REMOVAL AND INSTALLATION




<M/T>



Removal steps


1.
Water hose A


2.
Water pipe


3.
Water hose C


4.
Water hose D


5.
Water by-pass hose

>>H<<
6.
Coolant temperature sensor

>>E<<
7.
Radiator lower pipe

>>E<<
8.
O-ring


9.
Thermostat housing assembly


10.
Water inlet fitting

>>G<<
11.
Thermostat


12.
Thermostat housing

>>F<<
13.
Water pump assembly

>>F<<
14.
Water pump gasket

>>F<<
15.
Water inlet pipe

>>F<<
16.
Gasket

>>E<<
17.
O-ring


18.
Water outlet fitting

>>D<<
19.
Water outlet fitting gasket

>>C<<
20.
Oil pressure switch


21.
EGR cooler assembly


22.
O-ring


23.
EGR cooler


24.
Spacer


25.
Oil cooler fitting


26.
Water EGR pipe


27.
Water by-pass fitting

>>B<<
28.
Water by-pass fitting gasket

>>A<<
29.
Camshaft position sensor

>>A<<
30.
O-ring

>>A<<
31.
Crank angle sensor

>>A<<
32.
O-ring

<A/T>



Removal steps


1.
Water hose A


2.
Water pipe


3.
Water hose C


4.
Water hose D


5.
Water by-pass hose

>>H<<
6.
Coolant temperature sensor

>>E<<
7.
Radiator lower pipe

>>E<<
8.
O-ring


9.
Thermostat housing assembly


10.
Water inlet fitting

>>G<<
11.
Thermostat


12.
Thermostat housing

>>F<<
13.
Water pump assembly

>>F<<
14.
Water pump gasket

>>F<<
15.
Water inlet pipe

>>F<<
16.
Gasket

>>E<<
17.
O-ring


18.
Water outlet fitting

>>D<<
19.
Water outlet fitting gasket

>>C<<
20.
Oil pressure switch


21.
Water hose


22.
Oil cooler


23.
O-ring


24.
EGR cooler assembly


25.
O-ring


26.
EGR cooler


27.
Spacer


28.
Oil cooler bracket


29.
Water EGR pipe


30.
Water by-pass fitting

>>B<<
31.
Water by-pass fitting gasket

>>A<<
32.
Camshaft position sensor

>>A<<
33.
O-ring

>>A<<
34.
Crank angle sensor

>>A<<
35.
O-ring

INSTALLATION SERVICE POINTS



>>A<< O-RING/SENSOR INSTALLATION


caution
  • Do not apply a force such as torsion or twist to the O-ring during assembly of the sensor.
  • Assemble the sensor, taking care not to give a shock to it.
  • Do not use a sensor that has been dropped.
1.Apply a small amount of engine oil to the O-ring.
2.Install the O-ring to the sensor with care to avoid damage to the O-ring.
3.Sufficiently remove the sealant attached to the crank angle sensor.

4.Apply the sealant to the crank angle sensor as shown in the figure.
Specified sealant: ThreeBond 1207D or equivalent
note Install the crank angle sensor immediately after applying sealant.
5.
caution After the installation, until a sufficient period of time (one hour or more) elapses, do not apply the engine oil or water to the sealant application area or start the engine.
Tighten the sensor to the specified torque.
Tightening torque: 9.5 ± 2.5 N·m

>>B<< WATER BY-PASS FITTING GASKET INSTALLATION



Put the water by-pass fitting gasket tab in the position shown in the illustration to install the water bypass fitting gasket.

>>C<< OIL PRESSURE SWITCH INSTALLATION



caution
  • Do not allow the sealant to run into the thread end.
  • Do not tighten the oil pressure switch to the more torque than the specified torque.
1.Sufficiently remove the sealant attached to the oil pressure switch and the cylinder block threaded hole.
2.Apply the sealant of 5 mm to the threaded portion of the oil pressure switch as shown in the illustration.
Sealant
    ThreeBond 1215, ThreeBond 1212D or equivalent
3.Tighten the oil pressure switch to the specified torque of 19 ± 3 N·m together with the oil cooler fitting <M/T>.
4.Tighten the oil pressure switch to the specified torque of 13 ± 5 N·m together with the oil cooler bracket <A/T>.

>>D<< WATER OUTLET FITTING GASKET INSTALLATION



Put the water outlet fitting gasket tab in the position shown in the illustration to install the water outlet fitting gasket.

>>E<< RADIATOR LOWER PIPE / O-RING INSTALLATION



1.
caution Never use grease such as engine oil to the o-ring.
Apply water to replace the o-ring and easily install the new one.
2.Straightly insert the radiator lower pipe into the water inlet fitting.

>>F<< WATER PUMP ASSEMBLY / WATER PUMP GASKET / WATER INLET PIPE / GASKET INSTALLATION



1.Put the water inlet pipe gasket tab in the position shown in the illustration to install the water pump assembly, the water pump gasket, the water inlet pipe and the gasket.

2.Install the water pump gasket and the water pump assembly to the cylinder. Tighten them to the specified torque of 24 ± 3 N·m in the order shown in the illustration.
note Pay attention to the installation bolts because they are different in length.

>>G<< THERMOSTAT INSTALLATION



Install the thermostat with the jiggle valve facing almost straight upwards.

>>H<< COOLANT TEMPERATURE SENSOR INSTALLATION


caution Pay attention to the coolant temperature sensor so that the tool does not give a shock and so on to it during the installation.

1.Apply an appropriate and minimum amount of sealant to the coolant temperature sensor, not allowing the sealant to go beyond the specified range.
Specified sealant:
    LOCTITE 262, Three bond 1324N or equivalent
2.Tighten the coolant temperature sensor to the cylinder block to the specified torque of 30 ± 9 N·m.