WATER PUMP INSTALLATION
PROCEDURE
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INSTALL ENGINE WATER PUMP ASSEMBLY
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Temporarily install a new gasket and the water pump assembly without cover to the water pump cover with the bolt.
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Temporarily install a new gasket and the engine water pump assembly to the cylinder block sub-assembly with the 2 nuts and 5 bolts.
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Text in Illustration *1 Nut Fully tighten the 5 bolts A and the 2 nuts.
- Torque:
- 13 N*m { 133 kgf*cm, 10 ft.*lbf }
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Fully tighten the bolt B.
- Torque:
- 9.1 N*m { 93 kgf*cm, 81 in.*lbf }
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INSTALL CYLINDER BLOCK INSULATOR
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INSTALL NO. 2 TIMING BELT COVER
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INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY
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INSTALL CAMSHAFT TIMING PULLEY
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INSTALL TIMING BELT
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INSTALL NO. 1 TIMING BELT COVER
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INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
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INSTALL VENTILATION PIPE
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INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET
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INSTALL GENERATOR ASSEMBLY
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INSTALL GENERATOR BRACKET
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CONNECT COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)
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INSTALL NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (for Cold Area Specification Vehicles)
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INSTALL VISCOUS WITH MAGNET CLUTCH HEATER ASSEMBLY (for Cold Area Specification Vehicles)
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INSTALL COMPRESSOR OUTLET ELBOW
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INSTALL AIR CLEANER CASE SUB-ASSEMBLY
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INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
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INSTALL AIR CLEANER CAP SUB-ASSEMBLY
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INSTALL NO. 1 AIR CLEANER HOSE
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INSTALL FAN SHROUD
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Install the fan pulley to the engine water pump assembly.
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Install the No. 2 water by-pass hose to the water inlet.
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Temporarily install the shroud together with the coupling fan to the engine water pump assembly with the 4 nuts. Tighten the nuts as much as possible by hand.
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Attach the claws of the shroud to the radiator as shown in the illustration.
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Install the fan shroud to the radiator with the 2 bolts.
- Torque:
- 5.0 N*m { 51 kgf*cm, 44 in.*lbf }
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Install the fan and generator V belt Click here.
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Install the fan with fluid coupling assembly to the engine water pump assembly with the 4 nuts.
- Torque:
- 23 N*m { 235 kgf*cm, 17 ft.*lbf }
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Attach the No. 2 water by-pass hose to the clamp on the fan shroud.
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for Automatic Transmission:
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Text in Illustration *a RH Side *b 2 to 7 mm Connect the 2 oil cooler hoses.
Tech Tips
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Position the hose clamps as shown in the illustration.
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Position the clips so that the distance from the end of hose is 2 to 7 mm (0.0787 to 0.275 in.).
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Attach the 2 oil cooler hoses to the clamp on the fan shroud.
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Connect the No. 2 water by-pass hose to the radiator reservoir.
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Connect the No. 1 water by-pass hose to the fan shroud and attach the 2 clamps.
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Install the radiator reservoir assembly with the 3 bolts.
- Torque:
- 5.0 N*m { 51 kgf*cm, 44 in.*lbf }
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INSTALL INTERCOOLER AIR HOSE
Note
Before installation, remove any oil residue from the inside of the inlet pipe and intercooler.
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Text in Illustration *1 Embossed Mark *2 Paint Mark *a Rear Side of Vehicle *b LH Side *c Upper Align the paint mark of the intercooler air hose with the embossed mark of the intake pipe.
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Tighten the 2 clamps.
- Torque:
- 6.5 N*m { 66 kgf*cm, 58 in.*lbf }
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Connect the vacuum transmitting hose.
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INSTALL NO. 1 AIR HOSE
Note
Before installation, remove any oil residue from the inside of the inlet pipe and intercooler.
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Text in Illustration *1 Embossed Mark *2 Paint Mark *a Rear Side of Vehicle *b LH Side *c Upper Align the paint mark of the intercooler air hose with the embossed mark of the intercooler.
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Tighten the 2 clamps.
- Torque:
- 6.5 N*m { 66 kgf*cm, 58 in.*lbf }
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INSTALL NO. 1 RADIATOR HOSE
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Text in Illustration *1 Protrusion *2 Paint Mark *a Upper *b LH Side Install the radiator hose and attach the clamp.
Tech Tips
Make sure the direction of the hose clamp is as shown in the illustration.
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INSTALL FRONT HEATER BRACKET (for Cold Area Specification Vehicles)
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INSTALL NO. 3 ENGINE WIRE (for Cold Area Specification Vehicles)
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Install the 2 nuts to the battery terminals.
- Torque:
- 7.5 N*m { 76 kgf*cm, 66 in.*lbf }
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Attach the 3 wire harness clamps to the fan shroud.
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INSTALL NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY
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INSTALL NO. 4 INJECTION PIPE SUB-ASSEMBLY
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INSTALL MANIFOLD STAY WITH VACUUM SWITCHING VALVE
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INSTALL INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY ASSEMBLY (w/o EGR System)
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CONNECT ENGINE WIRE (w/o EGR System)
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INSTALL AIR CONNECTOR STAY (w/o EGR System)
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INSTALL NO. 1, NO. 2 AND NO. 3 INJECTION PIPE (w/o EGR System)
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INSTALL THROTTLE BODY BRACKET (w/o EGR System)
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INSTALL NO. 1 INTAKE PIPE (w/o EGR System)
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INSTALL NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/o EGR System)
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INSTALL INLET HEATER WATER HOSE (w/o EGR System)
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INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System)
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Install the electric EGR control valve assembly Click here.
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CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Note
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
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ADD ENGINE COOLANT
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BLEED AIR FROM FUEL SYSTEM
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INSPECT FOR ENGINE COOLANT LEAK
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INSPECT FOR FUEL LEAK
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INSTALL ENGINE REAR UNDER COVER ASSEMBLY
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INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY
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INSTALL FRONT BUMPER LOWER COVER
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INSTALL UPPER RADIATOR SUPPORT SEAL