Installation

ENGINE

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

COMPONENTS (Part 5):

COMPONENTS (Part 6):

COMPONENTS (Part 7):

COMPONENTS (Part 8):

COMPONENTS (Part 9):

COMPONENTS (Part 10):

COMPONENTS (Part 11):

COMPONENTS (Part 12):

COMPONENTS (Part 13):

COMPONENTS (Part 14):

COMPONENTS (Part 15):

COMPONENTS (Part 16):

INSTALLATION
1. INSTALL IGNITION COIL ASSEMBLY
2. INSTALL KNOCK SENSOR
3. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

4. INSTALL ENGINE OIL LEVEL SENSOR
(a) Install the oil level sensor with the 4 bolts.
Torque: 7.0 N*m (71 kgf*cm, 62 in.*lbf)

5. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
6. INSTALL WATER INLET HOUSING
7. INSTALL WATER PUMP PULLEY

8. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY
(a) Install the idler pulley with the bolt.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)

9. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
(a) Install the idler pulley with the bolt.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)

10. INSTALL NO. 4 ENGINE COVER SUB-ASSEMBLY
(a) Install the engine cover.

11. INSTALL ENGINE WIRE
(a) Install the engine wire with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 in.*lbf)
(b) Connect the 4 knock sensor connectors.

12. INSTALL SEPARATOR CASE
13. INSTALL FUEL INJECTOR ASSEMBLY (for Direct Injection)
14. INSTALL NO. 2 FUEL DELIVERY PIPE (for Direct Injection)
15. INSTALL FUEL DELIVERY PIPE (for Direct Injection)
16. INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY
17. INSTALL FUEL PUMP ASSEMBLY (for High Pressure)
18. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY
19. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY
20. INSTALL FUEL PRESSURE PULSATION DAMPER ASSEMBLY
21. INSTALL ENGINE COVER SUB-ASSEMBLY
22. INSTALL FUEL INJECTOR ASSEMBLY (for Port Injection)
23. INSTALL FUEL DELIVERY PIPE (for Port Injection)
24. INSTALL FUEL TUBE SUB-ASSEMBLY
25. INSTALL NO. 3 COVER SUB-ASSEMBLY
26. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY
27. INSTALL INTAKE MANIFOLD
28. INSTALL THROTTLE BODY ASSEMBLY
29. INSTALL VENTILATION HOSE
30. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
31. INSTALL NO. 1 ENGINE COVER
32. INSTALL INJECTOR DRIVER

33. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH
(a) Install the mounting bracket with the 6 bolts.
Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf)

34. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH
(a) Install the mounting bracket with the 6 bolts.
Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf)

35. INSTALL ENGINE MOUNTING DAMPER
(a) Install the 2 mounting dampers with the 2 nuts.
Torque: 11 N*m (112 kgf*cm, 8 ft.*lbf)

36. INSTALL GENERATOR ASSEMBLY

37. REMOVE ENGINE STAND
(a) Install the 2 engine hangers with the 2 bolts as shown in the illustration.
Torque: 43 N*m (438 kgf*cm, 32 ft.*lbf)

(b) Attach an engine sling device and hang the engine with a chain block.

NOTICE: When hanging the engine, make sure to hang the engine with the sling device's hanging angle at 50° or less. If not, the engine or engine hangers may be damaged.

(c) Remove the bolts and engine assembly from the engine stand.

38. INSTALL ENGINE MOUNTING SPACER

39. INSTALL FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY
(a) Install the crossmember with the 2 nuts.
Torque: 35 N*m (357 kgf*cm, 26 ft.*lbf)

40. INSTALL DRIVE PLATE AND RING GEAR SUBASSEMBLY
(a) Using SST, hold the crankshaft.
SST 09213-54015 (90119-08216), 09330-00021
(b) Install the sensor rotor, ring gear and spacer plate on the crankshaft.

(c) Uniformly install and tighten 10 new bolts in the sequence shown in the illustration.
Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)

NOTICE:
^ Do not reuse the flywheel installation bolts.
^ Do not impact or damage the flywheel installation bolts. Be sure to handle them carefully.

(d) Mark the upside of each flywheel installation bolt with paint.
(e) Retighten the flywheel installation bolts by 90° as shown.
(f) Check that the painted marks are now at a 90° angle to the upside.

41. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY
42. INSTALL STARTER ASSEMBLY

43. INSTALL ENGINE WIRE
(a) Install the engine wire with the 4 nuts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(b) Connect the clamp and 2 clamp brackets with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(c) Connect the intake air control valve actuator connector.
(d) Connect the No. 1 vacuum switching valve connector.

(e) Connect the 4 injector driver connectors as shown in the illustration.

(f) for Engine RH Side:
(1) Connect the 2 clamps and install the 3 clamp brackets with the 3 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(2) Connect the engine oil level sensor connector.
(3) Connect the crankshaft position sensor connector.
(4) Connect the starter connector and starter wire with the nut.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(5) Connect the generator connector and generator wire with the nut.
Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)
(6) Connect the camshaft position sensor connector.
(7) Connect the engine wire connector.
(8) Connect the 2 camshaft timing control motor connectors (for Bank 2).
(9) Connect the fuel pump connector (for high pressure).
(10) Connect the 2 VVT sensor connectors.
(11) Connect the 4 ignition coil connectors.
(12) Connect the camshaft timing control valve connector.

(g) for Engine LH Side:
(1) Install the clamp bracket with the bolt.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(2) Connect the 3 clamps and 3 ground wires with the 3 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(3) Connect the 2 camshaft timing control motor connectors (for Bank 1).
(4) Connect the oil pressure sensor connector.
(5) Connect the engine coolant temperature sensor connector.

(6) Connect the clamp and install the 2 clamp brackets with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(7) Connect the No. 8 engine wire connector.
(8) Connect the fuel pump connector (for high pressure).
(9) Connect the 2 VVT sensor connectors.
(10) Connect the 4 ignition coil connectors.
(11) Connect the camshaft timing control valve connector.
(h) Connect the throttle body connectors.

44. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR
45. INSTALL OIL COOLER TUBE
46. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY (for Bank 2)
47. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
48. INSTALL OIL LEVEL DIPSTICK GUIDE
(a) Apply a light coat of engine oil to a new O-ring.
(b) Install the new O-ring to the guide.

(c) Install the dipstick guide with the 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)
(d) Install the dipstick.

49. INSTALL ENGINE AND TRANSMISSION
(a) Place the engine on an engine lifter.

HINT: Place the engine on wooden blocks or an equivalent so that the engine is level.

(b) Remove the 2 bolts and 2 engine hangers.
(c) Operate the engine lifter, then install the engine to the vehicle.

NOTICE: Make sure that the engine is clear of all wiring and hoses.

(d) Align the crossmember to the marks on the vehicle, and temporarily install the engine and transmission with crossmember with the 4 bolts.

NOTICE: Make sure the crossmember is aligned to the vehicle marks as accurately as possible. If not performed accurately, the suspension alignment may become extremely misaligned.

(e) Tighten the 4 bolts.
Torque: 204 N*m (2080 kgf*cm, 150 ft.*lbf)

(f) Install the 4 engine rear mounting member's bolts.
Torque: 26 N*m (265 kgf*cm, 19 ft.*lbf)

50. CONNECT FLOOR SHIFT GEAR SHIFTING ROD SUB-ASSEMBLY
51. CONNECT FRONT NO. 2 LOWER SUSPENSION ARM ASSEMBLY
(a) Connect the front No. 2 lower suspension arm.

52. CONNECT COOLER COMPRESSOR ASSEMBLY
(a) Connect the cooler compressor with the 2 stud bolts, 2 nuts and 2 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for stud bolts
25 N*m (255 kgf*cm, 18 ft.*lbf) for nuts
25 N*m (255 kgf*cm, 18 ft.*lbf) for bolts

53. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY (for Bank 1)
54. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR
55. INSTALL POWER STEERING LINK ASSEMBLY (w/VGRS)
56. INSTALL POWER STEERING LINK ASSEMBLY (w/o VGRS)
57. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (w/VGRS)
58. INSTALL NO. 2 STEERING INTERMEDIATE SHAFT ASSEMBLY (w/o VGRS)
59. INSTALL STEERING SLIDING YOKE WITH SHAFT SUB-ASSEMBLY (w/VGRS)
60. INSTALL STEERING SLIDING YOKE WITH SHAFT SUB-ASSEMBLY (w/o VGRS)
61. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT LH
62. INSTALL FRONT SUSPENSION MEMBER REINFORCEMENT RH
63. INSTALL FRONT STABILIZER BAR
(a) Install the stabilizer bar.

64. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY
(a) Install the propeller shaft.

65. INSTALL NO. 1 EXHAUST PIPE SUPPORT BRACKET SUB-ASSEMBLY
66. INSTALL FRONT EXHAUST PIPE ASSEMBLY
(a) Install the front exhaust pipe.

67. CONNECT HOSES AND CONNECTORS
(a) Connect the purge line hose.

(b) Connect the 2 heater hoses.

(d) Connect the ground wire with the bolt.
Torque: 21 N*m (214 kgf*cm, 15 ft.*lbf)

(e) Connect the 3 connectors with front controller with the clamp.

(f) Attach the clamp and connect the cooler compressor connector.

(g) Connect the 3 ECT connectors and 4 ECM connectors.
(h) Install the ECM box cover (upper).

68. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY
69. CONNECT NO. 3 FUEL HOSE

70. INSTALL ENGINE ROOM ECU OUTLET DUCT
(a) Install the outlet duct.

71. CONNECT NO. 2 RADIATOR HOSE
72. CONNECT NO. 1 RADIATOR HOSE
73. INSTALL AIR CLEANER ASSEMBLY RH
74. INSTALL AIR CLEANER ASSEMBLY LH
75. INSTALL V-RIBBED BELT
76. INSTALL INTAKE AIR CONNECTOR PIPE
77. INSTALL NO. 1 AIR CLEANER INLET

78. INSTALL FRONT SUSPENSION CROSSMEMBER LOWER
(a) Install the suspension crossmember lower with the 6 bolts and 4 nuts.
Torque: 30 N*m (306 kgf*cm, 22 ft.*lbf)

79. INSTALL FRONT BUMPER COVER
(a) Install the front bumper cover.

80. CONNECT NO. 1 OIL COOLER OUTLET HOSE
(a) Using needle-nose pliers, grip the claws of the clip and slide the clip to connect the oil cooler hose.

81. CONNECT NO. 1 OIL COOLER INLET HOSE
(a) Using needle-nose pliers, grip the claws of the clip and slide the clip to connect the oil cooler hose.

82. ADD ENGINE OIL
83. ADD ENGINE COOLANT
84. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
85. PERFORM INITIALIZATION
(a) Perform initialization. Repair Instruction - Initialization

NOTICE: Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.

86. INSPECT FOR OIL LEAK
(a) Inspect for engine oil leak.

87. INSPECT FOR COOLANT LEAK
88. INSPECT FOR FUEL LEAK
89. INSPECT FOR EXHAUST GAS LEAK
90. INSTALL FRONT WHEEL
91. PLACE FRONT WHEELS FACING STRAIGHT AHEAD
92. CHECK AND ADJUST FRONT WHEEL ALIGNMENT
(a) Check and adjust the front wheel alignment.

93. CHECK SHIFT LEVER POSITION

94. INSTALL FRONT SUSPENSION MEMBER PROTECTOR LOWER
(a) Install the suspension member protector with the 8 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf)

95. INSTALL NO. 2 ENGINE UNDER COVER
(a) Install the under cover with the 8 bolts.
Torque: 10 N*m (102 kgf*cm, 7 ft.*lbf) for bolt A
27 N*m (275 kgf*cm, 20 ft.*lbf) for bolt B

96. INSTALL NO. 1 ENGINE UNDER COVER
97. CHECK IGNITION TIMING
98. CHECK IDLE SPEED
99. CHECK CO/HC
100. CHECK ENGINE OIL LEVEL

101. INSTALL ENGINE ROOM SIDE COVER RH
(a) Install the side cover with the 4 clips.

102. INSTALL ENGINE ROOM SIDE COVER LH
(a) Install the side cover with the 4 clips.

103. INSTALL AIR CLEANER INLET COVER SUBASSEMBLY
104. INSTALL V-BANK COVER SUB-ASSEMBLY
105. INSTALL COWL TOP VENTILATOR LOUVER RH