ENGINE UNIT INSTALLATION

PROCEDURE


  1. INSTALL IGNITION COIL ASSEMBLY

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  2. INSTALL FUEL INJECTOR SEAL

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  3. INSTALL FUEL INJECTOR ASSEMBLY (for Direct Injection)

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  4. INSTALL FUEL DELIVERY PIPE RH

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  5. INSTALL FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY LH

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  6. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY

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  7. SET FUEL PUMP ASSEMBLY

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

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  9. INSTALL FUEL PUMP ASSEMBLY

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  10. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

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  11. INSTALL INTAKE MANIFOLD

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  12. INSTALL FUEL INJECTOR ASSEMBLY (for Port Injection)

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  13. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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  14. INSTALL WIRE HARNESS CLAMP BRACKET (for RHD)

    B000OIGC06
    *1 Oil Cooler Outlet Hose Bracket - -
    B004C4F Bolt B004ANI V-bank Cover Bracket

    1. Install the wire harness clamp bracket to the cylinder head cover RH with the V-bank cover bracket.

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

    2. Install the V-bank cover bracket to the cylinder head LH.

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

    3. Install the oil cooler outlet hose bracket with the bolt.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    4. Install the 14 wire harness clamp brackets with the 17 bolts.

      Torque:
      for Bolt A
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      for Bolt B
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for Bolt C
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      for Bolt D
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for Bolt E
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

    5. Install the wire harness clamp bracket to the wire harness protector of the cylinder head cover RH.

  15. INSTALL WIRE HARNESS CLAMP BRACKET (for LHD)

    B000R14C02
    *1 Oil Cooler Outlet Hose Bracket - -
    B004C4F Bolt B004ANI V-bank Cover Bracket

    1. Install the wire harness clamp bracket to the cylinder head cover RH with the V-bank cover bracket.

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

    2. Install the V-bank cover bracket to the cylinder head LH.

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

    3. Install the oil cooler outlet hose bracket with the bolt.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    4. Install the 15 wire harness clamp brackets with the 18 bolts.

      Torque:
      for Bolt A
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      for Bolt B
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for Bolt C
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      for Bolt D
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for Bolt E
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

    5. Install the wire harness clamp bracket to the wire harness protector of the cylinder head cover RH.

  16. INSTALL ENGINE WIRE

  17. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

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  18. INSTALL NO. 2 WATER BY-PASS PIPE ASSEMBLY


    1. Connect the No. 2 water by-pass pipe assembly to the No. 1 water outlet pipe and slide the hose clamp to secure the hose.

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

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

  19. INSTALL EGR COOLER ASSEMBLY

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  20. INSTALL EGR VALVE ASSEMBLY

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  21. INSTALL THROTTLE BODY BRACKET

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  22. INSTALL NO. 3 WATER BY-PASS HOSE ASSEMBLY


    1. Connect the No. 3 water by-pass hose assembly to the EGR cooler assembly and slide the hose clamp to secure the hose.

    2. Install the No. 3 water by-pass hose assembly with the nut.

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

  23. INSTALL NO. 4 WATER BY-PASS HOSE


    1. Install the No. 4 water by-pass hose and slide the 2 hose clamps to secure the hose.

  24. INSTALL WATER BY-PASS PIPE ASSEMBLY (w/ Oil Cooler)


    1. Install the water by-pass pipe assembly with the bolt and nut.

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

    2. Install the 4 water by-pass hoses and slide the 4 hose clamps to secure the hose.

  25. INSTALL WATER INLET CAP (w/o Oil Cooler)


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

  26. INSTALL WATER HOSE SUB-ASSEMBLY


    1. Install the 2 water hose sub-assembly and slide the 2 hose clamps to secure the hose.

  27. INSTALL NO. 2 WATER BY-PASS HOSE


    1. Install the No. 2 water by-pass hose and slide the 2 hose clamps to secure the hose.

  28. INSTALL NO. 6 WATER BY-PASS HOSE


    1. Install the No. 6 water by-pass hose and slide the 2 hose clamps to secure the hose.

  29. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET


    1. Install the No. 1 compressor mounting bracket with the 2 bolts.

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

  30. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY

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  31. INSTALL V-RIBBED BELT

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  32. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH


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

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

  33. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH


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

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