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6A – 62 ENGINE MECHANICAL INSTALLATION 1. Valve stem seal 1) Use the special tool to install the stem seal to the valve guide. Stem Seal Installer: 5-8840-2033-0 2. Valve spring. 1) Install the lower valve seat spring, valve spring, then the upper valve spring seat. 2) Use valve spring compressor to compress the spring then install the split collar. Valve spring compressor: 5-8840-2441-0 NOTE: Make sure the split collar installs completely. 3. Install cylinder head assembly. Refer to “Cylinder Head” in this manual. 4. Install the camshaft carrier with camshaft. Refer to “Camshaft” in this manual. 5. Install oil rail assembly. Refer to “Oil rail and injector” in this manual. 6. Install injector assembly. Refer to “Oil rail and injector” in this manual. 7. Install the injector harness assembly. Refer to “Injector” in this manual. 8. Reconnect harness connecter to oil pressure sensor and oil temperature sensor on the oil rail. 9. Reconnect Injector harness connecter to injector. Refer to “Injector” in this manual. 10. Install cylinder head cover with gasket. Refer to “Cylinder Head Cover” in this manual. 11. Install glow plug with specified torque. Torque: 15 N·m (1.5 kg·m / 10.8 lb ft) 12. Install the intake manifold assembly. Refer to “Intake Manifold” in this manual. 13. Install the fuel pipe. 14. Install the water pipe between the cylinder head and water pump. Torque: 20 N·m (2.0 k·m / 14.5 lb ft) 15. Install the front plate. Refer to “Timing Gear” in this manual. 17. Install timing belt and set the tensioner. Refer to “Timing Belt” in this manual. 18. Install CMP sensor bracket. Torque: 20 N·m (2.0 kg·m / 14.5 lb ft) 19. Install timing belt cover. Torque: 9 N·m (0.9 kg·m / 6.5 lb ft) 20. Fill the oil rail with engine oil then immediately install the high pressure oil pipe with the specified Torque: 80 N·m (8.1 kg·m / 57.9 lb ft) 21. Install the noise insulator cover. Refer to “Turbocharger” in this manual. 24. Install water hose and oil pipe for turbocharger. Refer to “Turbocharger” in this manual. 25. Install the valve assembly and install heat protector. assembly and set drive belt. 28. Reconnect harness connector around cylinder head. 29. Reconnect vacuum hose to EGR valve. Refer to “Intercooler” in this manual. 33. Install the air duct assembly. 014RW042 |