REMOVAL AND INSTALLATION



Removal steps


1.
 Water hose


2.
 Water hose


3.
 Water hose


4.
 Water hose

>>I<<
 5.
 Coolant temperature sensor


6.
 EGR valve

>>H<<
 7.
 EGR valve gasket

>>G<<
 8.
 Oil pipe


9.
 Water inlet fitting

>>F<<
 10.
 Thermostat


11.
 Thermostat housing


12.
 Thermostat housing gasket

>>E<<
 13.
 Thermostat housing gasket

>>D<<
 14.
 O-ring

>>D<<
 15.
 Water pipe

>>D<<
 16.
 O-ring

>>C<<
 17.
 Oil feeder control valve (OCV)


18.
 O-ring

>>B<<
 19.
 Plug

>>A<<
 20.
 Oil feeder control valve housing

>>A<<
 21.
 Oil feeder control valve housing gasket


22.
 Water pump


23.
 Water pump gasket

INSTALLATION SERVICE POINTS

>>A<< OIL FEEDER CINTROL VALVE HOUSING / GASKET INSTALLATION
caution
  • Oil passage shall be free from foreign matters.
  • Shall confirm fully that matching plane and such are free from foreign matters.

1.Install the oil feeder control valve housing gasket and oil seal case gasket so that the protuberant is positioned as shown in the illustration.
2.Tighten the oil feeder control valve housing and oil seal case to the specified torque.
Tightening torque: 24 ± 3 N·m (18 ± 1 ft-lb)

>>B<< TAPER PLUG INSTALLATION

1.Apply sealant to the threads of the oil pressure switch or taper plug.

    Specified sealant:
    Three bond 1212D, Three bond 1215 or equivalent
2.Install the oil pressure switch or taper plug to the oil feeder control valve housing.

>>C<< OIL FEEDER CONTROL VALVE (OCV) INSTALLATION
caution
  • Never re-use the O-ring.
  • Before installing O-ring, wind sealing tape around the oil passages cut-out area of oil feeder control valve, to prevent damage. If the O-ring is damaged, it can cause an oil leak.

1.Apply a small amount of engine oil to the O-ring and then install it to the oil feeder control valve.
2.Install the oil feeder control valve to the cylinder head.
3.Tighten the oil feeder control valve.
Tightening torque: 11 ± 1 N·m

>>D<< WATER PIPE / O-RING INSTALLATION


caution Keep the O-ring free of oil or grease.

1.Wet the O-ring (with water) to ease assembly.
2.Install the water pipe into the thermostat housing.

>>E<< THERMOSTAT HOUSING GASKET INSTALLATION



Install the thermostat housing gasket so that the tab is positioned as shown in the illustration.

>>F<< THERMOSTAT INSTALLATION

Install the thermostat in the thermostat housing with its jiggle valve located at the top position.

>>G<< OIL PIPE INSTALLATION

1.Temporarily tighten the eye bolts on the both ends of the oil pipe.
2.Temporarily tighten the flange bolt on the clamp.
3.Tighten the eye bolts on the both ends of the oil pipe to the specified torque.
4.Tighten the flange bolt on the clamp to the specified torque.

>>H<< EGR VALVE GASKET INSTALLATION

Install the EGR valve gasket so that the tab is positioned as shown in the illustration.

>>I<< COOLANT TEMPERATURE SENSOR INSTALLATION

Apply sealant to the coolant temperature sensor.
Specified sealant:
    Three bond 1324, LOCTITE 262 or equivalent