ENGINE UNIT INSTALLATION

PROCEDURE


  1. INSTALL AIR PRESSURE SENSOR BRACKET (w/ Differential Pressure Sensor)


    1. Install the 2 air pressure sensor brackets with the 4 bolts

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

  2. INSTALL WIRE HARNESS CLAMP BRACKET (w/ Differential Pressure Sensor)


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

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

  3. INSTALL NO. 3 V-BANK COVER BRACKET SUB-ASSEMBLY


    1. Install the No. 3 V-bank cover bracket sub-assembly with the bolt.

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

  4. INSTALL NO. 4 V-BANK COVER BRACKET SUB-ASSEMBLY


    1. Install the No. 4 V-bank cover bracket sub-assembly with the nut.

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

  5. INSTALL IGNITION COIL ASSEMBLY

    Click here

  6. INSTALL KNOCK CONTROL SENSOR

    Click here

  7. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  8. INSTALL ENGINE OIL LEVEL SENSOR

    Click here

  9. INSTALL ENGINE OIL TEMPERATURE SENSOR

    Click here

  10. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  11. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. B0065UQ

      Install the No. 2 water by-pass pipe sub-assembly with the 4 bolts.

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

    2. Connect the No. 2 water by-pass pipe sub-assembly to the oil cooler and heat exchanger assembly and slide the 3 clips to secure it.

  12. INSTALL WATER INLET HOUSING


    1. B00676O

      Install the water inlet housing and a new gasket with the 3 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    2. B0066ED

      Connect the water inlet hose to the water inlet housing and slide the clip to secure it.

  13. INSTALL WATER PUMP PULLEY

    Click here

  14. INSTALL OIL PUMP DRIVE SHAFT PULLEY


    1. B0067R8C02
      *a Hold
      *b Turn
      *c Protective Tape

      Temporarily install the pulley with the 4 bolts.

    2. Using a screwdriver or an equivalent, hold the pulley and tighten the 4 bolts.

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

      Tech Tips

      Tape the screwdriver tip before use to avoid damage.

  15. 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 }

  16. INSTALL NO. 4 ENGINE COVER SUB-ASSEMBLY


    1. Install the No. 4 engine cover sub-assembly.

  17. INSTALL NO. 5 ENGINE WIRE


    1. Engage the clamp.

    2. Install the No. 5 engine wire with the 2 bolts.

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

    3. Connect the 4 knock sensor connectors.

  18. INSTALL FUEL INJECTOR SEAL

    Click here

  19. INSTALL FUEL INJECTOR ASSEMBLY

    Click here

  20. INSTALL FUEL DELIVERY PIPE LH

    Click here

  21. INSTALL FUEL DELIVERY PIPE RH

    Click here

  22. INSTALL CASE SEPARATOR


    1. Install separator case to the cylinder head with the 4 bolts.

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

    2. Connect the fuel pressure sensor connector.

  23. INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY

    Click here

  24. INSTALL NO. 2 ENGINE COVER SUB-ASSEMBLY LH

    Click here

  25. SET FUEL PUMP WITH SEAL SUB-ASSEMBLY (for Bank 1)

    Click here

  26. SET FUEL PUMP WITH SEAL SUB-ASSEMBLY (for Bank 2)

    Tech Tips

    Use the same procedure as for the bank 1 side.

  27. TEMPORARILY INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY

    Click here

  28. TEMPORARILY INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY

    Click here

  29. INSTALL FUEL PUMP WITH SEAL SUB-ASSEMBLY (for Bank 1)

    Click here

  30. INSTALL FUEL PUMP WITH SEAL SUB-ASSEMBLY (for Bank 2)

    Click here

  31. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY

    Click here

  32. INSTALL NO. 3 FUEL PIPE SUB-ASSEMBLY

    Click here

  33. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

    Click here

  34. INSTALL NO. 3 COVER SUB-ASSEMBLY

    Click here

  35. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

    Click here

  36. INSTALL INTAKE AIR SURGE TANK ASSEMBLY

    Click here

  37. CONNECT NO. 1 FUEL PIPE SUB-ASSEMBLY

    Click here

  38. INSTALL FUEL INJECTOR ASSEMBLY (for Port Injection)

    Click here

  39. INSTALL INJECTOR VIBRATION INSULATOR

    Click here

  40. INSTALL NO. 1 DELIVERY PIPE SPACER

    Click here

  41. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY (for Port Injection)

    Click here

  42. INSTALL NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY (for Port Injection)

    Click here

  43. INSTALL FUEL TUBE SUB-ASSEMBLY

    Click here

  44. CONNECT VENTILATION HOSE

    Click here

  45. INSTALL PURGE VALVE (PURGE VSV)

    Click here

  46. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Install the water by-pass pipe sub-assembly to the intake air surge tank assembly with the 2 bolts.

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

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

    3. Connect the water by-pass hose to the water by-pass pipe sub-assembly and slide the clip to secure it.

    4. Connect the No. 3 water by-pass hose to the water by-pass pipe sub-assembly and slide the clip to secure it.

  47. INSTALL INJECTOR DRIVER BRACKET

    Click here

  48. INSTALL INJECTOR DRIVER

    Click here

  49. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

    Click here

  50. INSTALL TRANSMISSION BREATHER ASSEMBLY

    Click here

  51. INSTALL WIRE HARNESS CLAMP BRACKET


    1. B0065YFC02
      *a for LH Side
      *b for RH Side

      Install the 2 wire harness clamp brackets with the 2 bolts.

      Torque:
      for LH side
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for RH side
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  52. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH


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

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  53. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH


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

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  54. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine assembly.

  55. INSTALL ENGINE HANGER

    Click here

  56. REMOVE ENGINE FROM ENGINE STAND


    1. B0065EQC02
      *a No. 1 Engine Hanger
      *b Engine Assembly
      *c 50° or Less

      Attach an engine sling device and hang the engine assembly with a chain block.

      Tech Tips

      When hanging the engine assembly, make sure to hang the engine assembly with the chain at an angle of 50° or less. Otherwise, the engine assembly or engine hangers may be damaged.

    2. Remove the bolts and engine assembly from the engine stand.