ENGINE UNIT INSTALLATION

PROCEDURE

  1. INSTALL THERMOSTAT

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  2. INSTALL WATER INLET

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  3. INSTALL WATER INLET HOSE

    1. Install the water inlet hose and slide the 2 clamps to secure it.

  4. INSTALL WATER BY-PASS HOSE

    1. Connect the water by-pass hose to the cylinder head sub-assembly and slide the clamp to secure it.

  5. INSTALL NO. 1 WATER BY-PASS PIPE

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

      21 N*m

      214 kgf*cm

      15 ft.*lbf

  6. CONNECT NO. 3 WATER BY-PASS HOSE

    1. Connect the No. 3 water by-pass hose and slide the clip to secure it.

  7. INSTALL VENTILATION HOSE

    1. Connect the ventilation hose to the ventilation valve and slide the clip to secure it.

  8. INSTALL EXHAUST MANIFOLD

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  9. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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  10. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    1. Apply engine oil to a new O-ring and install it to the engine oil level dipstick guide.

    2. Install the engine oil level dipstick guide with the bolt.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

  11. INSTALL IGNITION COIL ASSEMBLY

    1. Install the 4 ignition coil assemblies with the 4 bolts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

      Note:

      When installing each ignition coil assembly, do not damage the plug cap on the engine head cover opening or the upper edge of the spark plug tube.

  12. INSTALL FUEL INJECTOR ASSEMBLY

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  13. INSTALL NO. 1 DELIVERY PIPE SPACER

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  14. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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  15. CONNECT FUEL TUBE SUB-ASSEMBLY

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  16. INSTALL INTAKE MANIFOLD

    1. Install a new No. 1 intake manifold to head gasket to the intake manifold.

    2. Install the intake manifold and intake manifold stay with the 5 bolts and 2 nuts.

      28 N*m

      286 kgf*cm

      21 ft.*lbf

    3. Connect the 2 clamps.

    4. Connect the ventilation hose.

    5. Connect the 2 water by-pass hoses.

    6. Install the air tube to the cylinder head cover sub-assembly with the 2 bolts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  17. INSTALL VACUUM SURGE TANK

    1. Install the vacuum surge tank with the 2 bolts.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

    2. Connect the 2 hoses and slide the clip to secure it.