ENGINE UNIT INSTALLATION

PROCEDURE


  1. INSTALL IGNITION COIL ASSEMBLY

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  2. INSTALL VENTILATION HOSE


    1. Install the ventilation hose to the PCV valve (ventilation valve sub-assembly) and slide the clip to secure it.

  3. INSTALL FUEL INJECTOR ASSEMBLY

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  4. INSTALL NO. 1 DELIVERY PIPE SPACER

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  5. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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  6. INSTALL FUEL VAPOR FEED PIPE


    1. Install the fuel vapor feed pipe to the cylinder head cover sub-assembly with the 2 bolts.

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

  7. INSTALL PURGE VALVE (PURGE VSV)

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  8. INSTALL NO. 6 WATER BY-PASS PIPE


    1. Install the No. 6 water by-pass pipe to the cylinder head sub-assembly with the 2 bolts.

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

    2. Connect the No. 6 water by-pass pipe to the water inlet sub-assembly and slide the clip to secure it.

  9. INSTALL NO. 5 WATER BY-PASS PIPE (w/ Exhaust Heat Recirculation System)


    1. A003NI6N01

      Install the No. 5 water by-pass pipe to the cylinder block sub-assembly with the 2 bolts.

      Torque:
      Bolt (A)
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Bolt (B)
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

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

  10. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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  11. INSTALL ENGINE OIL LEVEL DIPSTICK

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  12. INSTALL INTAKE MANIFOLD

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  13. CONNECT VENTILATION HOSE

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  14. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst)

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  15. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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  16. TEMPORARILY INSTALL EGR VALVE ASSEMBLY WITH EGR COOLER


    1. Install a new EGR cooler gasket.

    2. Using an E8 "TORX" socket wrench, temporarily install the EGR valve assembly with EGR cooler with the 2 stud bolts.

      Torque:
      9.5 N*m  { 97 kgf*cm, 84 in.*lbf }

    3. Temporarily install the bolt and 4 nuts.

  17. TEMPORARILY INSTALL EGR PIPE ASSEMBLY


    1. Install new inlet EGR gasket and EGR pipe gasket.

    2. Temporarily install the EGR pipe assembly with the 4 bolts.

  18. INSTALL EGR VALVE ASSEMBLY WITH EGR COOLER


    1. A003K9XC02
      B006IR6 Bolt
      B006IKP Nut

      Tighten the bolt and 4 nuts.

      Torque:
      Nut (A)
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Nut (B)
      26 N*m  { 265 kgf*cm, 19 ft.*lbf }
      Bolt
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  19. INSTALL EGR PIPE ASSEMBLY


    1. Tighten the bolt and 4 bolts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  20. INSTALL WATER OUTLET (w/ Flow Shutting Valve (Water Valve))


    1. Install the water outlet and a new water outlet gasket to the cylinder head sub-assembly with the 2 nuts.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

    2. Connect the No. 9 water by-pass hose to the purge valve and slide the clip to secure it.

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

    4. Connect the No. 7 water by-pass hose to the No. 2 water by-pass hose and slide the clip to secure it.

  21. INSTALL WATER OUTLET (w/o Flow Shutting Valve (Water Valve))


    1. Install the water outlet and new water outlet gasket to the cylinder head sub-assembly with the 2 nuts.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

    2. Connect the No. 9 water by-pass hose to the purge valve and slide the clip to secure it.

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