ENGINE UNIT INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

Perform "Inspection After Repair" after replacing the engine assembly.

Click here

PROCEDURE


  1. INSTALL IGNITION COIL ASSEMBLY

    Click here

  2. INSTALL WATER INLET HOUSING

    Note

    If a stud bolt is deformed or its threads are damaged, replace it.


    1. Using an E6 "TORX" socket wrench, install the 5 stud bolts to the water inlet housing.

      B0086MPC01
      *a 21 mm (0.827 in.) *b 9.0 mm (0.354 in.)
      *c 34 mm (1.34 in.) *d 16 mm (0.630 in.)
      *e 27 mm (1.06 in.) - -
      Torque:
      Stud Bolt (A), (B)
      4.4 N*m  { 45 kgf*cm, 39 in.*lbf }
      Stud Bolt (C)
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    2. Install a new gasket to the cylinder block sub-assembly.

    3. Install the water inlet housing to the cylinder block sub-assembly with the 4 bolts and nut.

      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  3. INSTALL ENGINE OIL TEMPERATURE SENSOR

    Click here

  4. INSTALL OIL COOLER ASSEMBLY

    Click here

  5. INSTALL THERMOSTAT

    Click here

  6. INSTALL WATER INLET

    Click here

  7. INSTALL ENGINE WATER PUMP ASSEMBLY

    Click here

  8. INSTALL WIRE HARNESS CLAMP BRACKET


    1. B008917

      Install the wire harness clamp bracket with the bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    2. B00891Z

      Install the wire harness clamp bracket with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  9. INSTALL NO. 1 WATER BY-PASS PIPE


    1. Install a new gasket and the No. 1 water by-pass pipe with the 2 nuts and bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  10. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. Install the V-ribbed belt tensioner assembly to the water inlet housing with the bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    2. Install the dust cover to the V-ribbed belt tensioner assembly.

  11. INSTALL FUEL INJECTOR SEAL

    Click here

  12. INSTALL DIRECT FUEL INJECTOR ASSEMBLY

    Click here

  13. INSTALL FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY

    Click here

  14. INSTALL NO. 5 ENGINE WIRE


    1. Engage the 2 clamps and install the No. 5 engine wire.

    2. Connect the fuel pressure sensor connector, knock control sensor connector and 4 fuel injector set connectors.

    3. Connect the No. 5 engine wire to the fuel delivery pipe (for Direct Injection) with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  15. INSTALL INTAKE MANIFOLD


    1. Install a new manifold gasket to the intake manifold.

    2. Temporarily install the intake manifold to the cylinder head sub-assembly with the 6 bolts.

    3. B0084TLN01

      Tighten the 6 bolts in the order shown in the illustration.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  16. CONNECT NO. 2 VENTILATION HOSE

    Click here

  17. INSTALL THROTTLE BODY GASKET

    Click here

  18. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

    Click here

  19. INSTALL PORT FUEL INJECTOR ASSEMBLY

    Click here

  20. INSTALL INJECTOR VIBRATION INSULATOR

    Click here

  21. INSTALL FUEL DELIVERY SPACER

    Click here

  22. INSTALL FUEL DELIVERY PIPE

    Click here

  23. CONNECT FUEL TUBE SUB-ASSEMBLY (for Port Injection)

    Click here

  24. TEMPORARILY INSTALL FUEL PUMP WITH SEAL SUB-ASSEMBLY

    Click here

  25. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

    Click here

  26. INSTALL FUEL PUMP WITH SEAL SUB-ASSEMBLY

    Click here

  27. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

    Click here

  28. INSTALL NO. 1 FUEL PIPE

    Click here

  29. CONNECT NO. 2 FUEL TUBE SUB-ASSEMBLY (for Direct Injection)

    Click here

  30. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET


    1. Install the No. 1 compressor mounting bracket with the 4 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  31. INSTALL DRIVE SHAFT BEARING BRACKET


    1. Install the drive shaft bearing bracket with the 3 bolts.

      Torque:
      63.7 N*m  { 650 kgf*cm, 47 ft.*lbf }

      Note

      Make sure that the bolts and bolt holes are free of oil. Clean them if necessary.

  32. INSTALL COMPRESSOR ASSEMBLY WITH MAGNETIC CLUTCH


    1. for Type A:


      1. Using an E8 "TORX" socket wrench, temporarily install the compressor assembly with magnetic clutch with the 2 stud bolts.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      2. B0083CCC02
        *a Bracket
        B00888T Bolt
        B0086HX Nut

        Install the compressor assembly with magnetic clutch and bracket with the 2 bolts and 2 nuts.

        Torque:
        24.5 N*m  { 250 kgf*cm, 18 ft.*lbf }

        Tech Tips

        Tighten the bolts and nuts in the order shown in the illustration to install the compressor assembly with magnetic clutch.

    2. for Type B:


      1. B0085MZC02
        *a Bracket

        Install the compressor assembly with magnetic clutch and bracket with the 4 bolts.

        Torque:
        24.5 N*m  { 250 kgf*cm, 18 ft.*lbf }

        Tech Tips

        Tighten the bolts in the order shown in the illustration to install the compressor assembly with magnetic clutch.

  33. INSTALL WIRE HARNESS CLAMP BRACKET

    Click here

  34. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the wire harness clamp bracket with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Install the wire harness clamp bracket with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    3. Install the wire harness clamp bracket with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    4. Install the wire harness clamp bracket with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  35. INSTALL GENERATOR ASSEMBLY

    Click here

  36. INSTALL V-RIBBED BELT

    Click here

  37. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (TWC: Front Catalyst)


    1. Install a new exhaust manifold gasket to the cylinder head sub-assembly.

    2. Temporarily install the exhaust manifold converter sub-assembly (TWC: Front Catalyst) to the cylinder head sub-assembly with the 5 nuts.

    3. B0083O9N06

      Tighten the 5 nuts in the order shown in the illustration.

      Torque:
      62 N*m  { 632 kgf*cm, 46 ft.*lbf }

  38. INSTALL NO. 2 MANIFOLD STAY

    Click here

  39. INSTALL MANIFOLD STAY

    Click here

  40. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  41. INSTALL EGR VALVE WITH COOLER ASSEMBLY

    Click here

  42. INSTALL FUEL PUMP PROTECTOR

    Click here

  43. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Apply a light coat of engine oil to a new O-ring.

    2. Install the O-ring to the engine oil level dipstick guide.

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

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    4. Install the engine oil level dipstick.