ENGINE UNIT INSTALLATION

PROCEDURE


  1. INSTALL IGNITION COIL ASSEMBLY

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  2. INSTALL KNOCK SENSOR

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  3. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

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  4. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Connect the No. 2 water by-pass pipe sub-assembly to the oil cooler and heat exchanger assembly and slide the 3 clips to secure it.

    2. Install the No. 2 water by-pass pipe sub-assembly with the 4 bolts.

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

  5. INSTALL ENGINE OIL LEVEL SENSOR

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  6. INSTALL ENGINE OIL TEMPERATURE SENSOR

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  7. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

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  8. INSTALL WATER INLET HOUSING


    1. Install the water inlet housing and a new gasket with the 3 bolts.

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

    2. Connect the water inlet hose to the water inlet housing and slide the clip to secure it.

  9. INSTALL WATER PUMP PULLEY

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  10. INSTALL OIL PUMP DRIVE SHAFT PULLEY


    1. B000Y01N02

      Temporarily install the oil pump drive shaft pulley with the 4 bolts.

    2. Using SST, hold the oil pump drive shaft pulley and tighten the 4 bolts.

      SST
      09960-10010
      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

  11. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. Install the No. 2 idler pulley sub-assembly with the bolt.

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

  12. INSTALL NO. 4 ENGINE COVER SUB-ASSEMBLY


    1. Install the No. 4 engine cover sub-assembly.

  13. INSTALL NO. 5 ENGINE WIRE


    1. B000YJPC02
      *a Bolt A
      *b Bolt B

      Install the No. 5 engine wire with the 2 bolts.

      Torque:
      for bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for bolt B
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

    2. Attach the 3 clamps.

    3. Connect the 4 knock sensor connectors.

  14. INSTALL FUEL INJECTOR SEAL

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  15. INSTALL DIRECT FUEL INJECTOR ASSEMBLY

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  16. INSTALL FUEL DELIVERY PIPE LH

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  17. INSTALL FUEL DELIVERY PIPE RH

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  18. INSTALL CASE SEPARATOR

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  19. INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY

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  20. INSTALL NO. 2 ENGINE COVER SUB-ASSEMBLY LH

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  21. SET FUEL PUMP WITH SEAL SUB-ASSEMBLY (for Bank 1)

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  22. SET FUEL PUMP WITH SEAL SUB-ASSEMBLY (for Bank 2)

    Tech Tips

    Use the same procedure as for the bank 1 side.

  23. TEMPORARILY INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY

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  24. TEMPORARILY INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY

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  25. INSTALL FUEL PUMP WITH SEAL SUB-ASSEMBLY (for Bank 1)

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  26. INSTALL FUEL PUMP WITH SEAL SUB-ASSEMBLY (for Bank 2)

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  27. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY

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  28. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY

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  29. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

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  30. INSTALL NO. 3 COVER SUB-ASSEMBLY

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  31. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

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  32. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

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  33. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY

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  34. INSTALL PORT FUEL INJECTOR ASSEMBLY

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  35. INSTALL INJECTOR VIBRATION INSULATOR

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  36. INSTALL NO. 1 DELIVERY PIPE SPACER

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  37. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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  38. INSTALL NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY

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  39. INSTALL FUEL TUBE SUB-ASSEMBLY

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  40. CONNECT PCV HOSE

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  41. INSTALL NO. 3 PCV HOSE


    1. Connect the No. 3 PCV hose to the cylinder head cover sub-assembly LH and slide the clip to secure the hose.

  42. INSTALL NO. 2 PCV HOSE


    1. Connect the No. 2 PCV hose to the cylinder head cover sub-assembly and slide the clip to secure the hose.

  43. INSTALL FUEL VAPOR FEED HOSE

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  44. CONNECT VACUUM HOSE SUB-ASSEMBLY

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  45. INSTALL PURGE VSV

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  46. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Install the water by-pass pipe sub-assembly to the intake air surge tank assembly with the 2 bolts.

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

    2. Connect the No. 5 water by-pass hose to the water by-pass pipe sub-assembly and slide the clip to secure it.

    3. Connect the water by-pass hose to the water by-pass pipe sub-assembly and slide the clip to secure it.

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

  47. INSTALL INJECTOR DRIVER

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  48. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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  49. INSTALL WIRE HARNESS CLAMP BRACKET

    B000TU0C05
    *1 Intake Air Connector Bracket *2 No. 1 Intake Air Connector Bracket
    *3 No. 2 Intake Air Connector Bracket *4 Crank Position Sensor Bracket
    B000XM7 Bolt B000TT4 V-bank Cover Bracket
    B000YI8 Injector Driver Bracket - -

    1. Install the 13 wire harness clamp brackets with the 15 bolts.

      Torque:
      for bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for bolt B
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      for bolt C
      17.5 N*m  { 178 kgf*cm, 13 ft.*lbf }
      for bolt D
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    2. Install the 2 injector driver brackets with the 4 bolts.

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

    3. Install the 2 V-bank cover brackets with the 2 bolts.

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

    4. Install the No. 2 intake air connector bracket with the bolt.

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

    5. Install the No. 1 intake air connector bracket with the 2 bolts.

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

    6. Install the intake air connector bracket with the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    7. Install the crank position sensor bracket with the bolt.

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

  50. INSTALL NO. 3 V-BANK COVER BRACKET SUB-ASSEMBLY


    1. Install the No. 3 V-bank cover bracket sub-assembly with the bolt.

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

  51. INSTALL NO. 4 V-BANK COVER BRACKET SUB-ASSEMBLY


    1. Install the No. 4 V-bank cover bracket sub-assembly with the bolt.

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

  52. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. Install the front No. 1 engine mounting bracket LH with the 4 bolts.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  53. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. Install the front No. 1 engine mounting bracket RH with the 4 bolts.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  54. CONNECT NO. 5 ENGINE WIRE

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  55. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine assembly.

  56. INSTALL NO. 1 ENGINE HANGER

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  57. REMOVE ENGINE FROM ENGINE STAND


    1. B000V9ZC02
      *a No. 1 Engine Hanger
      *b Engine Assembly
      *c 50° or Less

      Attach an engine sling device and hang the engine assembly with a chain block.

      Tech Tips

      When hanging the engine assembly, make sure to hang the engine assembly with the chain at an angle of 50° or less. Otherwise, the engine assembly or engine hangers may be damaged.

    2. Remove the bolts and engine assembly from the engine stand.