ENGINE UNIT INSTALLATION


  1. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 RH

    Torque:
    68 N*m  { 694 kgf*cm, 50 ft.*lbf }

  2. INSTALL ENGINE MOUNTING BRACKET FRONT NO.1 LH

    Torque:
    68 N*m  { 694 kgf*cm, 50 ft.*lbf }

  3. INSTALL ENGINE OIL LEVEL SENSOR

    Torque:
    5 N*m  { 51 kgf*cm, 44 in.*lbf }

  4. INSTALL WATER TEMPERATURE SENDER GAGE ASSEMBLY

    Torque:
    20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  5. INSTALL CRANK POSITION NO.2 SENSOR

    Torque:
    8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  6. INSTALL CRANK POSITION SENSOR

    Torque:
    8.5 N*m  { 87 kgf*cm, 75 in.*lbf }

  7. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A01KGET

      Install the alternator with belt tensioner assembly and 5 bolts.

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

  8. INSTALL OIL LEVEL GAGE GUIDE

    Torque:
    8 N*m  { 82 kgf*cm, 71 in.*lbf }

  9. INSTALL WATER INLET

    Torque:
    13 N*m  { 133 kgf*cm, 9.6 ft.*lbf }

  10. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY NO.2

    Torque:
    8 N*m  { 82 kgf*cm, 71 in.*lbf }

  11. INSTALL EXHAUST MANIFOLD


    1. A01KEQS

      Install a new gasket and the exhaust manifold with the 6 bolts and 2 nuts.

    2. Uniformly tighten the bolts and nuts in several passes.

      Torque:
      52 N*m  { 530 kgf*cm, 38 ft.*lbf }

  12. INSTALL VENTILATION HOSE HEAT INSULATOR

    Torque:
    12 N*m  { 122 kgf*cm, 8.9 ft.*lbf }

  13. INSTALL VACUUM PIPE

  14. INSTALL OIL COOLER COVER SUB-ASSEMBLY


    1. A01KH79

      Install a new gasket and oil cooler cover sub-assembly with the 13 bolts.

      Torque:
      13 N*m  { 130 kgf*cm, 9 ft.*lbf }

    2. Disconnect the oil pressure switch connector.

    3. Disconnect the engine coolant temperature sensor connector.

  15. INSTALL INJECTION PUMP ASSEMBLY

    Click here

  16. INSTALL COMMON RAIL ASSEMBLY

    Click here

  17. INSTALL GLOW PLUG ASSEMBLY

    Click here

  18. INSTALL WATER OUTLET

    Torque:
    19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  19. INSTALL TURBO WATER HOSE NO.1

  20. INSTALL INTAKE MANIFOLD


    1. A01KEQG

      Install a new gasket and intake manifold with the 4 bolts and 2 nuts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  21. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY NO.2

    A01KHU4
    Torque:
    Bolt
    12.7 N*m  { 130 kgf*cm, 9 ft.*lbf }
    Union bolt
    12.7 N*m  { 130 kgf*cm, 9 ft.*lbf }
    Check valve
    21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  22. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    A01KICG

    1. Temporarily install the fuel inlet pipe sub-assembly.

    2. Using a union wrench 17 mm, tighten the fuel inlet pipe sub-assembly union of common rail side.

      Torque:
      31.9 N*m  { 325 kgf*cm, 23 ft.*lbf, for use with SST }
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Tech Tips

      Use a torque wrench with a fulcrum length of 30 cm (11.81 in)..

    3. Using a union wrench 17 mm, tighten the fuel inlet pipe sub-assembly union of injection pump side.

      Torque:
      31.9 N*m  { 325 kgf*cm, 23 ft.*lbf, for use with SST }
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

    4. Install the injection pipe clamp to the fuel inlet pipe sub- assembly.

      Tech Tips

      Use a torque wrench with a fulcrum length of 30 cm (11.81 in)..

  23. INSTALL INJECTION PIPE SET

    A01KGBT

    1. Temporarily install the 4 injection pipes.

    2. Install the injection pipe No. 1 clamp with the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

      Note


      • Make sure that the rubber is fit inside the clamp.

      • When installing, properly position the rubber and clamp.

    3. Install the injection pipe clamp No. 2 with the bolt.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    4. Install the injection pipe clamp No. 3 with the 2 nuts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    5. Using a 17 mm union nut wrench, tighten the injection pipe union of common rail side.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here

    6. Using a 17 mm union nut wrench, tighten the injection pipe union of injector side.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here

    7. Tighten the 2 bolts, union bolt and check valve for No. 2 nozzle leakage pipe.

      Torque:
      Bolt
      12.7 N*m  { 130 kgf*cm, 9 ft.*lbf }
      Union bolt
      12.5 N*m  { 128 kgf*cm, 9 ft.*lbf }
      Check valve
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

  24. INSTALL OIL FILTER SUB-ASSEMBLY


    1. A01KGTFE01

      Tighten the oil filter by hand until the rubber gasket contacts the seat of the filter mounting.

    2. Using SST, give it an additional 3/4 turn to seat the filter.

      SST
      09228-10002
      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

  25. INSTALL VSV ASSEMBLY


    1. A01KHL6

      Install the VSV assembly and 2 bolts.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  26. INSTALL EGR PIPE SUB-ASSEMBLY NO.1


    1. A01KFVT

      Install the 2 gaskets, EGR control valve and EGR pipe sub-assembly.

    2. Install the 2 nuts.

      Torque:
      13 N*m  { 133 kgf*cm, 9.6 ft.*lbf }

  27. INSTALL CRANKSHAFT PULLEY


    1. A01KF3DE01

      Align the pulley set key with the key groove of the pulley.

    2. Using SST and a hammer, tap in the pulley.

      SST
      09214-60010
    3. A01KHSEE01

      Using SST, install and torque the plate bolt.

      SST
      09213-58012
      09330-00021
      Torque:
      365 N*m  { 3,700 kgf*cm, 269 ft.*lbf }

  28. INSTALL VACUUM PUMP ASSEMBLY


    1. A01KEI6E01
      Text in Illustration
      *1 New O-ring

      Install 2 new O-rings to the vacuum pump.

    2. A01KGGU

      Install the vacuum pump with the 2 nuts.

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

  29. INSTALL PUMP DRIVE SHAFT PULLEY

  30. INSTALL TIMING BELT

    Click here

  31. INSTALL ENGINE WIRE

  32. INSTALL ENGINE ASSEMBLY

    Click here