RM3660EC _51 Engine / Hybrid System _080726 8ZR-FXE ENGINE MECHANICAL _0391620 ENGINE UNIT A

8ZR-FXE ENGINE MECHANICAL ENGINE UNIT INSTALLATION

PROCEDURE

Hide Display 1.INSTALL WIRE HARNESS CLAMP BRACKET

Install the wire harness clamp bracket to the timing chain cover assembly with the bolt.

Torque:: 8.0 N*m (82 kgf*cm, 71 in.*lbf)

Hide Display 19500 2.INSTALL IGNITION COIL ASSEMBLY

Click hereEngine / Hybrid System>8ZR-FXE (ENGINE CONTROL)>IGNITION COIL AND SPARK PLUG>INSTALLATION201906,999999,_51,_080778,_0392138,RM100000001HO8D_01_0002,

Hide Display 12261 3.INSTALL VENTILATION HOSE

Install the ventilation hose to the PCV valve (ventilation valve sub-assembly) and slide the clip to secure it.

Hide Display 23250 4.INSTALL FUEL INJECTOR ASSEMBLY

Click hereEngine / Hybrid System>8ZR-FXE (FUEL)>FUEL INJECTOR>INSTALLATION201906,202304,_51,_080749,_0393855,RM100000001I0F6_01_0052,202304,999999,_51,_080749,_0393855,RM100000002BCRZ_01_0052,

Hide Display 23807V 5.INSTALL NO. 1 DELIVERY PIPE SPACER

Click hereEngine / Hybrid System>8ZR-FXE (FUEL)>FUEL INJECTOR>INSTALLATION201906,202304,_51,_080749,_0393855,RM100000001I0F6_01_0076,202304,999999,_51,_080749,_0393855,RM100000002BCRZ_01_0076,

Hide Display 23807 6.INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY

Click hereEngine / Hybrid System>8ZR-FXE (FUEL)>FUEL INJECTOR>INSTALLATION201906,202304,_51,_080749,_0393855,RM100000001I0F6_01_0077,202304,999999,_51,_080749,_0393855,RM100000002BCRZ_01_0077,

Hide Display 23818 7.INSTALL FUEL VAPOR FEED PIPE

Install the fuel vapor feed pipe to cylinder head cover sub-assembly with the 2 bolts.

Torque:: 10 N*m (102 kgf*cm, 7 ft.*lbf)

Hide Display 17650G 8.INSTALL PURGE VALVE (PURGE VSV)

Click hereEngine / Hybrid System>8ZR-FXE (EMISSION CONTROL)>PURGE VALVE>INSTALLATION201906,999999,_51,_080789,_0392062,RM100000001HNVE_01_0012,

Hide Display 1628A 9.INSTALL WATER BY-PASS PIPE

Install the water by-pass pipe to the cylinder head sub-assembly with the 2 bolts.

Torque:: 21 N*m (214 kgf*cm, 15 ft.*lbf)

Connect the water by-pass pipe to the water inlet sub-assembly and slide the clip to secure it.

Hide Display 11452 10.INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

Click hereEngine / Hybrid System>8ZR-FXE (COOLING)>THERMOSTAT>INSTALLATION201906,999999,_51,_080775,_0392615,RM100000001HRUK_01_0017,

Hide Display 15301 11.INSTALL ENGINE OIL LEVEL DIPSTICK

Click hereEngine / Hybrid System>8ZR-FXE (COOLING)>THERMOSTAT>INSTALLATION201906,999999,_51,_080775,_0392615,RM100000001HRUK_01_0024,

Hide Display 17111 12.INSTALL INTAKE MANIFOLD

Click hereEngine / Hybrid System>8ZR-FXE (INTAKE / EXHAUST)>INTAKE MANIFOLD>INSTALLATION201906,202304,_51,_080790,_0392072,RM100000001HNW1_01_0077,202304,999999,_51,_080790,_0392072,RM100000002B0QP_01_0077,

Hide Display 12261 13.CONNECT VENTILATION HOSE

Click hereEngine / Hybrid System>8ZR-FXE (INTAKE / EXHAUST)>INTAKE MANIFOLD>INSTALLATION201906,202304,_51,_080790,_0392072,RM100000001HNW1_01_0163,202304,999999,_51,_080790,_0392072,RM100000002B0QP_01_0163,

Hide Display 17141 14.INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst)

Click hereEngine / Hybrid System>8ZR-FXE (INTAKE / EXHAUST)>EXHAUST MANIFOLD>INSTALLATION201906,202304,_51,_080790,_0392073,RM100000001HNW4_01_0099,202304,999999,_51,_080790,_0392073,RM100000002B0QW_01_0099,

Hide Display 17167 15.INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

Click hereEngine / Hybrid System>8ZR-FXE (INTAKE / EXHAUST)>EXHAUST MANIFOLD>INSTALLATION201906,202304,_51,_080790,_0392073,RM100000001HNW4_01_0167,202304,999999,_51,_080790,_0392073,RM100000002B0QW_01_0167,

Hide Display 25601L 16.TEMPORARILY INSTALL EGR VALVE ASSEMBLY WITH EGR COOLER

Install a new EGR cooler gasket.

Using an E8 "TORX" socket wrench, temporarily install the EGR valve assembly with EGR cooler with the 2 stud bolts.

Torque:: 9.5 N*m (97 kgf*cm, 84 in.*lbf)

0,0 0,0 false

	Bolt
	Nut

Temporarily install the bolt and 2 nuts.

Temporarily install 2 new nuts.

Hide Display 25610 17.TEMPORARILY INSTALL EGR PIPE ASSEMBLY

Install a new EGR pipe gasket and inlet EGR gasket.

Temporarily install the EGR pipe assembly with the 4 bolts.

Hide Display 25601L 18.INSTALL EGR VALVE ASSEMBLY WITH EGR COOLER

1.01,1.438 1.25,1.635 0.24,0.198 10 true A 1.552,1.896 1.781,2.073 0.229,0.177 10 true A 3.208,0.646 3.396,0.844 0.188,0.198 10 false B 3.125,1.958 3.313,2.156 0.188,0.198 10 true B

	Bolt
	Nut

Tighten the bolt and 4 nuts.

Torque:: Nut (A) : 21 N*m (214 kgf*cm, 15 ft.*lbf); Nut (B) : 26 N*m (265 kgf*cm, 19 ft.*lbf); Bolt : 21 N*m (214 kgf*cm, 15 ft.*lbf)

Hide Display 25610 19.INSTALL EGR PIPE ASSEMBLY

Tighten the 4 bolts.

Torque:: 8.5 N*m (87 kgf*cm, 75 in.*lbf)

Hide Display 16331 20.INSTALL WATER OUTLET

Install the water outlet and a new water outlet gasket to the cylinder head sub-assembly with the 2 nuts.

Torque:: 28 N*m (286 kgf*cm, 21 ft.*lbf)

Connect the No. 9 water by-pass hose to the purge valve and slide the clip to secure it.

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