ENGINE UNIT INSTALLATION

PROCEDURE


  1. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

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  2. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

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  3. INSTALL IGNITION COIL ASSEMBLY

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  4. INSTALL FUEL INJECTOR SEAL

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  5. INSTALL FUEL INJECTOR ASSEMBLY (for Direct Injection)

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  6. INSTALL FUEL DELIVERY PIPE RH

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  7. INSTALL FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY LH

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  8. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY

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  9. TEMPORARILY INSTALL FUEL PUMP ASSEMBLY

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

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  11. INSTALL FUEL PUMP ASSEMBLY

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  12. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

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  13. INSTALL INTAKE MANIFOLD

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  14. INSTALL FUEL INJECTOR ASSEMBLY (for Port Injection)

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  15. INSTALL FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY

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  16. INSTALL WATER PUMP PULLEY

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  17. INSTALL WIRE HARNESS CLAMP BRACKET

    B003U2GC06
    *A w/o Oil Cooler - -
    *a Front Side *b Upper Side
    *c Rear Side - -
    B003WAF Bolt B003U82 Nut
    B003WLN V-bank Cover Bracket - -

    1. Install the wire harness clamp bracket with the V-bank cover bracket (A).

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

    2. Install the V-bank cover bracket (B).

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

    3. Install the 14 wire harness clamp brackets with the 14 bolts.

      Torque:
      Bolt (A)
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Bolt (B)
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }
      Bolt (C)
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

    4. w/o Oil Cooler:


      1. Install the wire harness clamp bracket with the nut.

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

      2. Install the wire harness clamp bracket with the bolt.

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

  18. INSTALL NO. 11 WATER BY-PASS HOSE


    1. Install the No. 11 water by-pass hose to the No. 1 water outlet pipe and slide the clip to secure it.

  19. INSTALL NO. 10 WATER BY-PASS HOSE


    1. Install the No. 10 water by-pass hose to the rear water by-pass joint and slide the clip to secure it.

  20. INSTALL NO. 2 WATER BY-PASS PIPE


    1. Install the No. 2 water by-pass pipe and slide the 2 clips to secure them.

    2. Install the bolt.

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

  21. INSTALL NO. 1 WATER BY-PASS PIPE (w/ Oil Cooler)


    1. Install the No. 1 water by-pass pipe with the 2 bolts and nut.

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

    2. Connect the 4 water hoses and slide the 4 clips to secure the 4 hoses.

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


    1. Install the water inlet cap to the water inlet sub-assembly and slide the clip to secure it.

  23. INSTALL WATER BY-PASS HOSE


    1. Install the water by-pass hose to the rear water by-pass joint and slide the clip to secure it.

  24. INSTALL NO. 2 WATER BY-PASS HOSE ASSEMBLY


    1. Install the No. 2 water by-pass hose assembly and slide the 2 clips to secure them.

    2. Engage the 3 clamps.

  25. INSTALL NO. 3 WATER BY-PASS HOSE


    1. Install the No. 3 water by-pass hose and slide the 2 clips to secure them.

  26. INSTALL NO. 2 WATER BY-PASS HOSE


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

  27. INSTALL NO. 6 WATER BY-PASS HOSE


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

  28. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine assembly.

  29. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. Install the V-ribbed belt tensioner assembly with the 2 bolts.

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

  30. 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 }

  31. 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 }

  32. INSTALL COMPRESSOR AND MAGNETIC CLUTCH

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  33. INSTALL GENERATOR ASSEMBLY

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  34. INSTALL V-RIBBED BELT

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  35. 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 }

    2. Engage the 2 clamps.

  36. 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 }

  37. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

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