Removal and Installation

NOTE: Before changing the starter. check these items again:
^ Connector connection
^ Accessory installation. e.g.: theft deterrent system











COMPONENTS FOR REMOVAL AND INSTALLATION

STARTER REMOVAL
1. REMOVE LH NO.3 TIMING BELT COVER
2. REMOVE AIR INTAKE CHAMBER ASSEMBLY
3. REMOVE INTAKE MANIFOLD ASSEMBLY





4. REMOVE RH FRONT TWC
a. Remove the 2 bolts and 2 nuts holding the front exhaust pipe to the TWC.
b. Remove the 3 nuts holding the TWC to the exhaust manifold.
c. Remove the TWC and 2 gaskets.

5. REMOVE REAR WATER BYPASS JOINT AND NO.1 EGR PIPE ASSEMBLY
(See step 17 in cylinder head removal in Engine Mechanical)





6. REMOVE WATER BYPASS PIPE
a. Remove the bolt.
b. Pull out the water bypass pipe from the water pump.
c. Disconnect the wire clamp from the bracket on the water bypass pipe.
d. Remove the O-ring from the water bypass pipe.

7. REMOVE STARTER





a. Remove the 2 bolts holding the starter to the cylinder block.
b. Disconnect the starter from the cylinder block.





c. Disconnect the starter connector.
d. Remove the nut, and disconnect the starter wire.
e. Remove the bolt, and disconnect the wire clamp from the starter and remove the starter.

STARTER INSTALLATION

1. INSTALL STARTER





a. Install the wire clamp to the wire bracket with the bolt.
Torque: 9.81 N.m (98 kgf.cm, 84 in.lbf)
b. Connect the starter wire with the nut.
Torque: 9.81 N.m (98 kgf.cm, 84 in.lbf)
c. Connect the starter connector.





d. Install the starter with the 2 bolts.
Torque: 39 N.m (400 kgf.cm, 29 ft.lbf)





2. INSTALL WATER BYPASS PIPE
a. Install a new O-ring to the water bypass pipe.
b. Apply soapy water to the O-ring.
c. Push in the water bypass pipe end into the pipe hole of the water pump.
d. Install the wire clamp to the bracket on the water bypass pipe.
e. Install the water bypass pipe with the bolt.

Torque: 18 N.m (185 kgf.cm, 13 ft.lbf)

3. INSTALL REAR WATER BYPASS JOINT AND NO.1 EGR PIPE ASSEMBLY





4. INSTALL RH FRONT TWC
a. Install new gasket and the TWC to the exhaust manifold with 3 new nuts.
Torque: 62 N.m (630 kgf.cm, 46 ft.lbf)
b. Install a new gasket and the TWC to the front exhaust pipe with the 2 bolts and 2 new nuts.
Torque: 43 N.m (440 kgf.cm, 32 ft.lbf)

5. INSTALL INTAKE MANIFOLD ASSEMBLY
6. INSTALL AIR INTAKE CHAMBER ASSEMBLY
7. INSTALL LH NO.3 TIMING BELT COVER