Replacement
REPLACEMENT1. INSTALL ENGINE STAND
2. REMOVE THROTTLE BODY ASSY
3. REMOVE INTAKE MANIFOLD ASSY
a. Disconnect the VSV connector for EVAP.
b. Disconnect the EVAP hose from the VSV for EVAP.
c. Remove the bolt, disconnect the VSV for EVAP from the upper intake manifold.
d. Remove the bolt and V-bank cover bracket No. 2.
e. Remove the bolt and V-bank cover bracket No. 3.
f. Disconnect the VSV connector for ACIS.
g. Remove the bolt and V-bank cover bracket No. 1.
h. Remove the bolt and V-bank cover fastener.
i. Remove the 4 bolts, and disconnect the engine wire protector (LH side) from upper intake manifold and camshaft bearing cap.
j. Disconnect the 2 wire clamps on the engine wire (RH side) from the brackets on the RH delivery pipe.
k. Remove the 2 bolts, and disconnect the engine wire protector (rear side) from the rear water bypass joint and RH cylinder head.
l. Disconnect the 8 injector connectors.
m. Remove the 6 bolts, 4 nuts, the intake manifold assy and 2 gaskets.
4. REMOVE STARTER ASSY
5. REMOVE GENERATOR ASSY
6. REMOVE TIMING BELT COVER SUB-ASSY N0.3 LH
a. Remove the cap nut and disconnect the water by-pass pipe No.3 from the timing belt cover.
b. Disconnect the 2 water by-pass hoses from the water by-pass pipe No.3.
c. Disconnect the engine wire from the 2 wire clamps.
d. Disconnect the camshaft position sensor connector.
e. Disconnect the camshaft position sensor wire from the wire clamp on the timing belt cover.
f. Remove the wire grommet from the timing belt cover.
g. Remove the 4 bolts.
h. Disconnect the timing belt cover from the timing plate and camshaft bearing cap.
i. Disconnect the wire clamp for the sensor from the timing belt cover.
j. Remove the connector holder from the sensor connector.
k. Remove the timing belt cover.
7. REMOVE TIMING CHAIN OR BELT COVER NO.2
a. Disconnect the 2 PS air hoses from the clamp on the timing belt cover No. 2.
b. Remove the cap nut, 3 bolts, timing belt cover No. 2 and gasket.
8. REMOVE WATER INLET HOUSING
9. REMOVE WATER BY-PASS JOINT FR
a. Disconnect the ECT sensor connector.
b. Remove the 4 nuts, water by-pass joint and 2 gaskets.
10. REMOVE WATER BY-PASS JOINT RR
a. Disconnect the heater inlet hose from the water by-pass joint.
b. Remove the 4 nuts, water by-pass joint and 2 gaskets.
11. REMOVE WATER BY-PASS PIPE SUB-ASSY
a. Disconnect the heater outlet hose from the water by-pass pipe.
b. Disconnect the wire clamp (for knock sensor 1, 2) from bracket of the water by-pass pipe.
c. Remove the bolt.
d. Pull out the water bypass pipe from the water pump.
e. Remove the O-ring from the water by-pass pipe.
12. REMOVE OIL LEVEL GAGE GUIDE
13. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY (RH BANK)
14. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY (LH BANK)
15. REMOVE CAM POSITION SENSOR ASSY
16. REMOVE VVT SENSOR
17. REMOVE KNOCK CONTROL SENSOR
18. REMOVE ENGINE HANGER NO.1
19. REMOVE ENGINE HANGER NO.2
20. REMOVE IGNITION COIL ASSY
21. REMOVE OIL FILTER BRACKET SUB-ASSY
a. Disconnect the oil pressure switch connector.
b. Remove the stud bolt, 2 nuts and oil filter bracket with gasket.
22. REMOVE CRANK POSITION SENSOR
23. REMOVE ENGINE OIL LEVEL SENSOR
24. REMOVE ENGINE WIRE
25. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1
26. REMOVE EXHAUST MANIFOLD SUB-ASSY RH
27. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2
28. REMOVE EXHAUST MANIFOLD SUB-ASSY LH
29. REMOVE WIRING HARNESS HEAT INSULATOR NO.2
30. REMOVE ENGINE MOUNTING BRACKET FRONT NO.1 RH
31. REMOVE ENGINE MOUNTING BRACKET FRONT NO.1 LH
32. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 LH
a. Install the mounting bracket with the 4 bolts
Torque: 36 Nm (370 kgf-cm, 27 ft. lbs.)
HINT: The LH mounting bracket is marked with "L".
33. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 RH
a. Install the mounting bracket with the 4 bolts
Torque: 36 Nm (370 kgf-cm, 27 ft. lbs.)
HINT: The RH mounting bracket is marked with "R".
34. INSTALL WIRING HARNESS HEAT INSULATOR NO.2
35. INSTALL EXHAUST MANIFOLD SUB-ASSY LH
a. Place a new gasket on the cylinder head with the white mark facing the manifold side.
NOTICE: Be careful of the installation direction.
b. Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes.
Torque: 44 Nm (450 kgf-cm, 32 ft. lbs.)
36. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2
37. INSTALL EXHAUST MANIFOLD SUB-ASSY RH
a. Place a new gasket on the cylinder head with the white mark facing the manifold side.
NOTICE: Be careful of the installation direction.
b. Install the exhaust manifold with 8 new nuts. Uniformly tighten the nuts in several passes.
Torque: 44 Nm (450 kgf-cm, 32 ft. lbs.)
38. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
39. INSTALL ENGINE WIRE
40. INSTALL ENGINE OIL LEVEL SENSOR
41. INSTALL CRANK POSITION SENSOR
42. INSTALL OIL FILTER BRACKET SUB-ASSY
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
43. INSTALL IGNITION COIL ASSY
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
44. INSTALL ENGINE HANGER NO.2
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)
45. INSTALL ENGINE HANGER NO.1
Torque: 37 Nm (380 kgf-cm, 27 ft. lbs.)
46. INSTALL KNOCK CONTROL SENSOR
Torque: 44 Nm (450 kgf-cm, 33 ft. lbs.)
47. INSTALL VVT SENSOR
48. INSTALL CAM POSITION SENSOR ASSY
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
49. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY (RH BANK)
50. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY (LH BANK)
51. INSTALL OIL LEVEL GAGE GUIDE
52. INSTALL WATER BY-PASS PIPE SUB-ASSY
a. Install a new O-ring to the water by-pass pipe.
b. Apply soapy water to the O-ring.
c. Push in the water bypass pipe end into the pipe hole of the water pump.
d. Install the water bypass pipe with the bolt.
Torque: 18 Nm (185 kgf-cm,13 ft. lbs.)
e. Install the wire clamp to the bracket of the water by-pass pipe.
53. INSTALL WATER BY-PASS JOINT RR
a. Install 2 new gaskets and the water bypass joint with the 4 nuts. Alternately tighten the nuts.
Torque: 18 Nm (185 kgf-cm,13 ft. lbs.)
54. INSTALL WATER BY-PASS JOINT FR
a. Install 2 new gaskets and the water bypass joint with the 4 nuts. Alternately tighten the nuts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
b. Connect the ECT sensor connector.
55. INSTALL WATER INLET HOUSING
56. INSTALL TIMING CHAIN OR BELT COVER NO.2
a. Install the gasket to the timing belt cover.
b. Install the timing belt cover with the cap nut and 3 bolts.
c. Connect the 2 PS air hoses to the clamp on the timing belt cover.
57. INSTALL TIMING BELT COVER SUB-ASSY N0.3 LH
a. Install the gasket to the timing belt cover.
b. Run the camshaft position sensor wire through the timing belt cover hole.
c. Install the timing belt cover with the 4 bolts.
d. Install the wire grommet to the timing belt cover.
e. Install the sensor connector to the sensor holder.
f. Connect the sensor connector.
g. Install the sensor wire to the wire clamp on the timing belt cover.
h. Install the engine wire to the 2 wire clamps on the timing belt cover.
i. Connect the 2 water by-pass hoses to the water bypass pipe No.3.
j. Install the No.3 water by-pass pipe to the timing belt cover No. 3 LH with the cap nut.
58. INSTALL GENERATOR ASSY
59. INSTALL STARTER ASSY
60. INSTALL INTAKE MANIFOLD ASSY
a. Place 2 new gaskets on the cylinder heads with the white mark facing outward.
NOTICE: Be careful of the installation direction.
b. Install the intake manifold assy with the 6 bolts and 4 nuts.
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
c. Connect the 8 injector connectors.
d. Install the engine wire protector (rear side) with the 2 bolts.
e. Install the engine wire protector (LH side) with the 4 bolts.
f. Install the 2 wire clamps on the engine wire (RH side) to the brackets on the RH delivery pipe.
g. Install the V-bank cover fastener with bolt.
h. Install the V-bank cover bracket No. 1 with bolt
i. Connect the VSV connector for ACIS.
j. Install the V-bank cover bracket No. 3 with bolt.
k. Install the V-bank cover bracket No. 2 with bolt.
l. Connect the VSV for EVAP to the intake manifold with the bolt.
m. Connect the EVAP hose to the VSV for EVAP.
n. Connect the VSV connector for EVAP.
61. INSTALL THROTTLE BODY ASSY
62. REMOVE ENGINE STAND