M20C-FKS, M20D-FKS ENGINE MECHANICAL ENGINE UNIT 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.
PROCEDURE
1.INSTALL STUD BOLT
- NOTICE:
-
If a stud bolt is deformed or its threads are damaged, replace it.
Using an E8 "TORX" socket wrench, install the stud bolt to the timing chain cover assembly.
| *a | 33.1 mm (1.30 in.) | *b | 15 mm (0.591 in.) |
| *c | 95 mm (3.74 in.) | - | - |
- Torque:
- 9.8 N*m (100 kgf*cm, 87 in.*lbf)
2.INSTALL WIRE HARNESS CLAMP BRACKET
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)
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)
25759A
3.INSTALL VACUUM SURGE TANK BRACKET
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)
4.INSTALL PURGE VALVE (PURGE VSV)
17169A
5.INSTALL NO. 3 EXHAUST MANIFOLD HEAT INSULATOR
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)
16032
6.INSTALL ENGINE WATER PUMP ASSEMBLY (WATER INLET HOUSING)
11452D
7.INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
Apply a light coat of engine oil to a new O-ring.
Install the O-ring to the engine oil level dipstick guide.
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)
Install the engine oil level dipstick.
19500
8.INSTALL IGNITION COIL ASSEMBLY
23255A
9.INSTALL FUEL INJECTOR SEAL
23250E
10.INSTALL DIRECT FUEL INJECTOR ASSEMBLY
23814B
11.INSTALL FUEL DELIVERY PIPE
23250F
12.INSTALL PORT FUEL INJECTOR ASSEMBLY
82125N
13.INSTALL NO. 5 ENGINE WIRE
23291
14.INSTALL INJECTOR VIBRATION INSULATOR
23891
15.INSTALL FUEL DELIVERY SPACER
23807
16.INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY
82126A
17.INSTALL NO. 6 ENGINE WIRE
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)
Engage the 2 clamps.
Connect the 4 connectors.
82219A
18.INSTALL SENSOR WIRE
Install the sensor wire to the engine water pump assembly (water inlet housing) with the bolt.
- Torque:
- 10 N*m (102 kgf*cm, 7 ft.*lbf)
Engage the 3 clamps.
Connect the 4 connectors.
19.INSTALL NO. 1 WATER BY-PASS HOSE ASSEMBLY
Install the No. 1 water by-pass hose assembly and slide the 2 clips to secure it.
Install the bolt.
- Torque:
- 21 N*m (214 kgf*cm, 15 ft.*lbf)
23100X
20.TEMPORARILY INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)
23801P
21.TEMPORARILY INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY
23100X
22.INSTALL FUEL (ENGINE ROOM SIDE) PUMP ASSEMBLY (for High Pressure)
23801P
23.INSTALL NO. 1 FUEL PIPE SUB-ASSEMBLY
23910A
24.CONNECT FUEL TUBE SUB-ASSEMBLY
Install the fuel tube sub-assembly to the fuel delivery pipe sub-assembly.
Install the fuel pipe clamp to the fuel tube connector.
Connect the fuel tube sub-assembly to the fuel pump assembly (for high pressure).
17177
25.INSTALL NO. 1 INTAKE MANIFOLD TO HEAD GASKET
17111
26.INSTALL INTAKE MANIFOLD
23820
27.CONNECT NO. 2 FUEL VAPOR FEED HOSE
17138B
28.INSTALL INTAKE MANIFOLD STAY
16279
29.INSTALL NO. 3 WATER BY-PASS PIPE
Connect the No. 3 water by-pass pipe to the water outlet and slide the clip to secure it.
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)
25620
30.SET EGR VALVE ASSEMBLY
25680
31.INSTALL EGR COOLER ASSEMBLY
25620
32.INSTALL EGR VALVE ASSEMBLY
25601
33.INSTALL EGR PIPE SUB-ASSEMBLY NO.1
22271
34.INSTALL THROTTLE BODY GASKET
22030
35.INSTALL THROTTLE BODY WITH MOTOR ASSEMBLY
17141
36.INSTALL EXHAUST MANIFOLD (TWC: Front Catalyst)
17118
37.INSTALL MANIFOLD STAY
17167
38.INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
25715
39.INSTALL EMISSION CONTROL VALVE BRACKET
40.INSTALL NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY
Using a 14 mm union nut wrench, connect the No. 1 vacuum transmitting pipe sub-assembly to the exhaust manifold.
- Torque:
- 30 N*m (306 kgf*cm, 22 ft.*lbf)
- HINT:
- ·
Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.
·When using a 10 mm union nut wrench (fulcrum length of 22 mm (0.866 in.)) + torque wrench (fulcrum length of 162 mm (6.38 in.)): 26 N*m (265 kgf*cm, 19 ft.*lbf)
Install the No. 1 vacuum transmitting pipe sub-assembly to the exhaust manifold with the nut.
- Torque:
- 10 N*m (102 kgf*cm, 7 ft.*lbf)
16575B
41.INSTALL NO. 2 WATER HOSE CLAMP BRACKET
Install the No. 2 water hose clamp bracket to the camshaft housing sub-assembly with the 2 bolts.
- Torque:
- 13 N*m (133 kgf*cm, 10 ft.*lbf)
16260
42.INSTALL FLOW SHUTTING VALVE (WATER BY-PASS HOSE ASSEMBLY)
Install the flow shutting valve (water by-pass hose assembly) to the No. 2 water hose clamp bracket with the bolt.
- Torque:
- 19 N*m (194 kgf*cm, 14 ft.*lbf)
16207
43.INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY
Install the No. 2 water by-pass pipe sub-assembly to the No. 2 water hose clamp bracket with the bolt.
- Torque:
- 19 N*m (194 kgf*cm, 14 ft.*lbf)
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.
| *a | 2 to 7 mm (0.0787 to 0.276 in.) | *b | 120° |
| *c | Paint Mark | *d | Protrusion |
| *e | RH Side of Vehicle | - | - |
- NOTICE:
- ·
Make sure to slide the No. 2 water by-pass pipe sub-assembly until it contacts the hose stopper.
·Make sure that the claws of the clip are within the location shown in the illustration.
16620D
44.INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
- NOTICE:
-
- ·
Do not apply or add any oil or grease to the belt tensioner to prevent abnormal noises from the belt tensioner pulley, belt squealing, etc.
·Do not allow oil or grease to adhere to the moving parts of the belt tensioner, as this may cause malfunctions.
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)
88310
45.INSTALL COMPRESSOR ASSEMBLY WITH PULLEY
27020
46.INSTALL GENERATOR ASSEMBLY
16361A
47.INSTALL V-RIBBED BELT
43457
48.INSTALL DRIVE SHAFT BEARING BRACKET
Install the drive shaft bearing bracket with the 3 bolts.
- Torque:
- 63.7 N*m (650 kgf*cm, 47 ft.*lbf)