O-ring.

Install the oil level dipstick with the bolt through the new O-ring.

Torque:

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

Install the 4 ignition coils with the 4 bolts.

Torque:

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

Install 4 new injector vibration insulators to the 4 fuel injector assemblies.

Install 4 new injector vibration insulators to the 4 fuel injector assemblies.

Apply a light coat of gasoline or spindle oil to the contact surfaces of the the O-rings of the fuel injector assemblies.

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

NOTICE:

1. Do not twist the O-ring.
   
2. After installing the fuel injectors, check that they turn smoothly.
   

Install the 2 No. 1 delivery pipe spacers onto the cylinder head.

NOTICE:

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

Install the fuel delivery pipe sub-assembly with the 4 fuel injector assemblies, then temporarily install the 2 bolts.

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.
   

Tighten the 2 bolts to the specified torque.

Torque:

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

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

Torque:

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

Install the wire harness bracket with the bolt.

Torque:

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

Insert the fuel tube sub-assembly connector into the fuel delivery pipe until a "click" sound can be heard.

NOTICE:

1. Check that there are no scratches or foreign matter around the contact surfaces of the fuel tube connector and pipe before performing this work.
   
2. After connecting the fuel tube, check that the fuel tube connector and pipe are securely connected by pulling on them.
   

Install a new No. 2 fuel pipe clamp (Type B).

Install a new No. 2 fuel pump clamp (Type A).

Install a new gasket to the intake manifold.

Install the intake manifold and intake manifold stay with the 4 bolts and 2 nuts.

Torque:

28 N*m{286 kgf*cm, 21 ft.*lbf}

Connect the 2 water by-pass hoses.

Connect the ventilation hose to the intake manifold.

Install the air tube with the 2 bolts.

Torque:

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

Install the wire harness bracket.

Torque:

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

Install the fan belt adjusting bar with the bolt.

Torque:

19 N*m{194 kgf*cm, 14 ft.*lbf}

Remove the bolt and wire harness bracket.

Install the 2 engine hangers with the 2 bolts.

Torque:

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

Attach the engine to a sling device with the chain block.

Remove the engine from the engine stand.