ENGINE UNIT INSTALLATION

Tech Tips

Perform "Inspection After Repair" after replacing the engine assembly Click here.

  1. INSTALL IGNITION COIL ASSEMBLY

    1. Install the 4 ignition coil assemblies with the 4 bolts.

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

      Tech Tips

      Perform "Inspection After Repair" after replacing the ignition coil assembly Click here.

    2. Connect the 4 ignition coil assembly connectors.

  2. INSTALL SENSOR WIRE

    1. Install the sensor wire with the bolt.

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

    2. Connect the knock control sensor connector.

  3. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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

      A011VWEE01
      Text in Illustration
      *1 Fuel Delivery Spacer
      *a Fuel Delivery Pipe Side
      *b Cylinder Head Side

    2. Install the 2 fuel delivery spacers onto the cylinder head.

      Tech Tips

      Install the fuel delivery spacer so that the longer protrusion is on the cylinder head side.

    3. Install the fuel delivery pipe sub-assembly with the 4 fuel injector assemblies and install the 2 bolts.

      A011WS8
      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

      Note

      • Do not drop the fuel injectors when installing the fuel delivery pipe sub-assembly.

      • Check that the fuel injector assemblies rotate smoothly after installing the fuel delivery pipe sub-assembly.

    4. Connect the 4 fuel injector connectors.

  4. INSTALL INTAKE MANIFOLD

    1. Temporarily install the intake manifold with the 6 bolts.

    2. Tighten the 6 bolts in the order shown in the illustration.

      A011VMQE01
      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    3. Connect the 6 wire harness clamps.

    4. Connect the heated oxygen sensor connector.

    5. Connect the No. 2 ventilation hose.

  5. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET

    1. Install the No. 1 compressor mounting bracket with the 4 bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  6. INSTALL WATER INLET HOUSING

    1. Using an E5 "TORX" socket, install the stud bolt to the water inlet housing.

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

    2. Using an E8 "TORX" socket, install the stud bolt to the cylinder block.

      Torque:
      15 N*m  { 153 kgf*cm, 11 ft.*lbf }

    3. Install a new gasket.

    4. Install the water inlet housing with the 3 bolts and nut.

      A011WW3E01
      Text in Illustration
      *1 Bolt
      *2 Nut
      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

    5. Install the harness clamp bracket to the water inlet housing with the bolt.

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

    6. Install the harness clamp bracket to the cylinder block with the bolt.

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

  7. INSTALL WATER INLET SUB-ASSEMBLY

    1. Install a new gasket and the water inlet sub-assembly with the 2 bolts.

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

  8. INSTALL ENGINE WATER PUMP ASSEMBLY

    1. Install a new gasket and the engine water pump assembly with the 5 bolts.

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

    2. Connect the connector to the engine water pump assembly.

    3. Connect the clamp.

  9. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY

    1. Using an E8 "TORX" socket, and install the 2 stud bolts.

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

    2. Install the compressor with motor assembly with the bolt and 2 nuts.

      A011Z34E01

      Tech Tips

      Tighten the 2 bolts and nut in the order shown in the illustration.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

    3. Connect connector A and lock the green-colored lock as shown in the illustration.

      A011VXEE02
      Text in Illustration
      *1 Green-colored Lock

    4. Connect connector B.

  10. INSTALL NO. 1 EGR PIPE

    1. Install the No. 1 EGR pipe with the 2 bolts.

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

  11. INSTALL EGR COOLER ASSEMBLY

    1. Install the No. 4 water by-pass hose, No. 6 water by-pass hose and No. 1 water by-pass pipe with the 2 clamps.

    2. Temporarily install 2 new gaskets and the EGR cooler assembly with the bolt (A) and nut (A).

      A011XD3E01

    3. Temporarily install the bolt (B) and nut (B).

    4. Tighten the 3 bolts and nut.

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

      Note

      Make sure that all installation surfaces of the EGR cooler assembly are in even contact when tightening the bolts and nuts.

  12. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    1. Set a new gasket to the cylinder head sub-assembly.

    2. Temporarily install the exhaust manifold converter sub-assembly with the 5 nuts.

    3. Temporarily install the No. 2 manifold stay and manifold stay with the 2 bolts and 2 nuts.

    4. Tighten the 5 nuts in the order shown in the illustration.

      A011W7IE04
      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

  13. INSTALL MANIFOLD STAY

    1. Tighten the bolt and nut in the order shown in the illustration.

      A011W4AE01
      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  14. INSTALL NO. 2 MANIFOLD STAY

    1. Tighten the bolt and nut in the order shown in the illustration.

      A011XWFE01
      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

  15. INSTALL NO. 2 EGR PIPE

    1. Install 2 new gaskets to the No. 2 EGR pipe.

    2. Install the No. 2 EGR pipe with the 2 bolts and 2 nuts.

      Torque:
      36 N*m  { 367 kgf*cm, 26 ft.*lbf }

  16. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    1. Install the No. 1 exhaust manifold heat insulator with the 4 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  17. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY

    1. Install a new gasket to the intake manifold.

    2. Install the throttle with motor body assembly with the 4 bolts.

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

    3. Connect the throttle body connector.

    4. Connect the 2 water by-pass hoses to the throttle with motor body assembly.

    5. Connect the 2 hoses.

  18. INSTALL NO. 1 WATER BY-PASS HOSE

    1. Connect the No. 1 water by-pass hose with the clamp.

  19. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    1. Apply a light coat of engine oil to a new O-ring.

    2. Install the O-ring to the engine oil level dipstick guide.

    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.

  20. INSTALL ENGINE HANGERS

    1. Install the 2 engine hangers with the 4 bolts as shown in the illustration.

      A011VQFE02
      Part No.
      Item Part No.
      No. 1 Engine Hanger 12281-36020
      No. 2 Engine Hanger 12282-36021
      Bolt 91552-81040 or 91552-81025
      Torque:
      43 N*m  { 438 kgf*cm, 32 ft.*lbf }

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