ENGINE UNIT INSTALLATION

PROCEDURE


  1. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


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

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

  2. INSTALL DRIVE SHAFT HEAT INSULATOR BRACKET


    1. Install the drive shaft heat insulator bracket with the bolt and nut.

      Torque:
      18 N*m  { 179 kgf*cm, 13 ft.*lbf }

  3. INSTALL NO. 1 WATER HOSE CLAMP BRACKET


    1. Install the No. 1 water hose clamp bracket with the bolt.

      Torque:
      18 N*m  { 179 kgf*cm, 13 ft.*lbf }

  4. CONNECT NO. 3 WATER BY-PASS HOSE


    1. Connect the No. 3 water by-pass hose to the connector tube with the hose clamp.

  5. INSTALL EXHAUST MANIFOLD

    Click here

  6. INSTALL MANIFOLD SUPPORT BRACKET

    Click here

  7. INSTALL DRIVE SHAFT HEAT INSULATOR SUB-ASSEMBLY

    Click here

  8. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  9. INSTALL NO. 1 OUTLET WATER STAY


    1. Install No. 1 outlet water stay with the bolt.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  10. INSTALL WIRE HARNESS CLAMP BRACKET


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

      Torque:
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

  11. INSTALL BOOSTER VACUUM TUBE


    1. Install the booster vacuum tube with the 2 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  12. INSTALL MANIFOLD ABSOLUTE PRESSURE SENSOR


    1. Install the manifold absolute pressure sensor with the nut.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }

  13. INSTALL NO. 1 OIL PIPE

    Click here

  14. INSTALL NO. 1 WATER BY-PASS PIPE

    Click here

  15. INSTALL EGR DELIVERY CHAMBER


    1. Install the EGR delivery chamber and new No. 1 intake manifold gasket.

  16. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


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

  17. INSTALL NO. 2 INTAKE MANIFOLD INSULATOR

    Click here

  18. INSTALL INTAKE MANIFOLD

    Click here

  19. CONNECT UNION TO CONNECTOR TUBE HOSE

    Click here

  20. INSTALL ENGINE OIL LEVEL DIPSTICK SUB-ASSEMBLY


    1. Install the engine oil level dipstick sub-assembly.

  21. INSTALL NO. 1 IGNITION COIL

    Click here

  22. INSTALL EGR VALVE ASSEMBLY

    Click here

  23. INSTALL GENERATOR BRACKET


    1. Install the generator bracket with the bolt.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  24. INSTALL GENERATOR ASSEMBLY

    Click here

  25. INSTALL ENGINE WIRE


    1. Connect all sensor connectors and wire harness clamps to the engine assembly and install the engine wire harness.

  26. CONNECT OUTLET WATER BY-PASS

    Click here

  27. CONNECT INLET HEATER WATER HOSE A


    1. Connect the inlet heater water hose A to the cylinder head with the hose clamp.

  28. INSTALL WATER FILLER SUB-ASSEMBLY

    A005L7H

    1. Connect the No. 1 radiator hose to the cylinder head sub-assembly.

    2. Install the water filler sub-assembly with 2 nuts.

      Torque:
      7.5 N*m  { 76 kgf*cm, 66 in.*lbf }