1. Attach the fuel injector gaskets to the rocker cover using the ST.
NOTE:
Use a new fuel injector gasket.
| ST 498175600 | OIL SEAL INSTALLER |
2. Attach the rocker cover gasket to the rocker cover.
NOTE:
Use a new rocker cover gasket.
3. Apply liquid gasket sparingly to the mating surfaces of the cylinder head and rocker cover as shown in the figure.
CAUTION:
Do not apply liquid gasket excessively. Applying excessively may cause excess gasket to flow toward cam journal, resulting in engine seizure.
NOTE:
Install within 5 min. after applying liquid gasket.
Liquid gasket:
THREE BOND 1217G (Part No. K0877Y0100) or equivalent
Liquid gasket applying diameter:
3.5±0.5 mm (0.1378±0.0197 in)
• LH side
|
(A) |
205 mm (8.0709 in) |
(C) |
110 mm (4.3307 in) |
(D) |
30 mm (1.1811 in) |
|
(B) |
155 mm (6.1024 in) |
• RH side
|
(A) |
180 mm (7.0866 in) |
(C) |
80 mm (3.1496 in) |
(D) |
50 mm (1.9685 in) |
|
(B) |
130 mm (5.1181 in) |
4. Tighten the rocker cover bolts in the numerical order as shown in the figure.
NOTE:
When attaching the rocker cover, completely remove any liquid gasket that is squeezed out.
Tightening torque:
6.4 N·m (0.7 kgf-m, 4.7 ft-lb)
• LH side
• RH side
5. Install the turbo pipe to the rocker cover (RH).
NOTE:
Use a new gasket.
Tightening torque:
T1: 6.4 N·m (0.7 kgf-m, 4.7 ft-lb)
T2: 16 N·m (1.6 kgf-m, 11.8 ft-lb)
T3: 29 N·m (3.0 kgf-m, 21.4 ft-lb)
|
(A) |
Turbo pipe |
(B) |
Gasket |
(C) |
Union screw |
6. Install the air breather hose to the rocker cover (LH).
7. Connect engine and crossmember.
(1) Support the engine with a lifting device and wire.
(2) Hold it in place with the lifter slightly raised, and remove all STs.
(3) Lower the lift, and match the positions of the front cushion rubber stud bolts and the crossmember holes.
(4) Visually check that the positions of front cushion rubber stud bolts and locator are correct.
8. Lift up the vehicle.
9. Install the engine mounting connecting nuts and washers to the crossmember.
Tightening torque:
85 N·m (8.7 kgf-m, 62.7 ft-lb)
10. Install four bolts which holds the transmission cushion rubber to the transmission.
Tightening torque:
35 N·m (3.6 kgf-m, 25.8 ft-lb)
11. Install the front drive shaft into the transmission. 
12. Connect the front arm and housing, and install the stabilizer link.
13. Install the catalytic converter and DPF and the exhaust pipe (front).
14. Install the under cover.
15. Lower the vehicle.
16. Attach the engine oil filter. (LHD model only)
17. Install the pitching stopper.
18. Install the fuel delivery hose and fuel return hose to the clamp.
19. Connect the engine harness connectors, and install engine harness connector to the bracket.
20. Install the starter harness bracket.
21. Install the starter terminal B.
22. Install the brake booster vacuum hose.
23. Install the electric power steering control module bracket. (RHD model only)
24. Install the electric power steering control module. (RHD model only)
25. Install the fuel filter assembly, fuel filter protector and fuel filter lower bracket. (RHD model only)
26. Mount the A/C compressor to the engine, and connect the A/C compressor connector.
27. Install the V-belts.
28. Connect the connector and terminal B to the generator, and attach the collector cover bracket.
29. Install the radiator upper brackets.
30. Install the radiator main fan and fan motor.
31. Install the radiator sub fan and fan motor.
32. Install the intercooler.
33. Install the air intake duct and hose.
34. Install the air intake boot and the air intake boot bracket.
35. Install the air cleaner case and the air cleaner element.
36. Install the air intake duct (rear).
37. Install the battery.
38. Install the collector cover.
39. Fill transmission gear oil.
40. Check the engine oil level and replenish it if necessary.