WATER PUMP INSTALLATION


  1. INSTALL WATER PUMP ASSEMBLY


    1. A0136A4E02

      Temporarily tighten the 7 bolts of the water pump assembly and the water pump gasket to the specified torque.

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

    2. Fully tighten the 7 bolts to the specified torque.

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

  2. CONNECT WATER OUTLET BOX


    1. A01373IE01

      Connect the water outlet box, and install the 2 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

  3. CONNECT WATER BY-PASS HOSE NO.5


    1. A01380I

      Connect the water by-pass hose No.5 and a new clamp.

  4. SET TIMING MARK


    1. A0136QE

      Using SST, set the pulley of the camshaft so that the timing holes of the camshaft drive pulley and the cylinder head are aligned.

      SST
      09960-10010   ( 09962-01000, 09963-01000 )
    2. A0137Z1

      Using the crankshaft pulley bolt, turn the crankshaft so that the timing holes of the crankshaft timing pulley and the oil pump are aligned.

  5. INSTALL TIMING BELT


    1. A0138L6

      Temporarily install the timing belt tensioner with the bolt.

    2. Install the timing belt.

    3. A013842

      Check that the timing holes are aligned as shown in the illustration.

    4. A0137ALE01

      Using a hexagon socket wrench, turn the timing belt tensioner as shown in the illustration.

      Tech Tips

      Part A should be positioned within area B.

    5. Tighten the timing belt tensioner bolt.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

  6. CHECK VALVE TIMING


    1. A013842

      Slowly turn the crankshaft 2 complete revolutions (720°).

    2. Check that the timing holes are aligned as shown in the illustration.

    3. Remove the crankshaft pulley bolt.

  7. INSTALL CRANKSHAFT POSITION SENSOR


    1. A0136ZP

      Install the crankshaft timing pulley support with the bolt.

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

    2. Install the crankshaft position sensor with the bolt.

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

    3. Connect the crankshaft position sensor connector.

  8. INSTALL ENGINE MOUNT BRACKET


    1. A01374V

      Install the engine mount bracket with the 4 bolts.

      Torque:
      55 N*m  { 561 kgf*cm, 41 ft.*lbf }

  9. INSTALL TIMING BELT LOWER COVER


    1. A0135SJ

      Install the timing belt lower cover with the 5 bolts.

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

  10. INSTALL CRANKSHAFT PULLEY


    1. A0137WYE01

      Using SST, hold the crankshaft pulley.

      SST
      09330-00021

    2. Remove the bolt and crankshaft pulley.

  11. INSTALL TIMING BELT UPPER COVER


    1. A0138DM

      Install the timing belt upper cover with the 5 bolts.

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

  12. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A0136DLE01

      Install 4 new O-rings and a gasket to the cylinder head cover.

    2. Temporarily install the cylinder head cover with the 10 bolts.

    3. Tighten the 10 bolts in the order shown in the illustration.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    4. A013789

      Connect the diesel throttle valve connector.

  13. INSTALL EGR VALVE ASSEMBLY


    1. Install a new O-ring to the EGR pipe.

    2. Temporarily install the EGR valve assembly and gasket with the 2 screws and 2 bolts.

    3. A0136D4

      Install the clamp with the bolt.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }
    4. A01369N

      Tighten the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
    5. A0137SF

      Using a "torx" socket wrench, tighten the 2 screws.

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

  14. INSTALL EGR COOLER WATER BY-PASS HOSE


    1. A0137WQ

      Using pliers, slide the 2 clips to install the water by-pass hose.

  15. CONNECT HEATER WATER OUTLET HOSE A


    1. A0137MH

      Using pliers, slide the clip to install the heater water outlet hose A.

  16. INSTALL ENGINE WIRE NO.2


    1. A0136C6

      Install the engine wire No.2 to the injector.

      CAUTION:

      Be sure to connect the injector connectors correctly to prevent malfunctions in the injector.

    2. A0135V2

      Connect the fuel pressure sensor connector.

    3. A0138A5

      Connect the glow harness connector.

  17. INSTALL FUEL FILTER ASSEMBLY


    1. A0136XL

      Temporarily install the fuel filter assembly with the 2 bolts and screw.

    2. Tighten the 2 bolts.

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

    3. Using a "torx" socket wrench, tighten the screw.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
    4. A01393H

      Connect the fuel heater connector.

    5. A013931

      Connect the fuel level warning switch connector.

    6. A0137IZ

      Align the connector with the pipe, then push in the connector to the pipe until it makes a "click" sound to connect the fuel return hose to the fuel pump return pipe.

    7. Align the connector with the pipe, then push in the connector to the pipe until it makes a "click" sound to connect the fuel hose to the fuel pump pipe.

    8. A0135W0

      Connect the pressure control valve connector.

    9. A0135ZW

      Connect the fuel return hose to the No.4 injector.

  18. INSTALL AIR CLEANER CASE SUB-ASSEMBLY


    1. A0137UK

      Temporarily install the air cleaner case, air hose No.1 clamp and 2 screws.

    2. Using a "torx" socket wrench, tighten the 2 screws.

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

    3. Tighten the air hose No.1 clamp.

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

    4. Connect the PCV hose.

  19. INSTALL TURBO PRESSURE SENSOR


    1. A01362M

      Install the turbo pressure sensor with the bolt.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }
    2. A0137YA

      Connect the turbo pressure sensor connector.

    3. A0136M9

      Connect the turbo pressure sensor to the cylinder head cover.

  20. INSTALL INTAKE AIR RESONATOR


    1. A0137XK

      Install a new O-ring to the intake air resonator.

    2. Temporarily install the intake air resonator with the clamp, bolt and screw.

    3. Tighten the bolt.

      Torque:
      7.5 N*m  { 77 kgf*cm, 66 in.*lbf }

    4. Tighten the air hose No.1 clamp.

      Torque:
      3.5 N*m  { 36 kgf*cm, 31 in.*lbf }

    5. Using a "torx" socket wrench, tighten the screw.

      Torque:
      7.5 N*m  { 77 kgf*cm, 66 in.*lbf }
    6. A0136RX

      Connect the air temperature sensor connector.

  21. INSTALL AIR CLEANER CAP SUB-ASSEMBLY


    1. Install the air filter element.

    2. A0136UU

      Using a "torx" socket wrench, install the air cleaner case sub-assembly with the 3 screws.

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

  22. INSTALL ENGINE ASSEMBLY W/ TRANSAXLE

    Tech Tips

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