ENGINE UNIT INSTALLATION

PROCEDURE


  1. INSTALL NO. 8 ENGINE WIRE

    Click here

  2. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

    Click here

  3. INSTALL IDLER PULLEY SUB-ASSEMBLY

    Click here

  4. INSTALL OIL FILLER CAP GASKET


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

  5. INSTALL OIL FILLER CAP SUB-ASSEMBLY


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

  6. INSTALL WIRE HARNESS CLAMP BRACKET


    1. for Engine Upper Side:

      Install the 2 wire harness clamp brackets with the 2 bolts to the cylinder head cover sub-assembly.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
    2. B008IXMN02

      for Engine Rear Side:

      Install the 3 wire harness clamp brackets with the 3 bolts to the cylinder head sub-assembly.

      Torque:
      for bolt A
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }
      for bolt B
      12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }

  7. INSTALL ENGINE WIRE

  8. INSTALL TURBOCHARGER SUB-ASSEMBLY

    Click here

  9. CONNECT TURBO OIL INLET PIPE SUB-ASSEMBLY

    Click here

  10. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    Click here

  11. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  12. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  13. INSTALL IGNITION COIL ASSEMBLY

    Click here

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


    1. Install the 2 new No. 1 intake manifold to head gaskets to the intake manifold.

    2. B008GYZN01

      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 sequence shown in the illustration to install the intake manifold with intercooler assembly and throttle with motor body assembly.

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

  15. INSTALL NO. 2 PCV HOSE

    Click here

  16. CONNECT NO. 1 AND NO. 2 WATER BY-PASS HOSE


    1. Connect the No. 1 water by-pass hose to the cylinder head sub-assembly, and slide the clamp to secure the hose.

    2. Connect the No. 2 water by-pass hose to the No. 1 water by-pass pipe, and slide the clamp to secure the hose.

  17. CONNECT VACUUM TRANSMITTING HOSE ASSEMBLY

    Click here

  18. CONNECT NO. 2 VACUUM TRANSMITTING HOSE ASSEMBLY

    Click here

  19. INSTALL ENGINE WIRE

  20. INSTALL PURGE VSV

    Click here

  21. INSTALL NO. 2 WATER BY-PASS PIPE

    Click here

  22. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET


    1. Install the 2 stud bolts to the cylinder block sub-assembly and stiffening crankcase assembly.

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

    2. Install the No. 1 compressor mounting bracket with the 2 bolts and 2 nuts.

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

  23. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY

    Click here

  24. INSTALL GENERATOR ASSEMBLY

    Click here

  25. INSTALL FAN AND GENERATOR V BELT

    Click here