ENGINE UNIT(w/o DPF) INSTALLATION

PROCEDURE


  1. INSTALL NO. 3 TIMING CHAIN COVER


    1. Install No. 3 timing chain cover with the 2 clips.

  2. INSTALL OIL PAN COVER


    1. Install the oil pan cover with the 2 bolts and 2 washer plates.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  3. INSTALL NO. 2 OIL PAN COVER SILENCER


    1. Install the No. 2 oil pan cover silencer with the 2 washer plates and 2 bolts.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  4. INSTALL NO. 5 ENGINE COVER


    1. Install the No. 5 engine cover with the 2 bolts and 2 washer plates.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  5. INSTALL HARNESS BRACKET


    1. Install the harness bracket with the bolt.

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

  6. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. Install the V-ribbed belt tensioner with the 2 bolts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  7. INSTALL CAMSHAFT POSITION SENSOR


    1. Install the camshaft position sensor with the bolt.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  8. INSTALL VACUUM PUMP ASSEMBLY


    1. Install 2 new O-rings to the vacuum pump.

    2. A01VJMG

      Apply a small amount of engine oil to the 2 O-rings.

    3. A01VHNRE03

      Install the vacuum pump so that the coupling teeth A on the side of the vacuum pump can engage with the tip groove of camshaft B.

    4. Install the vacuum pump with the 2 new bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  9. INSTALL WATER INLET PIPE


    1. Install the water inlet pipe with the 2 bolts.

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

  10. INSTALL WATER INLET HOSE LH

    A01VJT0E02
    Text in Illustration
    *a View A
    *b Upper
    *c LH

    1. Install the water inlet hose LH.

      Tech Tips

      The clip at the inlet water housing can be installed in any orientation, as long as it does not contact any of the surrounding parts.

  11. INSTALL WATER INLET HOSE RH

    A01VETCE01
    Text in Illustration
    *a View A
    *b View B
    *c Upper
    *d LH
    *e Rear

    1. Install the water inlet hose RH.

  12. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Install a new O-ring to the water by-pass pipe.

      Note

      Apply water to all around of the O-ring inserting hole surface of the water inlet housing before installing the water by-pass pipe.

    2. A01VGZGE01

      Install the water by-pass pipe with the 2 bolts, in the order shown in the illustration.

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

    3. Install the 2 hose clamps.

  13. INSTALL WATER BY-PASS HOSE

    A01VJ0RE02
    Text in Illustration
    *a View A
    *b View B
    *c Upper
    *d Front
    *e RH

    1. Install the water by-pass hose.

  14. INSTALL NO. 2 WATER BY-PASS HOSE

    A01VKIOE01
    Text in Illustration
    *a View A
    *b Upper
    *c LH

    1. Install the No. 2 water by-pass hose.

  15. INSTALL NO. 3 WATER BY-PASS HOSE

    A01VFMUE02
    Text in Illustration
    *a View A
    *b Front
    *c LH

    1. Install the No. 3 water by-pass hose.

  16. INSTALL NO. 4 WATER BY-PASS HOSE

    A01VIH0E02
    Text in Illustration
    *a View A
    *b Upper
    *c Rear

    1. Install the No. 4 water by-pass hose.

  17. INSTALL NO. 2 OIL COOLER HOSE

    A01VK2XE02
    Text in Illustration
    *a View A
    *b Front
    *c LH

    1. Connect the 3 hose clamps and install the No. 2 oil cooler hose.

      Note

      Align the oil cooler hose paint mark with the clamp center.

    2. Install the 2 hose clamps.

      Note

      Align the oil cooler hose paint mark with the clamp center.

  18. INSTALL OIL COOLER HOSE

    A01VDRXE02
    Text in Illustration
    *a View A
    *b Front
    *c LH

    1. Install the oil cooler hose.

  19. INSTALL NO. 2 CYLINDER HEAD COVER


    1. Install the No. 2 cylinder head cover.

  20. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR


    1. Install the No. 1 intake manifold insulator.

  21. INSTALL COMMON RAIL ASSEMBLY


    1. Install the common rail with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  22. INSTALL NO. 1 SUPPLY PUMP DRIVE COUPLING

    Click here

  23. TEMPORARILY TIGHTEN SUPPLY PUMP ASSEMBLY

    Note

    When installing, clean the seal surfaces of the fuel inlet pipe, supply pump and common rail.


    1. Apply a light coat of engine oil to a new O-ring.

    2. Install the O-ring onto the supply pump.

    3. Temporarily tighten the supply pump with the 3 bolts.

  24. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  25. INSTALL NO. 2 FUEL HOSE


    1. Install the No. 2 fuel hose.

  26. INSTALL INJECTION NOZZLE SEAT

    Click here

  27. INSTALL INJECTOR ASSEMBLY

    Click here

  28. INSTALL NOZZLE HOLDER CLAMP SEAT

    Click here

  29. INSTALL NO. 1 NOZZLE HOLDER CLAMP

    Click here

  30. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY

    A01VJU7

    1. Install the nozzle leakage pipe into each injector.


      1. Make sure the lock bush is at top position.

        A01VGXQE01
        Text in Illustration
        *1 Lock Bush *2 Return Plug
        *3 Rest Arm *4 Injector
        *a Push - -

      2. Insert the rest arm into the injector and push both sides of the return plug until the rest arm engages with the injector, as shown in the illustration.

        Tech Tips

        Push the nozzle leakage pipe until it makes a click sound.

      3. Push the lock bush until it fits with the return plug, as shown in the illustration.

    2. Connect the nozzle leakage pipe and install new retainer spring onto the supply pump.

  31. INSTALL NOZZLE LEAKAGE PIPE SET CLAMP


    1. Install the 3 nozzle leakage pipe set clamps.

  32. INSTALL NO. 1 FUEL PIPE

    A01VIGDE01
    Text in Illustration
    *a View A
    *b Upper
    *c Front

    1. Connect the No. 4 fuel hose.

    2. Install the No. 1 fuel pipe with the bolt.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

  33. INSTALL NO. 2 INTAKE MANIFOLD INSULATOR

    Click here

  34. INSTALL GLOW PLUG ASSEMBLY


    1. Clean the glow plug installation holes in the cylinder head.

    2. Install the 4 glow plug assemblies.

      Torque:
      13 N*m  { 127 kgf*cm, 9 ft.*lbf }

  35. INSTALL NO. 1 GLOW PLUG CONNECTOR


    1. Install the No. 1 glow plug connector with the 4 nuts.

      Torque:
      2.2 N*m  { 22 kgf*cm, 19 in.*lbf }

    2. Install the 4 screw grommets.

  36. INSTALL NO. 1 INJECTION PIPE SUB-ASSEMBLY

    Click here

  37. INSTALL NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Click here

  38. INSTALL NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Click here

  39. INSTALL INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY ASSEMBLY


    1. Install the new intake air connector gasket to the cylinder head.

    2. Install the intake air connector with the diesel throttle body with the 2 bolts and 2 nuts.

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

    3. Connect the hose clamp.

  40. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE SUB-ASSEMBLY


    1. Install a new O-ring to the oil level dipstick guide.

    2. Install the oil level dipstick guide with the bolt.

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

  41. INSTALL ENGINE OIL LEVEL DIPSTICK SUB-ASSEMBLY

  42. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  43. INSTALL HARNESS BRACKET

    Click here

  44. INSTALL NO. 1 EGR COOLER BRACKET


    1. Install the No. 1 EGR cooler bracket with the 2 bolts.

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

  45. INSTALL EGR WITH COOLER PIPE ASSEMBLY


    1. Install a new EGR inlet gasket and a new EGR pipe gasket.

    2. Install the EGR with cooler pipe assembly with the 5 bolts and nut.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
    3. A01VGODE02
      Text in Illustration
      *a View A
      *b View B
      *c Rear
      *d LH

      Connect the No. 2 water by-pass hose.

    4. Connect the No. 2 oil cooler hose.

    5. Connect the 3 vacuum transmitting hoses and vacuum hose.

  46. INSTALL GENERATOR BRACKET


    1. Install the generator bracket with the 2 bolts.

      Torque:
      40 N*m  { 407 kgf*cm, 30 ft.*lbf }

  47. INSTALL GENERATOR ASSEMBLY


    1. A01VIKM

      Install the generator with the 2 bolts.

      Torque:
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

  48. INSTALL ENGINE COVER BRACKET


    1. Install the engine cover bracket with the bolt.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }