INSTALLATION

CAUTION / NOTICE / HINT

NOTICE:

This procedure includes the installation of small-head bolts. Refer to Small-Head Bolts of Basic Repair Hint to identify the small-head bolts.

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PROCEDURE

1. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

(a) Install the No. 3 exhaust manifold heat insulator to the cylinder block sub-assembly with the bolt.

Torque:

16 N·m {163 kgf·cm, 12 ft·lbf}

2. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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

(b) Install the O-ring to the engine oil level dipstick guide.

(c) 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}

(d) Install the engine oil level dipstick.

3. INSTALL IGNITION COIL ASSEMBLY

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4. INSTALL FUEL INJECTOR SEAL

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5. INSTALL DIRECT FUEL INJECTOR ASSEMBLY

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6. INSTALL FUEL DELIVERY PIPE

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7. INSTALL PORT FUEL INJECTOR ASSEMBLY

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8. INSTALL NO. 5 ENGINE WIRE

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9. INSTALL INJECTOR VIBRATION INSULATOR

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10. INSTALL NO. 1 DELIVERY PIPE SPACER

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11. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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12. INSTALL WIRE HARNESS CLAMP BRACKET

(a) 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}

13. INSTALL NO. 6 ENGINE WIRE

(a) 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}

(b) Attach the 2 clamps.

(c) Connect the 4 connectors.

14. INSTALL SENSOR WIRE

(a) 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}

(b) Attach the 3 clamps.

(c) Connect the 4 connectors.

15. INSTALL NO. 7 WATER BY-PASS HOSE

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

16. TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)

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

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18. INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)

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19. INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY

(a) 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}

NOTICE:

Do not adjust the torque in the loosening direction.

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

(b) 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}

NOTICE:

Do not adjust the torque in the loosening direction.

(c) Connect the No. 1 fuel pipe sub-assembly to the cylinder head sub-assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

20. CONNECT FUEL TUBE SUB-ASSEMBLY

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21. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET

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22. INSTALL INTAKE MANIFOLD

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23. INSTALL NO. 2 WATER BY-PASS PIPE

(a) Install the bolt (A). Torque: 21 N·m {214 kgf·cm, 15 ft·lbf}

(b) 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}

24. INSTALL NO. 3 WATER BY-PASS PIPE

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

(b) 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}

25. INSTALL EGR VALVE ASSEMBLY

(a) Using an 8 mm socket wrench, install the EGR valve bracket with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

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

*a Pin *b Hole

(c) Using the 8 mm socket wrench, install the EGR valve assembly with the EGR valve bracket to the camshaft housing sub-assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

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

26. INSTALL NO. 4 WATER BY-PASS HOSE

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

27. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

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28. INSTALL EGR COOLER ASSEMBLY

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

Torque:

24 N·m {245 kgf·cm, 18 ft·lbf}

(b) Connect the No. 3 water by-pass hose to the EGR cooler assembly and slide the clip to secure it.

(c) Connect the water hose to the EGR cooler assembly and slide the clip to secure it.

29. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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30. INSTALL EXHAUST MANIFOLD

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31. INSTALL MANIFOLD STAY

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32. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

(a) for Type A:

(1) Install the No. 1 exhaust manifold heat insulator to the exhaust manifold with the 3 bolts. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}

(b) for Type B:

(1) Install the No. 1 exhaust manifold heat insulator to the exhaust manifold with the 5 bolts. Torque: 10 N·m {102 kgf·cm, 7 ft·lbf}

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

(a) Install the water hose clamp bracket with the 2 bolts as shown in the illustration. Torque: 13 N·m {133 kgf·cm, 10 ft·lbf} NOTICE: Temporarily install the bolt (A), and then tighten the 2 bolts in the order of (B) and (A).

(b) 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. NOTICE: 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.

*a Paint Mark *b 90° (Claw of Clip Location)

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

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

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

(a) Connect the No. 2 water by-pass pipe sub-assembly with the bolt.

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

(b) 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.

35. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY

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

Torque:

5.0 N·m {51 kgf·cm, 44 in·lbf}

(b) Install the compressor assembly with pulley with the bolt and 2 nuts.

	Bolt
	Nut

Torque:

24.5 N·m {250 kgf·cm, 18 ft·lbf}

HINT:

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

36. INSTALL DRIVE SHAFT BEARING BRACKET

(a) Install the drive shaft bearing bracket with the 3 bolts.

Torque:

63.7 N·m {650 kgf·cm, 47 ft·lbf}