Partial Engine ASSY (FA20): Installation

1. Apply THREE BOND 1217G/1217H or equivalent to the mating surface of oil pan upper as shown in the figure.

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   CAUTION:

   • Clean and degrease the installation surface.
   • Install within 5 min. after applying liquid gasket.
   • Apply liquid gasket 1. 5 mm {0. 0591 in} outside from the groove on the oil pan upper. However, application of liquid gasket on the groove around the bolt hole is allowed.
2. Install three new O-rings to the cylinder block.

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3. Tighten the 13 bolts (A, B and C) in the order as shown in the figure to install the oil pan upper to the cylinder block.

   Standard value: T=18N. m {184kgf. cm} {13. 3ft. lbf}

   Fig 1: Oil Pan Bolts Tightening Sequence

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   Bolt type	Bolt length (except for head)
   Bolt A	25 mm {0. 984 in}
   Bolt B	75 mm {2. 953 in}
   Bolt C	30 mm{1. 181 in}

   NOTE:

   • Tighten the bolt C using Torx® bit T45.
   • After tightening, if the liquid gasket is squeezed out onto the seal surface of chain cover, completely remove any squeezed-out liquid gasket.

1. Install a new O-ring.

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2. Install the oil strainer to the oil pan upper with the two bolts.

   Standard value: T=6. 4N. m {65kgf. cm} {4. 7ft. lbf}

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1. Install two new oil pan seal rings to the oil pan.
2. Apply THREE BOND 1217G/1217H or equivalent to the mating surface of oil pan for the oil pan upper as shown in the figure.

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   CAUTION:

   • Clean and degrease the installation surface.
   • Install within 5 min. after applying liquid gasket.
   Fig 2: Housing Cover Bolts Tightening Sequence

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3. Tighten the 11 bolts in the order as shown in the figure to install the oil pan.

   Standard value: T=6. 4N. m {65kgf. cm} {4. 7ft. lbf}

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1. Install the housing cover to the oil pan upper with the two bolts.

   Standard value: T=5. 0N. m {51kgf. cm} {3. 7ft. lbf}

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1. Install the engine hanger NO. 2 to the cylinder block (bank 1 side) with the two bolts.

   Standard value: T=21N. m {214kgf. cm} {15. 5ft. lbf}

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1. Apply new engine oil to the valve shim and roller rocker arm pivot, and install them to the cylinder head LH.
2. Apply new engine oil to the eight roller rocker arms and two new O-rings, and install them to the cylinder head LH.

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3. Apply THREE BOND 1217G/1217H or equivalent to the mating surface of cam carrier LH as shown in the figure.

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   CAUTION:

   • Clean and degrease the installation surface.
   • Do not apply liquid gasket excessively.
   • Install within 5 min. after applying liquid gasket.
   • Completely remove any liquid gasket that is squeezed out on the installation surface of chain cover.
   Fig 3: Cam Carrier LH Bolts (Tightening Sequence)

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4. Tighten the 9 bolts in the order as shown in the figure to install the cam carrier LH.

   Standard value: T=18N. m {184kgf. cm} {13. 3ft. lbf}

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   NOTE: Set the intake camshaft LH and exhaust camshaft LH to the zero-lift position.
   Fig 4: Intake And Exhaust Camshaft LH Bolts (Loosening Sequence)

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5. Loosen the three bolts by 180° in the order as shown in the figure.
   Fig 5: Intake And Exhaust Camshaft LH Bolts (Tightening Sequence)

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6. Tighten the three bolts in the order as shown in the figure.

   Standard value: T=18N. m {184kgf. cm} {13. 3ft. lbf}

   Fig 6: Intake And Exhaust Camshaft LH Bolts (Loosening Sequence)

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7. Loosen the three bolts by 180° in the order as shown in the figure.
   Fig 7: Intake And Exhaust Camshaft LH Bolts (Tightening Sequence)

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8. Tighten the three bolts in the order as shown in the figure.

   Standard value: T=18N. m {184kgf. cm} {13. 3ft. lbf}

   Fig 8: Intake And Exhaust Camshaft LH Bolts (Loosening Sequence)

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9. Loosen the three bolts by 180° in the order as shown in the figure.
   Fig 9: Intake And Exhaust Camshaft LH Bolts (Tightening Sequence)

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10. Tighten the three bolts in the order as shown in the figure.

    Standard value: T=18N. m {184kgf. cm} {13. 3ft. lbf}

    NOTE: After tightening, if the liquid gasket is squeezed out onto the seal surface of chain cover, completely remove any squeezed-out liquid gasket.

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1. Apply a thin coat of new engine oil to two new spark plug pipe gaskets and insert them onto the spark plug pipe edge.
2. Install a new head cover gasket NO. 2 to the rocker cover LH.

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3. Apply THREE BOND 1217G/1217H or equivalent to the mating surface of rocker cover LH as shown in the figure.

   Application area	Application length
   A	10. 0 mm {0. 394 in} or more
   B	18. 8 mm {0. 740 in} or less
   C	63. 0 mm {2. 480 in} or more

4. Set the rocker cover LH and tighten the eight bolts in the order as shown in the figure.

   Standard value: T=6. 4N. m {65kgf. cm} {4. 7ft. lbf}

Fig 10: Rocker Cover LH Bolts (Tightening Sequence)

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1. Apply new engine oil to the valve shim and roller rocker arm pivot, and install them to the cylinder head RH.

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2. Apply new engine oil to the eight roller rocker arms and two new O-rings, and install them to the cylinder head RH.
3. Apply THREE BOND 1217G/1217H or equivalent to the mating surface of cam carrier RH as shown in the figure.

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   CAUTION:

   • Clean and degrease the installation surface.
   • Do not apply liquid gasket excessively.
   • Install within 5 min. after applying liquid gasket.
   • Completely remove any liquid gasket that is squeezed out on the installation surface of chain cover.
   Fig 11: Cam Carrier RH Bolts (Tightening Sequence)

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4. Tighten the 9 bolts in the order as shown in the figure to install the cam carrier RH.

   Standard value: T=18N. m {184kgf. cm} {1. 3. 3 ft. lbf}

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   NOTE: Set the intake camshaft RH and exhaust camshaft RH to the zero-lift position.
   Fig 12: Camshaft Bolts (Loosening Sequence)

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5. Loosen the three bolts by 180° in the order as shown in the figure.
   Fig 13: Camshaft Bolts (Tightening Sequence)

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6. Tighten the three bolts in the order as shown in the figure.

   Standard value: T=18N. m {184kgf. cm} {13. 3ft. lbf}

   Fig 14: Camshaft Bolts (Loosening Sequence)

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7. Loosen the three bolts by 180° in the order as shown in the figure.
   Fig 15: Camshaft Bolts (Tightening Sequence)

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8. Tighten the three bolts in the order as shown in the figure.

   Standard value: T=18N. m {184kgf. cm} {1. 3. 3 ft. lbf}

   Fig 16: Camshaft Bolts (Loosening Sequence)

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9. Loosen the three bolts by 180° in the order as shown in the figure.
   Fig 17: Camshaft Bolts (Tightening Sequence)

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10. Tighten the three bolts in the order as shown in the figure.

    Standard value: T=18N. m {184kgf. cm} {13. 3ft. lbf}

    NOTE: After tightening, if the liquid gasket is squeezed out onto the seal surface of chain cover, completely remove any squeezed-out liquid gasket.

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1. Apply a thin coat of new engine oil to two new spark plug pipe gaskets and insert them onto the spark plug pipe edge.
2. Install a new rocker cover gasket to the rocker cover RH.
3. Apply THREE BOND 1217G/1217H or equivalent to the mating surface of rocker cover RH as shown in the figure.

   Application area	Application length
   A	10. 0 mm {0. 394 in} or more
   B	68. 0 mm {2. 677 in} or more
   C	70. 7 mm {2. 784 in} or more

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   Fig 18: Rocker Cover RH Bolts (Tightening Sequence)

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4. Set the rocker cover RH and tighten the eight bolts in the order as shown in the figure.

   Standard value: T=6. 4N. m {65kgf. cm} {4. 7ft. lbf}

1. Install the injector driver bracket with the two bolts.

   Standard value: T=6. 4N. m {65kgf. cm} {4. 7ft. lbf}

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1. Using 2 bolts, install the ignition coil ASSY.

   Standard value: T=8. 5N. m {87kgf. cm} {6. 3ft. lbf}

2. Connect 2 connectors of the ignition coil ASSY.

1. Using 2 bolts, install the ignition coil ASSY.

   Standard value: T=8. 5N. m {87kgf. cm} {6. 3ft. lbf}

2. Connect 2 connectors of the ignition coil ASSY.

1. Install the crankshaft sprocket.

1. Apply THREE BOND 1217G/1217H or equivalent to the cam carrier RH as shown in the figure.
   CAUTION:

   • Clean and degrease the installation surface.
   • Install within 5 min. after applying liquid gasket.
   • Install the cylinder head plate with the three bolts.

   Standard value: T=16N. m {163kgf. cm} {11. 8ft. lbf}

1. Install the water by-pass pipe NO. 1 with the two bolts.

   Standard value: T=6. 4N. m {65kgf. cm} {4. 7ft. lbf}

2. Install the water by-pass hose with the hose clamp.

1. Install the water by-pass pipe NO. 1 with the two bolts.

   Standard value: T=6. 4N. m {65kgf. cm} {4. 7ft. lbf}

2. Install the two water by-pass hoses with the two hose clamps.

1. Install two new O-rings to the cylinder block.
2. Install the water pipe ASSY with the four bolts.

   Standard value: T=6. 4N. m {65kgf. cm} {4. 7ft. lbf}

3. Install the water by-pass hose NO. 3 with the hose clamp.

1. Connect the transmission oil cooler hose NO. 3.

1. Install the water by-pass hose NO. 2 with the hose clamp.

1. Install two new O-rings to the PCV hose connector.
2. Connect the water by-pass hose NO. 1 to the PCV hose connector and water pipe ASSY with the hose clamps.
3. Install the PCV hose connector with the three bolts.

   Standard value: T=6. 4N. m {65kgf. cm} {4. 7ft. lbf}

1. Connect the ventilation hose NO. 2 with the hose clamp.

1. Confirm the connection of each connector and clamp as shown in the figure.

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1. Install the two engine mounting insulators FR with the four bolts.

   Standard value: T=35N. m {357kgf. cm} {25. 8ft. lbf}

1. Support the engine ASSY with an engine sling device and mini-crane.
   CAUTION: Since the operation with the engine ASSY suspended are danger, never perform it other than when installing the ASSY to the engine stand or removing it from the stand.
2. Remove the engine ASSY from the engine stand.

1. Make sure that the knock pins are attached to 2 locations on the engine side.
2. Align the knock pins to the knock holes by leveling the engine and transmission ASSY using an engine sling device and mini-crane.

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1. Install the connecting bolt of transmission ASSY.

   Standard value: T=50N. m {510kgf. cm} {36. 9ft. lbf}

2. Remove the SST. (Transmission A/T)

1. Align the alignment marks on purge hose and pipe, and secure them with the hose clump.
2. Connect the fuel hose NO. 1 and fuel hose NO. 2.

1. Using two new nuts, install the front crossmember SUB-ASSY.

   Standard value: T=60N. m {612kgf. cm} {44. 2ft. lbf}

1. Install the manual transmission ASSY with the three bolts A and two nuts.

   Standard value: T=50N. m {510kgf. cm} {36. 9ft. lbf}

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1. Install the automatic transmission ASSY with the three bolts A and two nuts.

   Standard value: T=50N. m {510kgf. cm} {36. 9ft. lbf}

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1. Install the under cover rear LH with the three bolts and eight clips.

   Standard value: T=7. 5N. m {77kgf. cm} {5. 5ft. lbf}

1. Install the ground cable with the two bolts.

   Standard value: T=7. 5N. m {77kgf. cm} {5. 5ft. lbf}

1. Remove the SST from the starter hole of torque converter clutch case.

1. Remove the vinyl tape wrapped around the joint of the suction hose SUB-ASSY.
2. Apply sufficient compressor oil to a new O-ring and the fitting area of compressor ASSY (with pulley).
3. Install the O-ring to the suction hose SUB-ASSY.
   CAUTION: Do not allow dust etc. to adhere to the O-ring and O-ring sealing portion.
4. Connect the suction hose SUB-ASSY to the compressor ASSY (with pulley) with the bolt.

   Standard value: T=10N. m {102kgf. cm} {7. 4ft. lbf}

5. Remove the vinyl tape wrapped on the connection of suction hose SUB-ASSY and unit.
6. Apply sufficient compressor oil to a new O-ring and the connection of suction hose SUB-ASSY.
7. Install the O-ring to the suction hose SUB-ASSY.
   CAUTION: Do not allow dust etc. to adhere to the O-ring and O-ring sealing portion.
8. Push the shaft of the pipe joint into the seal hole until it is completely engaged.
9. Turn the hook type connector to the tightening position and tighten it with bolts.

   Standard value: T=7. 5N. m {77kgf. cm} {5. 5ft. lbf}

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10. Install the suction hose SUB-ASSY with the nut.

    Standard value: T=10N. m {102kgf. cm} {7. 4ft. lbf}

1. Connect the radiator outlet hose with the hose clamp.

1. Connect the transmission oil cooler hose NO. 1 with the hose clamp.

1. Connect the transmission oil cooler hose NO. 3 with the hose clamp.

1. Install the heater water hoses with the two hose clamps.

1. Install the vacuum tube connector hose with the bolt.

   Standard value: T=18N. m {184kgf. cm} {13. 3ft. lbf}

2. Connect the vacuum tube connector hose with the hose clamp.

1. Install the vacuum tube connector hose with the bolt.

   Standard value: T=18N. m {184kgf. cm} {13. 3ft. lbf}

2. Connect the vacuum tube connector hose with the hose clamp.

1. Use the SST to secure the crank pulley.

   SST 18355AA000, 18334AA000

2. Install the six drive plate & torque converter setting bolts through the service hole.

   Standard value: T=25N. m {255kgf. cm} {18. 4ft. lbf}

1. Install the flywheel housing under cover.

1. Connect the generator connector and connect the clamp.

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2. Connect the generator wire with the nut.

   Standard value: T=15. 5N. m {158kgf. cm} {11. 4ft. lbf}

3. Install the terminal cap.
4. Connect the 2 wire harness clamps

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5. Install the connector to the engine hanger No. 2.

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6. Connect the connector.

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7. Connect the connector (B).

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8. Connect the wire harness connector (A) and securely lock the connector.
9. Install the wire harness clamp bracket to the No. 2 engine hanger with the 2 bolts.

   Standard value: T=10N. m {102kgf. cm} {7. 4ft. lbf}

10. for Automatic Transmission:
    1. Connect the 4 wire harness clamps.

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    2. Install the wiring harness bracket with the bolt.

       Standard value: T=11N. m {112kgf cm} {8. 1ft. lbf}

    3. Slide the connector in the direction shown in the diagram, and connect the wire harness.

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    4. Connect the wire harness connector (A) and securely lock the connector.
    5. Connect the connector (B).

1. Install the water filler SUB-ASSY with the two hose clamps.
2. Install the water filler SUB-ASSY with the two bolts.

Standard value: T=7. 5N. m {77kgf. cm} {5. 5ft. lbf}

1. Install the stay with the bolt.

   Standard value: T=35N. m {357kgf. cm} {25. 8ft. lbf}

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2. Install the air cleaner case SUB-ASSY with the three bolts.

   Standard value: T=6. 0N. m {61kgf. cm} {4. 4ft. lbf}

3. Tighten the hose clamp.

   Standard value: T=2. 0N. m {20kgf. cm} {1. 5ft. lbf}

4. Engage the clamp and install the wiring harness to the air cleaner cap.
5. Connect the connector to the intake air flow meter SUB-ASSY.
6. Connect the ventilation hose NO. 2 with the hose clamp.
7. Install the chamber with the two bolts.

   Standard value: T=6. 0N. m {61kgf. cm} {4. 4ft. lbf}

8. Connect the hose to the chamber ASSY.

Standard value: T=6. 0N. m {61kgf. cm} {4. 4ft. lbf}

1. Change the front hood stay position from B to A and store it in the position A.

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