Installation
2AR-FXE ENGINE MECHANICAL: ENGINE UNIT: INSTALLATION
HINT
Perform "Inspection After Repair" after replacing the engine assembly Repair Instruction - Initialization.
1. INSTALL IGNITION COIL ASSEMBLY Installation
2. INSTALL SENSOR WIRE
(a) Install the sensor wire with the bolt.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
(b) Connect the knock control sensor connector.
3. INSTALL FUEL DELIVERY PIPE SUB-ASSEMBLY Installation
4. INSTALL INTAKE MANIFOLD Installation
5. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET
(a) Install the No. 1 compressor mounting bracket with the 4 bolts.
Torque : 25 Nm (255 kgf-cm, 18 ft-lbf)
6. INSTALL WATER INLET HOUSING
(a) Using an E5 "TORX" socket, install the stud bolt to the water inlet housing.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
(b) Using an E8 "TORX" socket, install the stud bolt to the cylinder block.
Torque : 15 Nm (153 kgf-cm, 11 ft-lbf)
(c) Install a new gasket.
(d) Install the water inlet housing with the 3 bolts and nut.
Text in Illustration
Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)
(e) Install the harness clamp bracket to the water inlet housing with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(f) Install the harness clamp bracket to the cylinder block with the bolt.
Torque : 8.0 Nm (82 kgf-cm, 71 in-lbf)
7. INSTALL WATER INLET SUB-ASSEMBLY
(a) Install a new gasket and the water inlet sub-assembly with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
8. INSTALL ENGINE WATER PUMP ASSEMBLY
(a) Install a new gasket and the engine water pump assembly with the 5 bolts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
(b) Connect the connector to the engine water pump assembly.
(c) Connect the clamp.
9. INSTALL COMPRESSOR WITH MOTOR ASSEMBLY Installation
10. INSTALL NO. 1 EGR PIPE
(a) Install the No. 1 EGR pipe with the 2 bolts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
11. INSTALL EGR COOLER ASSEMBLY
(a) Install the No. 4 water by-pass hose, No. 6 water by-pass hose and No. 1 water by-pass pipe with the 2 clamps.
(b) Temporarily install 2 new gaskets and the EGR cooler assembly with the bolt (A) and nut (A).
(c) Temporarily install the bolt (B) and nut (B).
(d) Tighten the 3 bolts and nut.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
NOTICE:
Make sure that all installation surfaces of the EGR cooler assembly are in even contact when tightening the bolts and nuts.
12. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY Installation
13. INSTALL MANIFOLD STAY Installation
14. INSTALL NO. 2 MANIFOLD STAY Installation
15. INSTALL NO. 2 EGR PIPE Installation
16. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR Installation
17. INSTALL NO. 1 WATER BY-PASS HOSE
(a) Connect the No. 1 water by-pass hose with the clamp.
18. INSTALL THROTTLE WITH MOTOR BODY ASSEMBLY Installation
19. 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) Install the engine oil level dipstick guide with the bolt.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(d) Install the engine oil level dipstick.
20. INSTALL ENGINE HANGERS
(a) Install the 2 engine hangers with the 4 bolts as shown in the illustration.
Part No.
Torque : 43 Nm (438 kgf-cm, 32 ft-lbf)
(b) Attach an engine sling device and hang the engine with a chain block.