ENGINE UNIT INSTALLATION

CAUTION / NOTICE / HINT

Note


  • Always be sure to check the tightening torque.

  • If the pressure lines are leaking after installation, they must be replaced.

  • Do not overtighten the pressure lines.

  • All pressure lines may only be reused 3 times. After the 3rd time, they must be replaced.

PROCEDURE


  1. INSTALL DRIVE SHAFT BEARING BRACKET


    1. Using a T50 "TORX" socket wrench, install the drive shaft bearing bracket with the 3 bolts.

      Torque:
      64 N*m  { 650 kgf*cm, 47 ft.*lbf }

  2. INSTALL VACUUM CONTROL VALVE BRACKET

    Click here

  3. INSTALL EGR BYPASS VALVE SWITCHING VALVE ASSEMBLY

    Click here

  4. INSTALL GLOW PLUG ASSEMBLY

    Click here

  5. INSTALL COMMON RAIL ASSEMBLY

    Click here

  6. INSTALL INJECTION PIPE SUB-ASSEMBLY

    Click here

  7. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  8. INSTALL NO. 1 ENGINE HANGER


    1. Install the No. 1 engine hanger to the cylinder head sub-assembly with the bolt.

      Tech Tips

      Refer to "SPECIFICATIONS - STANDARD BOLT" for the tightening torque.

  9. INSTALL NO. 2 ENGINE HANGER


    1. Install the No. 2 engine hanger to the cylinder head sub-assembly with the 2 bolts.

      Tech Tips

      Refer to "SPECIFICATIONS - STANDARD BOLT" for the tightening torque.

  10. INSTALL EGR VALVE BRACKET


    1. Install the EGR valve bracket to the cylinder head sub-assembly with the 2 bolts.

      Tech Tips

      Refer to "SPECIFICATIONS - STANDARD BOLT" for the tightening torque.

  11. INSTALL TURBOCHARGER STAY


    1. Install the turbocharger stay with the 2 bolts.

      Tech Tips

      Refer to "SPECIFICATIONS - STANDARD BOLT" for the tightening torque.

  12. INSTALL NO. 2 TURBO INSULATOR


    1. Install the No. 2 turbo insulator with the 3 bolts.

      Tech Tips

      Refer to "SPECIFICATIONS - STANDARD BOLT" for the tightening torque.

  13. INSTALL NO. 1 TURBO OIL PIPE


    1. Install the No. 1 turbo oil pipe, 2 nuts and 2 new gaskets with the union bolt.

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

      Tech Tips

      Refer to "SPECIFICATIONS - STANDARD BOLT" for the tightening torque.

  14. INSTALL EXHAUST MANIFOLD

    Click here

  15. INSTALL EGR COOLER ASSEMBLY WITH EGR VALVE ASSEMBLY

    Click here

  16. INSTALL TURBOCHARGER SUB-ASSEMBLY

    Click here

  17. CONNECT NO. 1 TURBO OIL PIPE

    Click here

  18. INSTALL TURBO OIL OUTLET PIPE

    Click here

  19. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    Click here

  20. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  21. INSTALL FUEL FEED PIPE SUB-ASSEMBLY


    1. Install the fuel feed pipe sub-assembly with the 2 bolts.

      Tech Tips

      Refer to "SPECIFICATIONS - STANDARD BOLT" for the tightening torque.

    2. Connect the 2 fuel hoses to the fuel supply pump assembly, and tighten the 2 clamps to secure the 2 hoses.

    3. Connect the fuel return tube to the common rail assembly.

      Click here

    4. Attach the fuel hose clamp.

    5. Connect the nozzle leakage pipe assembly to the fuel feed pipe sub-assembly.

  22. INSTALL INTAKE MANIFOLD

    Click here

  23. INSTALL NO. 1 VACUUM PIPE

    Click here

  24. INSTALL NO. 2 VACUUM HOSE ASSEMBLY


    1. Install the No. 2 vacuum hose assembly to the No. 2 engine hanger with the bolt and nut.

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

  25. CONNECT NO. 2 VACUUM HOSE ASSEMBLY

    Click here

  26. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  27. INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Click here

  28. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


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

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

  29. INSTALL ENGINE MOUNTING BRACKET


    1. Install the stud bolt to the engine mounting bracket.

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

    2. Using an E12 "TORX" socket wrench, install the engine mounting bracket with the 3 bolts.

      Torque:
      59 N*m  { 602 kgf*cm, 44 ft.*lbf }

  30. INSTALL IDLER PULLEY ASSEMBLY


    1. Using a T50 "TORX" socket wrench, tighten the bolt to install the idler pulley assembly.

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

  31. INSTALL GENERATOR ASSEMBLY

    Click here

  32. INSTALL COMPRESSOR ASSEMBLY WITH PULLEY (w/ Air Conditioning System)

    Click here

  33. INSTALL FAN AND GENERATOR V BELT

    Click here

  34. CONNECT ENGINE WIRE

  35. INSTALL ENGINE COVER