ENGINE UNIT INSTALLATION

CAUTION / NOTICE / HINT

Tech Tips

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

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PROCEDURE


  1. INSTALL WATER OUTLET SUB-ASSEMBLY

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  2. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

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  3. INSTALL FUEL INJECTOR SEAL

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  4. INSTALL FUEL INJECTOR SET

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  5. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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  6. INSTALL FUEL INJECTOR ASSEMBLY

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  7. INSTALL FUEL DELIVERY PIPE

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  8. SET FUEL PUMP WITH SEAL SUB-ASSEMBLY

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

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  10. INSTALL FUEL PUMP WITH SEAL SUB-ASSEMBLY

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  11. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

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  12. INSTALL NO. 1 FUEL PIPE

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  13. INSTALL WATER INLET HOUSING

    Note

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


    1. A01OCLKC03
      *a 16 mm (0.63 in.)
      *b 9.0 mm (0.354 in.)
      *c 27 mm (1.06 in.)

      Using an E6 "TORX" socket wrench, install the 8 stud bolts to the water inlet housing.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    2. Install a new gasket to the water inlet housing.

    3. Install the water inlet housing to the cylinder block sub-assembly with the 2 bolts and nut.

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

      Note

      Keep the contact surfaces of the cylinder block sub-assembly and water inlet housing free of foreign matter.

      Tech Tips

      Align the straight pin of the cylinder block sub-assembly with the straight pin hole of the water inlet housing.

  14. INSTALL NO. 5 WATER BY-PASS PIPE


    1. Install a new gasket to the water inlet housing.

    2. Install the No. 5 water by-pass pipe to the water inlet housing with the bolt and 2 nuts.

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

    3. Connect the No. 11 water by-pass hose to the water outlet sub-assembly and slide the clip to secure it.

  15. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

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  16. INSTALL ENGINE WATER PUMP ASSEMBLY

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  17. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the 7 wire harness clamp brackets with the 9 bolts.

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

  18. INSTALL ENGINE COVER JOINT


    1. Install the 3 engine cover joints to the cylinder head cover sub-assembly.

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

  19. INSTALL IGNITION COIL ASSEMBLY

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  20. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. Install the front No. 1 engine mounting bracket LH to the cylinder block sub-assembly with the 4 bolts.

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

  21. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. Install the front No. 1 engine mounting bracket RH to the cylinder block sub-assembly with the 4 bolts.

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

  22. INSTALL NO. 3 WATER BY-PASS PIPE


    1. Install the No. 3 water by-pass pipe to the cylinder block sub-assembly with the 3 bolts.

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

    2. Connect the No. 13 water by-pass hose to the water outlet sub-assembly and slide the clip to secure it.

  23. INSTALL NO. 2 WATER BY-PASS PIPE


    1. Install the No. 2 water by-pass pipe to the cylinder head sub-assembly with the 2 bolts.

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

  24. INSTALL EGR COOLER ASSEMBLY

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  25. INSTALL EGR VALVE BRACKET

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  26. INSTALL NO. 1 WATER BY-PASS PIPE


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

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

    2. Connect the water by-pass hose to the No. 2 water by-pass pipe and slide the clip to secure it.

  27. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET


    1. Install the No. 1 compressor mounting bracket with the 5 bolts.

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