Part 4 of 4
20. Install the LH/RH exhaust manifolds (A) by tightening the nuts as following method.Tightening torque :
49.0 - 53.9N.m (5.0 - 5.5kgf.m, 36.2 - 39.8lb-ft)
NOTE:
The "TOP"mark of the gasket must be face the exhaust manifold.
NOTE:
Tighten the exhaust manifold nuts as following method.
[RH]
[LH]
21. Install the LH/RH exhaust manifold heat protectors (A).
Tightening torque :
8.8 - 10.8 N.m ( 0.9 - 1.1kgf.m, 6.5 - 8.0lb-ft)
22. Install the engine coolant temperature sensor (ECTS) wiring assembly and bracket (A).
Tightening torque
Wiring bracket bolts :
9.8 - 11.8Nm (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
Engine coolant temperature sensor :
19.6 - 39.2Nm (2.0 - 4.0kgf.m, 14.5 - 28.9lb-ft)
23. Install the oil pressure switch (OPS) wiring assembly and bracket (A).
Tightening torque
Wiring bracket bolts :
9.8 - 11.8Nm (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
Oil pressure switch :
14.7 - 21.6Nm ( 1.5 - 2.2kgf.m, 10.8 - 15.9lb-ft)
24. Use the SST (09231-2J500, 09231-H1100), install the oil seals (B) and the gaskets (A), fuel pump adapter gaskets (C).
25. Install the LH/RH cylinder head covers.
(1) The sealant locations on cylinder head and timing chain upper case must be free of engine oil and etc.
(2) Before assembling the cylinder head cover, the liquid sealant LT5900H or equivalent should be applied on the gap between cylinder head and timing chain upper case.
The part must be assembled within 5 minutes after sealant was applied.
(3) Install the LH/RH cylinder head covers (A).
The part must be assembled within 5 minutes after sealant was applied.
Tightening torque
1st step : 4.9 - 5.9N.m (0.5 - 0.6kgf.m, 3.6 - 4.3lb-ft)
2nd step : 9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
NOTE:
Tighten the cylinder head cover bolts as following method.
[RH]
[LH]
26. Install the LH/RH fuel pumps (A).
Tightening torque :
12.7 - 14.7 N.m (1.3 - 1.5 kgf.m, 9.4 - 10.8 lb-ft)
27. Install the LH/RH ignition coils (A).
Tightening torque :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
28. Reconnect the water hose (A).
29. Install the knock sensors (A) and wiring assembly brackets (B).
Tightening torque
Knock sensor :
14.7 - 24.5 N.m (1.5 - 2.5 kgf.m, 10.8 - 18.1 lb-ft)
LH bracket bolts :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)
RH bracket & hanger bolts :
18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft)
30. Install the injector & rail assembly (B) and cross over pipe (A).
Tightening torque
Rail assembly bolts :
18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft)
Cross over pipe nuts :
26.5 - 32.4 N.m (2.7 - 3.3 kgf.m, 19.5 - 23.9 lb-ft)
31. Install the LH/RH high pressure fuel pipes (A).
Tightening torque
Pipe bracket bolt :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)
Pipe nuts :
26.5 - 32.4 N.m (2.7 - 3.3 kgf.m, 19.5 - 23.9 lb-ft)
32. Install the low pressure fuel tube (A).
33. Install the intake manifold module (A) by tightening the nuts as following method.
Tightening torque
1st step :
4.9 - 7.8N.m ( 0.5 - 0.8kgf.m, 3.6 - 5.8lb-ft)
2nd step :
19.6 - 26.5N.m ( 2.0 - 2.7kgf.m, 14.5 - 19.5lb-ft)
NOTE:
Tighten the intake manifold nuts as following method.
34. Install the injector connector bracket bolt (C), high pressure fuel pipe bracket bolts (B)and the low pressure fuel tube bracket bolt (A) to the intake manifold module.
Tightening torque :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)
35. Install the oil level gauge (A).
Tightening torque :
9.8 - 11.8Nm (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
36. Connect the engine wiring harness connectors and hoses.
(1) ETC module connector (A)
(2) PCV hose (B)
(3) Engine coolant temperature sensor (ECTS) connector (A)
(4) RH intake oil control valve (OCV) connector (B)
(5) RH exhaust oil control valve (OCV) connector (C)
(6) Alternator connector (A)
(7) RH ignition coil connectors (A)
(8) RH fuel pump connector (B)
(9) RH exhaust camshaft position sensor (CMPS) connector (C)
(10) RH intake camshaft position sensor (CMPS) connector (D)
(11) RH knock sensor connectors (A,B)
(12) RH front oxygen sensor (HO2S) connector (C)
(13) RH ignition coil condenser connector (D)
(14) Ground (E)
(15) Oil pressure switch (OPS) connector (A)
(16) LH intake oil control valve (OCV) connector (B)
(17) LH exhaust oil control valve (OCV) connector (C)
(18) Compressor connector (D)
(19) Purge control solenoid valve (PCSV) connector (A)
(20) LH ignition coil connectors (B)
(21) LH fuel pump connector (C)
(22) LH intake camshaft position sensor (CMPS) connector (D)
(23) LH exhaust camshaft position sensor (CMPS) connector (E)
(24) LH knock sensor connectors (A,B)
(25) Manifold absolute pressure (MAP) sensor connector (C)
(26) Crankshaft position sensor (CKPS) connector (D)
(27) LH ignition coil condenser connector (E)
(28) LH front oxygen sensor (HO2S) connector (F)
(29) Ground (G)
(30) Injector connectors (H)
37. Turn the tensioner (B) clockwise and loosen, then install the drive belt (A).
38. Install the radiator & cooling fan assembly.
39. Connect the heater hoses (A),
40. Connect the fuel hose (A), the purge control solenoid valve (PCSV) hose (B) and the brake booster vacuum hose (C).
41. Connect the radiator upper hose (A) and lower hose (B).
42. Install the air cleaner assembly.
(1) Install the air cleaner assembly (E) and the chamber air cleaner (D).
Tightening torque :
7.8 - 9.8 N.m (0.8 - 1.0 kgf.m, 5.8 - 7.2 lb-ft)
(2) Connect the air intake hose to the throttle body and then tighten the clamp (C).
Tightening torque :
2.9 - 4.98 N.m (0.3 - 0.5 kgf.m, 2.2 - 3.6 lb-ft)
(3) Reconnect the breather hose (B).
(4) Install the air duct (A).
43. Install the engine room cover (A), the engine cover (B) and the radiator grill upper cover (C).
44. Connect the battery negative terminal (A).
Tightening torque :
3.9 - 5.9 N.m (0.4 - 0.6 kgf.m, 2.9 - 4.3 lb-ft)
NOTE:
- Refill engine oil.
- Clean battery posts and cable terminals with sandpaper. Reassemble, then apply grease to prevent corrosion
- Inspect for fuel leakage.
- After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes.
- Repeat this operation two or three times, and then check for fuel leakage at any point in the fuel lines.
- Refill radiator and reservoir tank with engine coolant.
- Bleed air from the cooling system.
- Start engine and let it run until it warms up. (Until the radiator fan operates 3 or 4 times.)
- Turn Off the engine and let it cool down. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system.
- Put radiator cap on tightly, then run the engine again and check for leaks.