GLOW PLUG INSTALLATION


  1. INSTALL GLOW PLUG


    1. Using a deep socket wrench (12 mm), install the 4 glow plugs.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  2. INSTALL GLOW PLUG NO.1 CONNECTOR


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

      Torque:
      2.2 N*m  { 22 kgf*cm, 16 in.*lbf }

    2. Install the 4 grommets.

  3. INSTALL INTAKE MANIFOLD


    1. A01BHYI

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

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

    2. Install the manifold stay with the bolt and nut.

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

    3. Connect the ground cable with the bolt.

  4. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY NO.2


    1. Temporarily install the nozzle leakage pipe with the 2 bolts.

    2. A01BEHR

      Install the new gasket and union bolt to the nozzle leakage pipe.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    3. A01BCQO

      Tighten the 2 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  5. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Note


    • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket, or timing gear case with a new one, replace the fuel inlet pipe.

    • Be careful not to adhere dusts, dirt or any other materials onto the joint area of the fuel inlet pipe.


    1. Temporarily install the fuel inlet pipe.

    2. Using SST, tighten the injection pipe on the common rail side.

      SST
      09023-12701
      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf, for use with SST }

    3. Using SST, tighten the injection pipe on the supply pump side.

      SST
      09023-12701
      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf, for use with SST }

  6. INSTALL INJECTION PIPE

    SST
    09023-12701

    Note


    • When replacing the fuel injector, common rail, or cylinder head with a new one, replace injection pipes No. 1, No. 2, No. 3, and No. 4.

    • Keep clean the joint of the injection pipe.


    1. Install the injection pipes.


      1. A01BFG2

        Temporarily install the 4 injection pipes.

      2. A01BC89

        Install the injection pipe clamp No.3 in 2 nuts.

        Torque:
        5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
      3. A01BFG2E01

        Fasten the union sequentially, from the injection pipe common rail to the injector, using SST.

        SST
        09023-12701
        Torque:
        Use union nut wrench and torque wrench
        32 N*m  { 326 kgf*cm, 24 ft.*lbf }

  7. INSTALL OIL LEVEL GAUGE GUIDE


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

    2. Apply a light coat of engine oil to the O-ring.

    3. Install the oil level gauge guide with the bolt.

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

    4. Install the oil level gauge.

  8. INSTALL INTAKE AIR CONNECTOR (w/o EGR Valve)


    1. A01BEP8E01

      Temporarily install 2 new gaskets and intake air connector No.2 to the intake air connector.

    2. A01BDK1

      Temporarily tighten the intake air connector assembly with the bolt and 2 nuts.

    3. Tighten the manifold stay with the bolt.

    4. Tighten the intake air connector with the bolt and 2 nuts.

    5. Install the vacuum hose to the intake air connector.

  9. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR Valve)


    1. Temporarily tighten the EGR valve assembly with the sensor.


      1. A01BACYE01

        Install 2 new gaskets and the EGR valve to the intake air connector as shown in the illustration.

      2. A01BH7Q

        Temporarily tighten the intake air connector with EGR valve assembly to the intake manifold with the bolt and the 2 nuts.

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

      4. Temporarily tighten the manifold stay with the bolt.

      5. A01BAPE

        Connect the EGR valve position sensor connector.

      6. Connect the intake air temperature sensor connector.

    2. Install the vacuum regulating valve.


      1. A01BHSL

        Install the vacuum regulating valve with the 2 bolts.

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

      2. Connect the 2 vacuum hoses and the regulating valve connector.

  10. INSTALL ENGINE SERVICE HOLE COVER NO.2


    1. Install the engine service hole cover No.2 with the 3 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    2. A01BFN9

      Return the carpet.

  11. INSTALL EGR PIPE SUB-ASSEMBLY NO.1 (w/ EGR Valve)


    1. A01BG49

      Install 2 new gaskets to the cylinder head and the EGR pipe sub-assembly No.1 as shown in the illustration.

    2. A01BD88

      Install the EGR pipe with the 2 bolts and the 2 nuts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    3. A01BGWP

      Connect the fuel pressure sensor connector.

  12. INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Note

    After removing and installing, or replacing the throttle body, be sure to perform the operation check.


    1. Install a new gasket to intake air connector.

    2. A01BBJH

      Install the throttle body with the 2 bolts and the 2 nuts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    3. A01BCMO

      Connect the 2 throttle body connectors.

  13. INSTALL AIR HOSE NO.4


    1. A01BGX6

      Install the air hose No.4 with the 2 clamps.

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

  14. CONNECT OIL RETURN HOSE (w/ Inter Cooler)


    1. A01BFPG

      Connect the oil return hose with the clip.

  15. INSTALL VANE PUMP OIL RESERVOIR ASSEMBLY


    1. A01BBC4E01

      Install the vane pump oil reservoir assembly with the 2 bolts.

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

  16. INSTALL ENGINE SERVICE HOLE SUB COVER ASSEMBLY


    1. Install the engine service hole sub cover with the 5 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  17. INSTALL FRONT DOOR SCUFF PLATE RH

  18. INSTALL FRONT SEAT ASSEMBLY RH (for Hi-back Seat Type)


    1. Perform the same procedure as above on the opposite side. Click here

  19. INSTALL FRONT SEAT ASSEMBLY RH (for Low-back Seat Type)


    1. Perform the same procedure as above on the opposite side. Click here

  20. CONNECT NEGATIVE BATTERY CABLE

  21. INSPECT FUEL LEAK


    1. PERFORM ACTIVE TEST


      1. Connect the GTS to the DLC3.

      2. Turn the ignition switch on.

      3. Turn the GTS on.

      4. Enter the following menus: Powertrain / Engine and ECT / Active Test.

      5. Perform the Active Test.

        Tester Display Test Details Control Range Diagnostic Notes
        Test the Fuel Leak Pressurizes common rail internal fuel pressure, and checks for fuel leaks Stop/Start

        • Fuel pressure inside common rail pressurized to specified value and engine speed increased to 2,000 rpm when ON is selected

        • Above conditions preserved while test is ON

  22. INSPECT FUNCTION OF THROTTLE BODY


    1. Inspect the throttle control motor.


      1. A01BB4C

        Using an ohmmeter, measure the resistance between the terminals.

        Standard resistance
        Tester Connection Specified Condition
        1 (DUTY) - Body ground Infinity

  23. PERFORM INITIALIZATION


    1. Some system need initialization when reconnecting the battery cable. Click here