ENGINE UNIT INSTALLATION

PROCEDURE

  1. INSTALL IGNITION COIL ASSEMBLY

    Click here

  2. INSTALL SENSOR WIRE

    1. Install the sensor wire with the bolt.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

    2. Connect the knock control sensor connector.

  3. INSTALL INJECTOR VIBRATION INSULATOR

    Click here

  4. INSTALL FUEL DELIVERY PIPE

    Click here

  5. INSTALL INTAKE MANIFOLD

    1. Install a new No. 1 intake manifold to head gasket to the intake manifold.

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

    3. A257344N04

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

      28 N*m

      286 kgf*cm

      21 ft.*lbf

    4. Connect the purge line hose to the intake manifold, and slide the clamp to secure the hose.

    5. Connect the No. 2 PCV hose to the intake manifold, and slide the clamp to secure the hose.

  6. INSTALL WATER INLET HOUSING

    1. A316623C02

      *a

      34 mm (1.34 in.)

      *b

      21 mm (0.827 in.)

      *c

      9.0 mm (0.354 in.)

      Using an E6 "TORX" socket wrench, install the 2 stud bolts to the water inlet housing.

      4.4 N*m

      45 kgf*cm

      39 in.*lbf

      Note:

      If a stud bolt is deformed or its threads are damaged, replace it.

    2. A311168C02

      *a

      Bolt

      *b

      Nut

      Install a new gasket and water inlet housing with the 3 bolts and nut.

      43 N*m

      438 kgf*cm

      32 ft.*lbf

  7. INSTALL OIL COOLER ASSEMBLY (w/ Oil Cooler)

    Click here

  8. INSTALL THERMOSTAT

    Click here

  9. INSTALL WATER INLET

    Click here

  10. INSTALL ENGINE WATER PUMP ASSEMBLY

    Click here

  11. INSTALL NO. 3 WATER BY-PASS PIPE (w/o EGR System)

    1. Install the No. 3 water by-pass pipe with the 2 bolts.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

  12. TEMPORARILY INSTALL NO. 1 EGR PIPE (w/ EGR System)

    1. A311174

      Temporarily install the No. 1 EGR pipe with the 2 bolts.

  13. INSTALL NO. 1 WATER BY-PASS HOSE (w/ EGR System)

    1. Install the No. 1 water by-pass hose to the cylinder block, and slide the hose clamp to secure the hose.

  14. INSTALL NO. 3 WATER BY-PASS HOSE

    1. Install the No. 3 water by-pass hose, and slide the hose clamp to secure the hose.

  15. TEMPORARILY INSTALL EGR VALVE ASSEMBLY (w/ EGR System)

    1. A257332C02

      *1

      Gasket

      *a

      Claw

      Install 2 new gaskets to the No. 1 EGR pipe and intake manifold.

      Note:

      Make sure that the gasket is installed in the correct direction.

    2. A308621

      Temporarily install the No. 1 EGR valve to the intake manifold with the 3 bolts.

    3. Temporarily connect the No. 1 EGR pipe to the EGR valve assembly with the 2 nuts.

  16. INSTALL NO. 1 WATER BY-PASS PIPE (w/o EGR System)

    1. A331116N01

      Temporarily install a new gasket and No. 1 water by-pass pipe with the 3 bolts.

    2. Tighten the 2 bolts labeled A, and then tighten bolt B.

      for bolt A

      10 N*m

      102 kgf*cm

      7 ft.*lbf

      for bolt B

      21 N*m

      214 kgf*cm

      15 ft.*lbf

  17. INSTALL NO. 5 WATER BY-PASS HOSE (w/o EGR System)

    1. Install the No. 5 water by-pass hose to the water by-pass pipe and No. 3 water by-pass pipe, and slide the 2 hose clamps to secure the hose.

  18. TEMPORARILY INSTALL EGR COOLER ASSEMBLY (w/ EGR System)

    1. Install a new gasket to the No. 1 EGR pipe.

      Note:

      Make sure that the gasket is installed in the correct direction.

    2. A332512C01

      *a

      Claw

      Temporarily install the EGR cooler assembly with the nut and bolt.

      Tip:

      The nut and bolt can be installed to either side depending on the position of the stud bolt.

    3. Connect the No. 5 water by-pass hose to the EGR cooler assembly, and slide the hose clamp to secure the hose.

    4. Temporarily connect the No. 1 EGR pipe to the EGR cooler assembly with the bolt and nut.

  19. INSTALL WATER BY-PASS PIPE (w/ EGR System)

    1. Install 2 new gaskets and the water by-pass pipe with the 4 bolts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

  20. TIGHTEN NO. 1 EGR PIPE (w/ EGR System)

    1. A314968

      Tighten the 3 bolts and 3 nuts.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

  21. TIGHTEN EGR COOLER ASSEMBLY (w/ EGR System)

    1. Tighten the bolt and nut.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

  22. TIGHTEN EGR VALVE ASSEMBLY (w/ EGR System)

    1. Tighten the 3 bolts.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

    2. A308619

      Connect the No. 1 water by-pass hose and No. 2 water by-pass hose to the EGR valve assembly, and slide the 2 clamps to secure the hose.

  23. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY

    Click here

  24. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    Click here

  25. INSTALL MANIFOLD STAY

    Click here

  26. INSTALL NO. 2 MANIFOLD STAY

    Click here

  27. INSTALL NO. 2 EGR PIPE (w/ EGR System)

    Click here

  28. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  29. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET

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

      24.5 N*m

      250 kgf*cm

      18 ft.*lbf

  30. INSTALL COMPRESSOR ASSEMBLY WITH MOTOR

    Click here

  31. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

    1. Install the V-ribbed belt tensioner assembly with the bolt.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

  32. 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.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

    4. Install the engine oil level dipstick.