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ENGINE UNIT INSTALLATION

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PROCEDURE


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    INSTALL STUD BOLT


    1. Using an E8 "TORX" socket wrench, install the stud bolt to the timing chain cover assembly.

      10 N*m 102 kgf*cm 7 ft.*lbf
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    INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the 2 wire harness clamp brackets to the timing chain cover assembly with the 2 bolts.

      12.8 N*m 131 kgf*cm 9 ft.*lbf

    2. Install the wire harness clamp bracket to the cylinder block sub-assembly with the bolt.

      12.8 N*m 131 kgf*cm 9 ft.*lbf

    3. Install the 2 wire harness clamp brackets to the cylinder head cover sub-assembly with the 2 bolts.

      8.4 N*m 86 kgf*cm 74 in.*lbf
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    INSTALL NO. 4 ENGINE WIRE


    1. Connect the knock sensor connector to install the No. 4 engine wire.

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    INSTALL NO. 1 IGNITION COIL

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    INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. Install the V-ribbed belt tensioner assembly to the timing chain cover assembly with the 2 bolts.

      21 N*m 214 kgf*cm 15 ft.*lbf
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    INSTALL NO. 1 WATER BY-PASS PIPE


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

      22 N*m 224 kgf*cm 16 ft.*lbf

    2. Connect the No. 1 water by-pass hose to the water inlet with thermostat sub-assembly and slide the hose clip to secure it.

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    INSTALL NO. 2 WATER BY-PASS PIPE


    1. Install the No. 2 water by-pass pipe and wire harness clamp bracket to the cylinder head cover sub-assembly with the bolt and nut.

      10 N*m 102 kgf*cm 7 ft.*lbf

    2. Connect the No. 6 water by-pass hose to the No. 1 water by-pass pipe and slide the hose clip to secure it.

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    INSTALL NO. 6 ENGINE WIRE


    1. Engage the 4 clamps to install the No. 6 engine wire to the wire harness clamp bracket and cylinder head cover sub-assembly.

    2. Connect the 4 fuel injector assembly connectors.

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    INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET

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    INSTALL INTAKE MANIFOLD


    1. A00498CE01

      Clean and degrease the bolt thread and bolt hole.

      Note:

      Do not apply oil to the bolts.

    2. Temporarily install the intake manifold to the cylinder head sub-assembly with the 3 bolts and 2 nuts.

    3. Tighten the 3 bolts and 2 nuts in the order shown in the illustration.

      24 N*m 245 kgf*cm 18 ft.*lbf

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

    5. Engage the clamp to connect the No. 4 engine wire connector to the intake manifold.

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    INSTALL PURGE VALVE (PURGE VSV)


    1. Install the purge valve (purge VSV) to the intake manifold with the bolt.

      10 N*m 102 kgf*cm 7 ft.*lbf

    2. Connect the No. 2 fuel vapor feed hose to the purge valve (purge VSV).

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    INSTALL EGR INLET GASKET


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

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    INSTALL EGR VALVE ASSEMBLY


    1. Temporarily install the EGR valve assembly together with the EGR cooler assembly and EGR pipe assembly to the cylinder head sub-assembly and intake manifold with the bolt and 2 nuts.

    2. Temporarily install the EGR valve bracket to the EGR valve assembly, EGR cooler assembly, camshaft housing sub-assembly and timing chain cover assembly with the 2 bolts and 2 nuts.

    3. A0049IHE01

      Tighten the 3 bolts and 4 nuts.

      Bolt (A), Nut (A)
      10 N*m 102 kgf*cm 7 ft.*lbf
      Bolt (B), Nut (B)
      20 N*m 204 kgf*cm 15 ft.*lbf

    4. Engage the clamp to connect the No. 2 water by-pass hose to the hose clamp.

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

    6. Connect the No. 4 water by-pass hose to the EGR cooler assembly and slide the hose clip to secure it.

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    INSTALL VENTILATION HOSE ASSEMBLY


    1. Install the ventilation hose assembly to the cylinder head cover sub-assembly, EGR cooler assembly and intake manifold and slide the 3 hose clips to secure it.

    2. Engage the clamp to connect the ventilation hose assembly to the hose clamp.

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    INSTALL EGR PIPE GASKET

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    INSTALL EXHAUST MANIFOLD TO HEAD GASKET

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    INSTALL EXHAUST COOLER ASSEMBLY

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    INSTALL EXHAUST MANIFOLD GASKET

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    INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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    INSTALL MANIFOLD STAY

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