REMOVAL AND INSTALLATION

		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.

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
Three bond 1141J or equivalent
3.Tighten the oil pressure switch to the specified torque of 13 ± 5 N·m together with the oil cooler bracket.

>>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

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.