ENGINE UNIT INSTALLATION

CAUTION / NOTICE / HINT

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail, intake manifold or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, intake manifold or cylinder head, it is necessary to replace the fuel inlet pipe with a new one.

PROCEDURE


  1. INSTALL DRIVE SHAFT BEARING BRACKET


    1. Install the bearing bracket with the 3 bolts.

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

  2. INSTALL EXHAUST MANIFOLD WITH TURBOCHARGER SUB-ASSEMBLY

    Click here

  3. INSTALL NO. 2 TURBO OIL PIPE

    Click here

  4. INSTALL NO. 5 WATER BY-PASS PIPE (for Automatic Transaxle)

    Click here

  5. INSTALL NO. 2 TURBO WATER PIPE SUB-ASSEMBLY (for Manual Transaxle)

    Click here

  6. CONNECT NO. 3 WATER BY-PASS HOSE

  7. INSTALL NO. 1 TURBO WATER PIPE SUB-ASSEMBLY (for Manual Transaxle)

    Click here

  8. INSTALL NO. 1 TURBO INSULATOR

    Click here

  9. INSTALL TURBO OIL OUTLET PIPE

    Click here

  10. INSTALL EGR COOLER WITH PIPE ASSEMBLY

    Click here

  11. INSTALL NO. 2 WATER BY-PASS HOSE (for Automatic Transaxle)

  12. INSTALL NO. 5 WATER BY-PASS HOSE (for Manual Transaxle)

  13. INSTALL NO. 1 TURBO WATER HOSE (for Manual Transaxle)

  14. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    Click here

  15. INSTALL NO. 1 MANIFOLD CONVERTER INSULATOR

    Click here

  16. INSTALL VACUUM TRANSMITTING HOSE ASSEMBLY

    Click here

  17. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

    Click here

  18. INSTALL VACUUM REGULATING VALVE ASSEMBLY

    Click here

  19. INSTALL NO. 1 TURBO OIL PIPE


    1. A004UBME02

      Install the oil pipe and 2 new gaskets with the 2 union bolts.

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

      Tech Tips

      Be sure to install union bolt A so that the gasket is positioned as shown in the illustration.

  20. INSTALL NO. 3 WATER BY-PASS PIPE


    1. Apply soapy water to a new O-ring and install it to the by-pass pipe.

    2. Install the No. 3 water by-pass pipe with the 2 bolts.

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

  21. INSTALL FUEL HOSE PROTECTOR


    1. Install the fuel hose protector to the cylinder head.

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

  22. INSTALL SUPPLY PUMP ASSEMBLY


    1. Install a new O-ring to the supply pump.

    2. Install the supply pump drive coupling.

      Tech Tips

      Line up the coupling with the groove in the camshaft end.

      Note

      When reusing the coupling, it must be installed in the same orientation (top/bottom, front/back) as when it was removed,

    3. Install the supply pump with the 2 bolts.

      Torque:
      21 N*m  { 209 kgf*cm, 15 ft.*lbf }

      Tech Tips

      Line up the end of the supply pump drive shaft with the supply pump drive coupling.

      Note

      Apply engine oil to the O-ring of the supply pump.

  23. INSTALL NO. 3 FUEL HOSE

  24. INSTALL FUEL INJECTOR SEAL

    Click here

  25. INSTALL EXHAUST FUEL ADDITION INJECTOR ASSEMBLY

    Click here

  26. INSTALL FUEL TUBE SUB-ASSEMBLY

    Click here

  27. INSTALL FUEL HOSE PROTECTOR

    Click here

  28. INSTALL NO. 2 WATER BY-PASS PIPE

    Click here

  29. INSTALL NO. 4 WATER BY-PASS HOSE

  30. INSTALL NO. 8 WATER BY-PASS HOSE

  31. INSTALL NO. 6 WATER BY-PASS HOSE

  32. INSTALL WATER BY-PASS HOSE

    Click here

  33. INSTALL NO. 1 CYLINDER BLOCK INSULATOR

    Click here

  34. INSTALL GLOW PLUG ASSEMBLY


    1. Using a 10 mm deep socket wrench, install the 4 glow plugs.

      Torque:
      12 N*m  { 125 kgf*cm, 9 ft.*lbf }

    2. Install the glow plug connector with the 4 nuts.

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

    3. Install the 4 grommets.

  35. INSTALL INTAKE MANIFOLD

    Click here

  36. INSTALL NO. 2 INTAKE MANIFOLD

    Click here

  37. INSTALL ENGINE COVER BRACKET

    Click here

  38. INSTALL GAS FILTER BRACKET

    Click here

  39. INSTALL NO. 1 GAS FILTER

    Click here

  40. INSTALL DIESEL TURBO PRESSURE SENSOR

    Click here

  41. INSTALL INTAKE MANIFOLD INSULATOR

    Click here

  42. INSTALL COMMON RAIL ASSEMBLY

    Click here

  43. INSTALL NO. 4 FUEL HOSE

  44. INSTALL INJECTION PIPE SUB-ASSEMBLY

    Click here

  45. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  46. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  47. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY

    Click here

  48. INSTALL NO. 2 EGR PIPE SUB-ASSEMBLY

    Click here

  49. INSTALL EGR VALVE BRACKET

    Click here

  50. CONNECT NO. 8 WATER BY-PASS HOSE

  51. INSTALL NO. 7 WATER BY-PASS HOSE

  52. INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Click here

  53. INSTALL VACUUM PUMP ASSEMBLY

    Click here

  54. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. Install the belt tensioner with the 3 bolts.

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

      Note

      As the bolts' heads are not as thick as typical bolts, be careful not to damage them during installation.

  55. INSTALL ENGINE MOUNTING BRACKET


    1. A004NICE02

      Set the mounting bracket on the engine.

    2. Temporarily install the 2 bolts labeled B and 2 nuts.

    3. Install the 2 bolts labeled A.

      Torque:
      for bolt A
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

    4. Tighten the 2 bolts labeled B and 2 nuts.

      Torque:
      for bolt B, nut
      80 N*m  { 816 kgf*cm, 59 ft.*lbf }

  56. INSTALL NO. 4 WATER BY-PASS PIPE


    1. Install a new O-ring to the No. 4 water by-pass pipe.

    2. Install the No. 4 water by-pass pipe with the bolt.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  57. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. Install the idler pulley with the bolt.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  58. INSTALL IDLER PULLEY COVER PLATE


    1. Install the idler pulley cover plate.

  59. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. Install the idler pulley and plate with the bolt.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  60. INSTALL GENERATOR ASSEMBLY


    1. Install the generator with the 3 bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  61. INSTALL COMPRESSOR STAY


    1. Install the compressor stay to the cylinder block.

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