ENGINE UNIT INSTALLATION

PROCEDURE


  1. INSTALL THERMOSTAT (for Cylinder Block)

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  2. INSTALL WATER INLET HOUSING

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  3. INSTALL OIL PRESSURE SWITCHING VALVE ASSEMBLY

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  4. INSTALL NO. 4 WATER BY-PASS PIPE


    1. Install a new gasket to the water inlet housing.

    2. Install the No. 4 water by-pass pipe to the cylinder block sub-assembly and water inlet housing with the bolt and 2 nuts.

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

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

  5. INSTALL WATER BY-PASS PIPE ASSEMBLY

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  6. INSTALL VACUUM PUMP ASSEMBLY

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  7. INSTALL FUEL INJECTOR SEAL (for Direct Injection)

    Click here

  8. INSTALL DIRECT FUEL INJECTOR ASSEMBLY

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  9. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY (for Direct Injection)

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  10. INSTALL PORT FUEL INJECTOR ASSEMBLY

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  11. INSTALL FUEL DELIVERY PIPE (for Port Injection)

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  12. TEMPORARILY INSTALL FUEL PUMP ASSEMBLY (for High Pressure)

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  13. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY (for High Pressure)

    Click here

  14. INSTALL FUEL PUMP ASSEMBLY (for High Pressure)

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  15. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY (for High Pressure)

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  16. INSTALL AIR CLEANER BRACKET


    1. Install the air cleaner bracket to the timing chain cover assembly with the bolt.

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

  17. INSTALL NO. 1 TURBO WATER PIPE

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  18. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. B00753YN02

      Install the V-ribbed belt tensioner assembly with the 2 bolts in the order shown in the illustration.

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

  19. INSTALL IDLER PULLEY SUB-ASSEMBLY


    1. Install the idler pulley sub-assembly to the timing chain cover assembly with the bolt.

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

  20. INSTALL OIL FILLER CAP GASKET


    1. Install the oil filler cap gasket to the oil filler cap sub-assembly.

  21. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.

  22. INSTALL HOSE BRACKET (for RHD)


    1. Install the hose bracket to the cylinder head cover sub-assembly with the bolt.

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

  23. INSTALL WIRE HARNESS CLAMP BRACKET


    1. Install the wire harness clamp bracket to the timing chain cover assembly with the bolt.

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

    2. Connect the oil pressure sender gauge assembly connector.

    3. Install the wire harness clamp bracket to the cylinder head cover sub-assembly with the bolt.

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

    4. Install the 2 wire harness clamp brackets to the stiffening crankcase assembly with the 2 bolts.

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

    5. Install the wire harness clamp bracket to the cylinder head sub-assembly with the bolt.

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

  24. INSTALL SENSOR WIRE


    1. Install the sensor wire to the fuel delivery pipe sub-assembly with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

    2. Connect the 4 direct fuel injector assembly connectors.

    3. Connect the fuel pressure sensor connector.

  25. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

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  26. INSTALL TURBOCHARGER SUB-ASSEMBLY

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  27. CONNECT INLET TURBO OIL PIPE SUB-ASSEMBLY

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  28. INSTALL HEAT INSULATOR BRACKET

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  29. INSTALL COMPRESSOR OUTLET ELBOW


    1. Install a new gasket to the turbocharger sub-assembly.

    2. Install the compressor outlet elbow to the turbocharger sub-assembly with the 2 nuts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  30. INSTALL NO. 5 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  31. INSTALL NO. 4 VENTILATION HOSE


    1. B0077ALC05
      *a Upper Side
      *b 90°

      Install the No. 4 ventilation hose with the 2 clips as shown in the illustration.

      Tech Tips

      Install the clips so that they are positioned as shown in the illustration.

  32. INSTALL VENTILATION HOSE


    1. B007616C01
      *a Upper Side
      *b 90°

      Connect the ventilation hose with the clip as shown in the illustration.

      Tech Tips

      Install the clip so that it is positioned as shown in the illustration.

    2. Attach the clamp.

  33. INSTALL IGNITION COIL ASSEMBLY

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  34. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Install a new O-ring to the engine oil level dipstick guide.

    2. Apply a light coat of engine oil to the O-ring.

    3. Install the engine oil level dipstick guide with the bolt.

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

    4. Install the engine oil level dipstick.

  35. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. Install the front No. 1 engine mounting bracket RH to the cylinder block sub-assembly with the 4 bolts.

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

  36. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. Install the front No. 1 engine mounting bracket LH to the cylinder block sub-assembly with the 4 bolts.

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

  37. INSTALL FRONT ENGINE MOUNTING HEAT INSULATOR LH (w/ Front Engine Mounting Heat Insulator LH)


    1. Install the front engine mounting heat insulator LH to the front No. 1 engine mounting bracket LH with the 2 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  38. INSTALL INTAKE MANIFOLD WITH INTERCOOLER ASSEMBLY AND THROTTLE WITH MOTOR BODY ASSEMBLY


    1. Install 2 new No. 1 intake manifold to head gaskets to the intake manifold with intercooler assembly and throttle with motor body assembly.

    2. B0074ODN01

      Temporarily install the intake manifold with intercooler assembly and throttle with motor body assembly with the 4 bolts and 2 nuts.

    3. Tighten the 4 bolts and 2 nuts in the order shown in the illustration.

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

    4. Install the wire harness clamp bracket to the intake manifold with intercooler assembly and throttle with motor body assembly with the bolt.

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

  39. CONNECT NO. 3 WATER BY-PASS HOSE


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

    2. Engage the clamp to the engine oil level dipstick guide.

  40. INSTALL NO. 2 VENTILATION HOSE

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  41. CONNECT VACUUM TRANSMITTING HOSE ASSEMBLY

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  42. CONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY

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  43. INSTALL PURGE VALVE (PURGE VSV)

    w/ Canister Pump Module: Click here

    w/o Canister Pump Module: Click here

  44. INSTALL WATER BY-PASS PIPE ASSEMBLY


    1. Install the water by-pass pipe assembly to the intercooler assembly and No. 2 air tube with the 2 bolts.

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

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

    3. Connect the No. 2 turbo water hose to the No. 1 turbo water pipe sub-assembly and slide the clip to secure it.

  45. INSTALL NO. 2 WATER BY-PASS PIPE

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  46. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET

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  47. INSTALL COMPRESSOR AND MAGNETIC CLUTCH

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  48. INSTALL GENERATOR ASSEMBLY

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