DIESEL THROTTLE BODY INSTALLATION

PROCEDURE


  1. INSTALL DIESEL THROTTLE BODY ASSEMBLY (w/ DPF)


    1. A01VHHXE02

      Install a new gasket and diesel throttle body assembly to the intake air connector with the 4 bolts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }
      Bolt Length
      Bolt Length (mm (in.))
      A 50 (1.967)
      B 25 (0.984)
    2. A01VKT0E02
      Text in Illustration
      *a View A
      *b View B
      *c Upper Side
      *d Front Side
      *e Paint Mark

      Connect the No. 3 water by-pass hose and No. 5 water by-pass hose to the diesel throttle body assembly and slide the 2 hose clips to secure it.

      Note

      In the position shown in the illustration.

  2. INSTALL DIESEL THROTTLE BODY ASSEMBLY (w/o DPF)


    1. A01VFBME05
      Text in Illustration
      *1 Wiring Harness Clamp Bracket

      Install a new gasket, diesel throttle body assembly and wiring harness clamp bracket to the intake air connector with the 4 bolts.

      Torque:
      8.5 N*m  { 87 kgf*cm, 75 in.*lbf }
      Bolt Length
      Bolt Length (mm (in.))
      A 50 (1.967)
      B 25 (0.984)

  3. INSTALL INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY ASSEMBLY (w/ DPF)


    1. Install a new gasket to the cylinder head sub-assembly.

    2. Install the intake air connector with diesel throttle body assembly to the cylinder head sub-assembly with the 2 bolts, 2 nuts.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

    3. Connect the vacuum hose to the intake air connector.

    4. A01VHMUE02
      Text in Illustration
      *a View A
      *b Upper of Engine
      *c RH of Engine
      *d Paint Mark

      Connect the No. 3 water by-pass hose to the water by-pass pipe sub-assembly and slide the hose clip to secure it.

      Note

      In the position shown in the illustration.

  4. INSTALL INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY ASSEMBLY (w/o DPF)


    1. Install a new gasket to the cylinder head sub-assembly.

    2. Install the intake air connector with diesel throttle body assembly to the cylinder head sub-assembly with the 2 bolts and 2 nuts.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

    3. Connect the vacuum hose to the intake air connector.

  5. CONNECT OIL LEVEL DIPSTICK GUIDE SUB-ASSEMBLY


    1. A01VH3O

      Connect the oil level dipstick guide sub-assembly to the intake air connector with the bolt.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  6. CONNECT ENGINE WIRE


    1. A01VL4F

      Engage the clamp to connect the engine wire to the wiring harness clamp bracket.

    2. Connect the engine wire to the wiring harness clamp bracket with the nut.

      Torque:
      8.4 N*m  { 85 kgf*cm, 74 in.*lbf }

    3. Connect the diesel throttle body assembly connector.

    4. Connect the intake air temperature sensor connector.

    5. Connect the starter assembly connector.

    6. Connect the generator assembly connector.

  7. CONNECT AIR HOSE


    1. A01VELXE02
      Text in Illustration
      *a View A
      *b RH of Engine
      *c FR of Engine

      Connect the air hose to the diesel throttle body assembly and tighten the 2 hose clamps.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

      Note

      In the position shown in the illustration.

      Tech Tips

      Check the torque in one minute after tightening and confirm that it is 1.8 N*m or higher.

  8. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  9. PERFORM INITIALIZATION

    Click here