ENGINE UNIT INSTALLATION

CAUTION / NOTICE / HINT

PROCEDURE

1. INSTALL NO. 2 VACUUM SWITCHING VALVE BRACKET

   
   

   1. Using an 8 mm socket wrench, install the No. 2 vacuum switching valve bracket to the cylinder head sub-assembly with the 2 bolts.

      Torque:

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

2. INSTALL PURGE VALVE (PURGE VSV)

   
   

   • w/ Canister Pump Module:

     Click here

   • w/o Canister Pump Module:

     Click here

3. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

   
   

   1. Install the No. 3 exhaust manifold heat insulator to the cylinder block sub-assembly with the 2 bolts.

      Torque:

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

4. INSTALL ENGINE WATER PUMP ASSEMBLY (WATER INLET HOUSING)

   
   

   1. Install the engine water pump assembly (water inlet housing) and a new gasket to the cylinder block sub-assembly with the 4 bolts.

      Torque:

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

5. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

   Click here

6. 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. Using an 8 mm socket wrench, install the engine oil level dipstick guide to the cylinder head sub-assembly with the bolt.

      Torque:

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

   4. Install the engine oil level dipstick.

7. INSTALL IGNITION COIL ASSEMBLY

   Click here

8. INSTALL FUEL INJECTOR SEAL

   Click here

9. INSTALL DIRECT FUEL INJECTOR ASSEMBLY

   Click here

10. INSTALL FUEL DELIVERY PIPE

    Click here

11. INSTALL PORT FUEL INJECTOR ASSEMBLY

    Click here

12. INSTALL NO. 5 ENGINE WIRE

    Click here

13. INSTALL INJECTOR VIBRATION INSULATOR

    Click here

14. INSTALL NO. 1 DELIVERY PIPE SPACER

    Click here

15. INSTALL FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY

    Click here

16. INSTALL WIRE HARNESS CLAMP BRACKET

    
    

    1. Using an 8 mm socket wrench, install the wire harness clamp bracket to the No. 1 ventilation case with the 2 bolts.

       Torque:

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

17. INSTALL NO. 6 ENGINE WIRE

    
    

    1. Install the No. 6 engine wire to the wire harness clamp bracket with the 2 nuts.

       Torque:

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

    2. Engage the 2 clamps.

    3. Connect the 4 connectors.

18. INSTALL SENSOR WIRE

    
    

    1. Using an 8 mm socket wrench, install the sensor wire to the water inlet with thermostat sub-assembly with the bolt.

       Torque:

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

    2. Engage the 3 clamps.

    3. Connect the 4 connectors.

19. INSTALL NO. 7 WATER BY-PASS HOSE

    
    

    1. Install the No. 7 water by-pass hose and slide the 2 clips to secure them.

20. TEMPORARILY INSTALL FUEL PUMP ASSEMBLY (for High Pressure)

    Click here

21. TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

    Click here

22. INSTALL FUEL PUMP ASSEMBLY (for High Pressure)

    Click here

23. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

    
    
    1. 

       *a	17 mm Union Nut Wrench
       *b	Torque Wrench Fulcrum Length

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

       Torque:

       Specified tightening torque

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

       Note

       Do not adjust the torque in the loosening direction.

       Tech Tips

       
       

       • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

         Click here

       • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)

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

       Torque:

       Specified tightening torque

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

       Note

       Do not adjust the torque in the loosening direction.

       Tech Tips

       
       

       • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

         Click here

       • When using a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 30 N*m (306 kgf*cm, 22 ft.*lbf)

24. CONNECT FUEL TUBE SUB-ASSEMBLY

    Click here

25. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET

    Click here

26. INSTALL INTAKE MANIFOLD

    Click here

27. INSTALL NO. 2 WATER BY-PASS PIPE

    
    

    1. Install the bolt (A).

       Torque:

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

    2. 

       Using an 8 mm socket wrench, install the No. 2 water by-pass pipe with the 2 bolts (B) in the order shown in the illustration.

       Torque:

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

28. INSTALL NO. 3 WATER BY-PASS PIPE

    
    

    1. Connect the No. 3 water by-pass pipe to the water outlet and slide the clip to secure it.

    2. Using an 8 mm socket wrench, install the No. 3 water by-pass pipe to the intake manifold with the bolt.

       Torque:

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

29. INSTALL EGR VALVE ASSEMBLY

    
    

    1. Using an 8 mm socket wrench, install the EGR valve bracket with the bolt.

       Torque:

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

    2. 

       *a	Pin
       *b	Hole

       Align and fit the hole of the EGR valve bracket to the pin of the camshaft housing sub-assembly.

    3. Using an 8 mm socket wrench, install the EGR valve assembly with the 2 bolts.

       Torque:

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

    4. Connect the No. 8 water by-pass hose to the EGR valve assembly and slide the clip to secure it.

    5. Connect the clamp.

30. INSTALL WATER HOSE CONNECTOR

    
    
    1. 

       *a	Retainer
       	Push in

       Connect the water hose connector to the EGR valve assembly.

       
       

       1. Align the water hose connector with the EGR valve assembly, push the water hose connector onto the EGR valve assembly, then push in the retainer to secure the connection.

          Note

          Confirm that the retainer makes a "click" sound when pushed.

       2. Check that the EGR valve assembly and water hose connector are securely connected by pulling on them.

31. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

    
    

    1. Using an 8 mm socket wrench, install the No. 1 EGR pipe sub-assembly, a new EGR inlet gasket and a new EGR valve adapter gasket with the 4 bolts.

       Torque:

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

32. INSTALL NO. 1 EGR COOLER BRACKET

    
    

    1. Install the No. 1 EGR cooler bracket to the EGR valve bracket and water outlet with the 2 bolts.

       Torque:

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

33. INSTALL EGR COOLER ASSEMBLY

    
    

    1. Install the EGR cooler assembly, a new EGR cooler gasket and a new EGR valve gasket with the 5 bolts.

       Torque:

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

    2. Connect the No. 3 water by-pass hose to the EGR cooler assembly.

    3. Connect the water hose connector to the EGR cooler assembly.

34. INSTALL THROTTLE BODY GASKET

    Click here

35. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

    Click here

36. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst)

    Click here

37. INSTALL MANIFOLD STAY

    Click here

38. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    
    

    1. Install the No. 1 exhaust manifold heat insulator to the exhaust manifold (TWC: Front Catalyst) with the 5 bolts.

       Torque:

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

39. INSTALL FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY)

    
    
    1. 

       *a	Paint Mark
       *b	45° (Claw of Clip Location)

       Connect the flow shutting valve (water by-pass hose assembly) to the water by-pass outlet sub-assembly and slide the clip to secure it.

       Note

       
       

       • Make sure to slide the flow shutting valve (water by-pass hose assembly) until it contacts the hose stopper of the water by-pass outlet sub-assembly.

       • Make sure that the claws of the clip are within the location shown in the illustration.

    2. Install the water hose clamp bracket with the 2 bolts.

       Torque:

       13 N*m  { 133 kgf*cm, 10 ft.*lbf }

    3. Engage the 2 clamps to connect the wire harness.

    4. Connect the flow shutting valve (water by-pass hose assembly) with the bolt.

       Torque:

       19 N*m  { 194 kgf*cm, 14 ft.*lbf }

40. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY

    
    

    1. Connect the No. 2 water by-pass pipe sub-assembly with the bolt.

       Torque:

       19 N*m  { 194 kgf*cm, 14 ft.*lbf }

    2. Connect the No. 2 water by-pass pipe sub-assembly to the outlet water by-pass sub-assembly and slide the clip to secure it.

41. INSTALL NO. 3 TIMING CHAIN COVER

    
    

    1. Using an 8 mm socket wrench, install the No. 3 timing chain cover and plate washer to the No. 2 timing gear cover assembly with the bolt.

       Torque:

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

42. INSTALL TIMING GEAR COVER INSULATOR

    
    

    1. Using an 8 mm socket wrench, install the timing gear cover insulator and plate washer to the No. 2 timing gear cover assembly with the bolt.

       Torque:

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

43. INSTALL NO. 2 TIMING CHAIN COVER INSULATOR

    
    

    1. Install the No. 2 timing chain cover insulator to the V-ribbed belt tensioner assembly.

44. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

    Note

    
    

    • Do not apply or add any oil or grease to the belt tensioner to prevent abnormal noises from the belt tensioner pulley, belt squealing, etc.

    • Do not allow oil or grease to adhere to the moving parts of the belt tensioner, as this may cause malfunctions.

    

    
    

    1. Install the V-ribbed belt tensioner assembly to the No. 2 timing gear cover assembly with the 2 bolts.

       Torque:

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

45. INSTALL NO. 2 ENGINE COVER

    
    

    1. Install the No. 2 engine cover to the No. 2 timing gear cover assembly with the 2 bolts.

       Torque:

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

46. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY

    
    

    1. for Type A:

       
       

       1. Using an E8 "TORX" socket wrench, temporarily install the compressor assembly with pulley with the 2 stud bolts.

          Torque:

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

       2. 

          	Bolt
          	Nut

          Install the compressor assembly with pulley with the 2 bolts and 2 nuts.

          Torque:

          24.5 N*m  { 250 kgf*cm, 18 ft.*lbf }

          Tech Tips

          Tighten the bolts and nuts in the order shown in the illustration.

    2. for Type B:

       
       

       1. 

          Install the compressor assembly with pulley with the 4 bolts.

          Torque:

          24.5 N*m  { 250 kgf*cm, 18 ft.*lbf }

          Tech Tips

          Tighten the bolts in the order shown in the illustration.

47. INSTALL GENERATOR ASSEMBLY

    Click here

48. INSTALL V-RIBBED BELT

    Click here

49. INSTALL DRIVE SHAFT BEARING BRACKET

    
    

    1. Install the drive shaft bearing bracket with the 3 bolts.

       Torque:

       63.7 N*m  { 650 kgf*cm, 47 ft.*lbf }