Steps 86 - 118

Engine Con't





86. Install the water pump.
1. Position the water pump.
2. Install new bolts and tighten them in two stages.
^ Stage 1: 10 Nm
^ Stage 2: 90 degrees





87. Connect the water pump coolant hoses.
1. Connect the coolant hose to the oil filter adapter.
2. Connect the coolant hose to the cylinder block.





88. Install the water bypass.
^ Use new O-ring seals and lubricate them with coolant.





89. Install the positive crankcase ventilation valve and hoses.
1. Connect the positive crankcase ventilation valve and hoses.
2. Install the bracket nut.





90. Install the water pump drive belt.
^ Rotate the belt tensioner clockwise to relieve tension on the belt.





91. Install the left-hand engine lifting eye.
1. Position the lifting eye.
2. Install the bolt.

92. NOTE: Install the O-ring seal on the oil level indicator tube and lubricate with clean engine oil before installation.





Install the oil level indicator tube.
1. Position the oil level indicator tube using a twisting motion.
2. Install the oil level indicator tube bracket bolt.





93. Install the coolant distribution tube.





94. Install the thermostat housing with the coolant hoses.

95. NOTE:
^ Use new gaskets with the locating lugs facing downwards.
^ Install the bolts in the indicated sequence.





Install the lower part of the intake manifold.





96. Install the fuel injection system wiring harness.
1. Connect the fuel injector electrical connectors beginning at the front of the engine.
2. Connect the ECT sensor electrical connector.
3. Connect the DPFE sensor electrical connector.





97. Connect the CKP sensor electrical connector.
1. Attach the harness clip.
2. Connect the CKP sensor electrical connector.





98. Connect the CMP sensor electrical connector.
1. Attach the harness clip.
2. Connect the CMP sensor electrical connector.





99. Connect the oil pressure switch electrical connector.





100. Connect the Heated Oxygen Sensor (HO2S) electrical connector.

101. NOTE:
^ Use new gaskets with the locating lugs pointing downwards.
^ Install the bolts in the indicated sequence.





Install the upper part of the intake manifold.





102. Connect the Throttle Position (TP) sensor and the fuel injector pressure sensor electrical connectors.





103. Connect the positive crankcase ventilation hose to the throttle body.





104. Connect the Idle Air Control (IAC) valve electrical connector.





105. Position the vacuum harness and connect the vacuum lines.





106. Connect the EGR valve and the intake manifold vacuum hoses.





107. Install the ignition coil.
1. Position the coil.
2. Position the capacitor.
3. Position the ground cable.
4. Install the bolts.
5. Connect the ignition coil electrical connector.
108. Connect the six spark plug wires to the spark plugs.





109. Install the IMRC control unit.
1. Install the bolts.
2. Connect the electrical connector.





110. Connect the IMRC cable.
1. Connect the cable to the retainer.
2. Connect the cable end.
111. Position the wiring harness.





112. Attach the wiring harness to the right-hand valve cover and install two nuts.





113. Attach the in-line connectors to the bracket.





114. Connect the Engine Coolant Temperature (ECT) sensor electrical connector.





115. Connect the EGR vacuum regulator solenoid electrical connector.





116. Connect the DPFE sensor electrical connector.





117. Connect the generator electrical connections.
1. Install the battery positive cable.
2. Install the voltage regulator electrical connector.
3. Position the stator circuit electrical connector.





118. Install the connecting shaft bracket to the cylinder block.