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 STUD BOLT

(a) Using an E8 "TORX" socket wrench, install the stud bolt to the timing chain cover assembly. Torque: 9.8 N·m {100 kgf·cm, 87 in·lbf}

*a 33.1 mm (1.30 in.) *b 15 mm (0.591 in.) *c 95 mm (3.74 in.)

2. INSTALL WIRE HARNESS CLAMP BRACKET

(a) Using an 8 mm socket wrench, install the wire harness clamp bracket to the camshaft housing sub-assembly with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

(b) 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}

3. INSTALL NO. 2 VENTILATION HOSE

(a) Install the No. 2 ventilation hose to the cylinder head cover sub-assembly and slide the clip to secure it.

4. INSTALL VACUUM SURGE TANK BRACKET

(a) Using an 8 mm socket wrench, install the vacuum surge tank bracket to the camshaft housing sub-assembly with the 2 bolts.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

5. INSTALL VACUUM SURGE TANK

(a) Install the vacuum surge tank to the vacuum surge tank bracket with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

6. INSTALL PURGE VALVE (PURGE VSV)

7. INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR

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

Torque:

16 N·m {163 kgf·cm, 12 ft·lbf}

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

(a) 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}

9. INSTALL WATER INLET WITH THERMOSTAT SUB-ASSEMBLY

10. 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.

11. INSTALL IGNITION COIL ASSEMBLY

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12. INSTALL FUEL INJECTOR SEAL

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13. INSTALL DIRECT FUEL INJECTOR ASSEMBLY

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14. INSTALL FUEL DELIVERY PIPE

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15. INSTALL PORT FUEL INJECTOR ASSEMBLY

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16. INSTALL NO. 5 ENGINE WIRE

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17. INSTALL INJECTOR VIBRATION INSULATOR

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18. INSTALL FUEL DELIVERY SPACER

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19. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

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20. 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) Engage the 2 clamps.

(c) Connect the 4 connectors.

21. INSTALL SENSOR WIRE

(a) for TMC Made:

(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 3 connectors.

(b) except TMC Made:

(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.

22. INSTALL NO. 1 WATER BY-PASS HOSE ASSEMBLY

(a) Install the No. 1 water by-pass hose assembly and slide the 2 clips to secure it.

(b) Install the bolt.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}

(c) Install the plug to the No. 1 water by-pass hose assembly and slide the clip to secure it.

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

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

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

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26. 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. HINT: 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)

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

(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) Using an 8 mm socket wrench, tighten the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

27. CONNECT FUEL TUBE SUB-ASSEMBLY

(a) Connect the fuel tube sub-assembly to the fuel delivery pipe with sensor assembly.

(b) Install the fuel pipe clamp to the fuel tube connector.

(c) Connect the fuel tube sub-assembly to the fuel pump assembly.

28. INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET

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29. INSTALL INTAKE MANIFOLD

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30. INSTALL INTAKE MANIFOLD STAY

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31. 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}

32. INSTALL EGR VALVE ASSEMBLY

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33. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY

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34. INSTALL EGR COOLER ASSEMBLY

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35. INSTALL THROTTLE BODY GASKET

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36. INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY

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37. INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst)

for Double Wishbone Type Suspension: Click here

for Torsion Beam Type Suspension: Click here

38. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

for Double Wishbone Type Suspension: Click here

for Torsion Beam Type Suspension: Click here

39. INSTALL WATER HOSE CLAMP BRACKET

(a) Install the water hose clamp bracket to the camshaft housing sub-assembly with the 2 bolts.

Torque:

13 N·m {133 kgf·cm, 10 ft·lbf}

(b) Install the water hose clamp bracket to the water hose clamp bracket with the bolt.

Torque:

10 N·m {102 kgf·cm, 7 ft·lbf}

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

(a) 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.

(b) Install the flow shutting valve (water by-pass hose assembly) to the water hose clamp bracket with the bolt.

Torque:

19 N·m {194 kgf·cm, 14 ft·lbf}

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

(a) Install the No. 2 water by-pass pipe sub-assembly to the water hose clamp bracket 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 water by-pass outlet sub-assembly and slide the clip to secure it. NOTICE: Make sure to slide the No. 2 water by-pass pipe sub-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 60° (Claw of Clip Location)

42. CONNECT NO. 2 RADIATOR HOSE

(a) Connect the No. 2 radiator hose to the water inlet and slide the clip to secure it.

43. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

(a) Install the V-ribbed belt tensioner assembly to the No. 2 timing chain cover assembly with the 2 bolts.

Torque:

21 N·m {214 kgf·cm, 15 ft·lbf}