БЛОК ДВИГАТЕЛЯ УСТАНОВКА

INSTALL WATER OUTLET SUB-ASSEMBLY

1. Install a new O-ring to the timing chain cover assembly.

2. Install the water outlet sub-assembly with the 2 bolts and nut.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

INSTALL ENGINE COOLANT TEMPERATURE SENSOR

1. Install a new gasket onto the engine coolant temperature sensor.

2. Using a 19 mm ball joint lock nut wrench, install the engine coolant temperature sensor to the water outlet sub-assembly.

   Torque:

   20 N*m  { 200 kgf*cm, 14 ft.*lbf }

   Note

   
   

   • If an engine coolant temperature sensor has been struck or dropped, replace it.

   • Use the formula to calculate special torque values for situations where a ball joint lock nut wrench is combined with a torque wrench Click here.

   Tech Tips

   Perform "Inspection After Repair" after replacing an engine coolant temperature sensor.

   
   

   • w/ EGR System: Click here

   • w/o EGR System: Click here

3. Connect the engine coolant temperature sensor connector.

INSTALL FUEL INJECTOR SEAL

1. 

   Text in Illustration

   *a	Area to be Cleaned

   Apply engine conditioner to the area shown in the illustration. Using a piece of cloth, clean carbon deposits from the fuel injector set and its grooves.

   Note

   
   

   • Do not clean the tip of the fuel injector set.

   • Do not use a wire brush to clean the fuel injector set.

   • If a fuel injector set is dropped or the tip of a fuel injector set is struck, replace it with a new one.

2. 

   Text in Illustration

   *a	Tapered Inner Portion
   *b	SST (Guide)

   Apply engine oil to the fuel injector set contact surface of SST (guide). Then attach SST (guide) to the fuel injector set with the chamfer facing the tip of the fuel injector set as shown in the illustration.

   SST

   09260-39020   ( 09261-03020 )

3. 

   Text in Illustration

   *1	Fuel Injector Seal
   *a	CORRECT
   *b	INCORRECT
   *c	SST (Holder)

   Install a new fuel injector seal to SST (holder).

   SST

   09260-39020   ( 09261-03010 )

   Note

   Be careful not to install the fuel injector seal to SST (holder) at an angle. Doing so will stretch the fuel injector seal and correcting this problem is very complicated.

4. 

   Text in Illustration

   *a	SST (Holder)
   *b	SST (Guide)

   Install SST (holder) with fuel injector seal to the tip of the fuel injector set. Slide the fuel injector seal downward into the fuel injector set groove (fuel injector set connector side) with your fingers as shown in the illustration.

   SST

   09260-39020   ( 09261-03010, 09261-03020 )

   Tech Tips

   Check that the fuel injector seal covers the circumference of the fuel injector set groove as shown in the illustration.

5. 

   Text in Illustration

   *a	SST (Guide)

   Slowly slide SST (guide) toward the tip of the fuel injector set. When the fuel injector set contact surface of SST (guide) aligns with the fuel injector seal (fuel injector set tip side) as shown in the illustration, hold the position for 5 seconds or more to fully align the fuel injector seal into the fuel injector set groove.

   SST

   09260-39020   ( 09261-03020 )

   Note

   Be careful that the fuel injector seal is not pinched between SST (guide) and the fuel injector set groove. Replace the fuel injector seal if it becomes damaged.

   Tech Tips

   
   

   • Set SST (guide) so that its bottom surface and the fuel injector seal are flush.

   • If there is difficulty in sliding SST upward, slowly wiggle it from side to side while sliding it up the fuel injector set little by little.

6. 

   Text in Illustration

   *a	Normal
   *b	Protruding
   *c	Deformed
   *d	CORRECT
   *e	INCORRECT

   After installing the fuel injector seals, check that they are not scratched, deformed or protruding from the fuel injector set groove.

   Note

   If a fuel injector seal is scratched, deformed or protruding from the groove, replace it with a new one.

INSTALL FUEL INJECTOR SET

INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

INSTALL FUEL INJECTOR ASSEMBLY

1. Apply a light coat of spindle oil or gasoline to new O-rings, and install them to each fuel injector assembly.

   Note

   Check that there is no damage or foreign matter in the grooves of the fuel injector assembly when installing the fuel injector assembly O-rings.

2. 

   Text in Illustration

   *a	Claw
   *b	Plastic Stopper

   Install the 4 fuel injector assemblies to the fuel delivery pipe.

   Note

   
   

   • Make sure that the fuel injector assembly is located within the plastic stopper range as shown in the illustration.

   • Check that there is no damage or foreign matter on the fuel injector assembly installation holes.

   • When installing the O-rings, make sure they do not become pinched or cut.

INSTALL FUEL DELIVERY PIPE

1. Install 4 new injector vibration insulators to the cylinder head sub-assembly.

2. Install the 2 No. 1 delivery pipe spacers to the cylinder head sub-assembly.

3. Install the fuel delivery pipe together with the 4 fuel injector assemblies with the 2 bolts.

   Torque:

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

   Note

   Be careful not to drop the fuel injector assemblies when installing the fuel delivery pipe.

4. Connect the 4 fuel injector assembly connectors.

5. Connect the No. 6 engine wire connector.

6. Connect the 3 wire harness clamps to the fuel delivery pipe and wire harness clamp bracket.

SET FUEL PUMP WITH SEAL SUB-ASSEMBLY

1. 

   Text in Illustration

   *1	Fuel Pump lifter guide
   *2	Fuel Pump lifter assembly
   *a	Cam Lobe
   *b	Correct
   *c	Incorrect

   Turn the crankshaft pulley so that the flat surface of the cam lobe faces upward from the fuel pump with seal sub-assembly installation hole of the cylinder head cover sub-assembly.

   Tech Tips

   By performing the above procedure, the cam lobe nose does not push up the drive face of the fuel pump with seal sub-assembly when installing the fuel pump with seal sub-assembly.

2. 

   Text in Illustration

   *1	Cylinder Head Cover Sub-assembly
   *2	Pump Housing
   *3	O-ring
   *4	Fuel Pump Spacer Gasket
   *a	Pump Drive Cam (Engine Oil Application Point)
   *b	Pump Lifter (Engine Oil Application Point)
   *c	Knock Pin
   *d	Positioning Knock Hole

   Apply 30 cc (1.8 cu in.) of engine oil to the pump drive cam.

3. Apply engine oil to the fuel pump lifter assembly.

4. Apply engine oil to 2 new O-rings and install it to the pump housing.

5. Install a new fuel pump spacer gasket to the cylinder head cover sub-assembly.

6. 

   Text in Illustration

   *1	Fuel Pump with Seal Sub-assembly
   *2	O-ring
   *3	Fuel Pump Insulator
   *4	Fuel Pump Lifter Assembly
   *5	Fuel Pump Lifter Guide
   	Engine Oil Application Point

   Apply engine oil to a new O-ring and install it to the fuel pump sub-assembly.

7. Remove the fuel pump lifter assembly from the fuel pump lifter guide.

8. Apply engine oil to the inside of the fuel pump lifter guide and the outside of the fuel pump lifter assembly.

9. Install the fuel pump lifter assembly to the fuel pump lifter guide.

10. Install the fuel pump insulator to the fuel pump lifter guide.

11. Set the fuel pump with seal sub-assembly on the cylinder head cover sub-assembly.

12. Temporarily install the fuel pump with seal sub-assembly with the 2 bolts, leaving some allowance for left and right movement.

TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

1. Temporarily install the union nuts on the fuel delivery pipe sub-assembly side of the No. 1 fuel pipe sub-assembly until they are completely tightened.

2. Temporarily install the union nuts on the fuel pump with seal sub-assembly side of the No. 1 fuel pipe sub-assembly until they are completely tightened.

   Note

   Do not damage the seals of the union nuts of the No. 1 fuel pipe sub-assembly when installing.

INSTALL FUEL PUMP WITH SEAL SUB-ASSEMBLY

INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

1. Using a 17 mm union nut wrench, tighten the union nuts on the fuel pump with seal sub-assembly side of the No. 1 fuel pipe sub-assembly.

   Torque:

   35 N*m  { 357 kgf*cm, 26 ft.*lbf }

   Note

   
   

   • Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

   • Do not adjust the torque in the loosening direction.

   • The No. 1 fuel pipe sub-assembly can be reused 10 times.

   Tech Tips

   
   

   • This torque value is effective when the union nut wrench is parallel to the torque wrench.

   • Install the union nut wrench parallel with the torque wrench.

2. Using a 17 mm union nut wrench, tighten the union nuts on the fuel delivery pipe sub-assembly side of the No. 1 fuel pipe sub-assembly.

   Torque:

   35 N*m  { 357 kgf*cm, 26 ft.*lbf }

   Note

   
   

   • Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

   • Do not adjust the torque in the loosening direction.

   • The No. 1 fuel pipe sub-assembly can be reused 10 times.

   Tech Tips

   
   

   • This torque value is effective when the union nut wrench is parallel to the torque wrench.

   • Install the union nut wrench parallel with the torque wrench.

INSTALL NO. 1 FUEL PIPE

1. 

   Text in Illustration

   *a

   Stopper

   for Type A:

   
   

   1. Temporarily install the No. 1 fuel pipe and 2 new gaskets with the union bolt.

      Note

      The stopper of the No. 1 fuel pipe must contact the fuel pump with seal sub-assembly.

   2. Tighten the union bolt.

      Torque:

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

2. for Type B:

   
   

   1. Using a 17 mm deep socket wrench, install a new gasket and the No. 1 fuel pipe.

      Torque:

      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

1. Install a new gasket on the water inlet with thermostat sub-assembly.

2. Install the water inlet with thermostat sub-assembly with the 2 nuts.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

INSTALL ENGINE WATER PUMP ASSEMBLY

INSTALL IGNITION COIL ASSEMBLY

1. Install the 4 ignition coil assemblies to the cylinder head cover sub-assembly with the 4 bolts.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

   Note

   If an ignition coil assembly has been struck or dropped, replace it.

   Tech Tips

   
   

   • Install the same parts to their original positions.

   • Perform "Inspection After Repair" after replacing an ignition coil assembly.

     w/ EGR System: Click here

     w/o EGR System: Click here

2. Connect the engine wire to the cylinder head cover sub-assembly with the 3 nuts.

   Torque:

   10 N*m  { 102 kgf*cm, 7 ft.*lbf }

3. Connect the 4 ignition coil assembly connectors.

INSTALL EGR COOLER ASSEMBLY (w/ EGR System)

1. Install the EGR cooler assembly to the cylinder head sub-assembly with the 2 nuts and bolt.

   Torque:

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

2. Connect the No. 4 water by-pass hose to the EGR valve assembly and slide the clip to secure the hose.

3. Connect the No. 12 water by-pass hose to the EGR valve assembly and slide the clip to secure the hose.

4. Connect the No. 5 water by-pass hose to the EGR cooler assembly and slide the clip to secure the hose.

5. Connect the No. 6 water by-pass hose to the EGR cooler assembly and slide the clip to secure the hose.

INSTALL EGR VALVE BRACKET (w/ EGR System)