Part 2

PARTIAL ENGINE ASSEMBLY
REPLACEMENT
51. REMOVE INTAKE MANIFOLD ASSEMBLY





a. Disconnect the VSV connector for EVAP.
b. Disconnect the EVAP hose from the VSV for EVAP.
c. Remove the bolt, disconnect the VSV for EVAP from the upper intake manifold.
d. Remove the bolt and V-bank cover bracket No. 2.
e. Remove the bolt and V-bank cover bracket No. 3.





f. Disconnect the VSV connector for ACIS.
g. Remove the bolt and V-bank cover bracket No. 1.
h. Remove the bolt and V-bank cover fastener.





i. Remove the 4 bolts, and disconnect the engine wire protector (LH side) from the upper intake manifold and cam shaft bearing cap. Disconnect the 2 wire clamps on the engine wire (RH side) from the brackets on the RH delivery pipe.
k. Remove the 2 bolts, and disconnect the engine wire protector (rear side) from the rear water by-pass joint and RH cylinder head.





l. Disconnect the 8 injector connectors.
m. Remove the 6 bolts, 4 nuts, intake manifold assembly and 2 gaskets.
52. INSPECT INTAKE MANIFOLD ASSEMBLY





a. Upper intake manifold: Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for war page.
Maximum warpage: 0.15 mm (0.0059 inch)
If the warpage is greater than the maximum, replace the manifold.





b. Lower intake manifold Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for war page.
Maximum warpage: 0.15 mm (0.0059 inch)
If the warpage is greater than the maximum, replace the manifold.
53. REMOVE STARTER ASSEMBLY
54. REMOVE GENERATOR ASSEMBLY
55. REMOVE WATER INLET HOUSING
a. Remove the 2 bolts and inlet housing.





56. REMOVE WATER BY-PASS JOINT FR
a. Disconnect the ECT sensor connector.
b. Remove the 4 nuts, water by-pass joint and 2 gaskets.





57. REMOVE WATER BY-PASS JOINT RR
a. Disconnect the heater inlet hose from the water by-pass joint.
b. Remove the 4 nuts, water by-pass joint and 2 gaskets.
58. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY
a. Disconnect the heater outlet hose from the water by-pass pipe.
b. Disconnect the wire clamp (for knock sensor bank 1, 2) from the bracket of the water by-pass pipe.
c. Remove the bolt.
d. Pull out the water by-pass pipe from the water pump.
e. Remove the O-ring from the water by-pass pipe.
59. REMOVE OIL LEVEL GAGE GUIDE
60. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
61. REMOVE CAMSHAFT POSITION SENSOR
62. REMOVE VVT SENSOR





63. REMOVE KNOCK SENSOR
a. Disconnect the 2 knock sensor connectors.
b. Remove the 2 nuts and 2 knock sensors.
64. REMOVE ENGINE HANGER NO. 1
65. REMOVE ENGINE HANGER NO.2
66. REMOVE IGNITION COIL ASSEMBLY
67. REMOVE OIL FILTER BRACKET SUB-ASSEMBLY
a. Disconnect the oil pressure switch connector.
b. Remove the stud bolt, 2 nuts and oil filter bracket with gasket.
68. REMOVE CRANKSHAFT POSITION SENSOR
69. REMOVE ENGINE OIL LEVEL SENSOR
70. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1





71. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Remove the 8 nuts, exhaust manifold and gasket.





72. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for war page.
Maximum warpage: 0.50 mm (0.0197 inch)
If the warpage is greater than the maximum, replace the manifold.
73. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2





74. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
a. Remove the 8 nuts, exhaust manifold and gasket.





75. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH
a. Using a precision straight edge and feeler gauge, measure the surface contacting the cylinder head for war page.
Maximum warpage: 0.50 mm (0.0197 inch)
If the warpage is greater than the maximum, replace the manifold.
76. REMOVE WIRING HARNESS HEAT INSULATOR NO.2
77. REMOVE ENGINE MOUNTING BRACKET FRONT NO.1 RH
78. REMOVE ENGINE MOUNTING BRACKET FRONT NO.1 LH





79. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 LH
a. Install the mounting bracket with the 4 bolts.
Torque: 36 Nm (367 kgf-cm, 27 ft. lbs.)

HINT: The LH mounting bracket is marked with "L".





80. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 RH
a. Install the mounting bracket with the 4 bolts.
Torque: 36 Nm (367 kgf-cm, 27 ft. lbs.)

HINT: The RH mounting bracket is marked with "R".

81. INSTALL WIRING HARNESS HEAT INSULATOR NO.2
82. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY LH





a. Place a new gasket on the cylinder head with the white mark facing the manifold side.

NOTICE: Be careful of the installation direction.





b. Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)
83. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2
84. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH





a. Place a new gasket on the cylinder head with the white mark facing the manifold side.

NOTICE: Be careful of the installation direction.





b. Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)
85. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
86. INSTALL ENGINE OIL LEVEL SENSOR
87. INSTALL CRANKSHAFT POSITION SENSOR
88. INSTALL OIL FILTER BRACKET SUB-ASSEMBLY
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
89. INSTALL IGNITION COIL ASSEMBLY
Torque: 7.5 Nm (77 kgf-cm, 66 inch lbs.)
90. INSTALL ENGINE HANGER NO.2
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)
91. INSTALL ENGINE HANGER NO. 1
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)





92. INSTALL KNOCK SENSOR
a. Install the 2 knock sensors with the 2 nuts, as shown in the illustration.
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
b. Connect the 2 knock sensor connectors.
93. INSTALL VVT SENSOR
94. INSTALL CAMSHAFT POSITION SENSOR
Torque: 7.5 Nm (77 kgf-cm, 66 inch lbs.)
95. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
96. INSTALL OIL LEVEL GAGE GUIDE
Torque: 7.5 Nm (77 kgf-cm, 66 inch lbs.)
97. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
a. Install a new O-ring to the water by-pass pipe.
b. Apply soapy water to the O-ring.
c. Push in the water by-pass pipe end into the pipe hole of the water pump.
d. Install the water by-pass pipe with the bolt.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
e. Install the wire clamp to the bracket of the water by-pass pipe.





98. INSTALL WATER BY-PASS JOINT RR
a. Install 2 new gaskets and the water by-pass joint with the 4 nuts. Alternately tighten the nuts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)





99. INSTALL WATER BY-PASS JOINT FR
a. Install 2 new gaskets and the water by-pass joint with the 4 nuts. Alternately tighten the nuts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)
b. Connect the ECT sensor connector.





100. INSTALL WATER INLET HOUSING
a. Install a new O-ring to the inlet housing.
b. Apply soapy water on the O-ring.
c. Apply seal packing to the sealing groove of the inlet housing as shown in the illustration.
Seal packing: Part No. 08826-00100 or equivalent
^ Install a nozzle that has its opening cut to a 2 to 3 mm (0.08 to 0.12 inch).
^ Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
d. Install the water inlet and housing assembly with the 2 bolts. Alternately tighten the bolts.
Torque: 18 Nm (184 kgf-cm, 13 ft. lbs.)