ENGINE UNIT INSTALLATION

PROCEDURE

1. Click here

   INSTALL FUEL INJECTOR SEAL (w/ DPF)

   Click here

2. Click here

   INSTALL EXHAUST FUEL ADDITION INJECTOR ASSEMBLY (w/ DPF)

   Click here

3. Click here

   INSTALL COMPRESSOR BRACKET

   
   

   1. Install the compressor bracket with the bolt.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

4. Click here

   INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

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5. Click here

   INSTALL STIFFENER INSULATOR RH (w/ Intercooler)

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6. Click here

   INSTALL OIL PRESSURE REGULATOR ASSEMBLY

   
   
   1. 

      Hold the oil pressure regulator body in a vise between aluminum plates.

   2. Apply a light coat of engine oil to the oil pump relief valve labeled C.

   3. Install the oil pump relief valve labeled C to the oil pressure regulator body.

   4. Install the 2 springs labeled B to the oil pressure regulator body.

   5. Using a 10 mm hexagon wrench, install a new gasket and the oil pump relief valve plug labeled A.

      50 N*m

      510 kgf*cm

      37 ft.*lbf

   6. Apply a light coat of engine oil to a new O-ring, and install it to the oil pressure regulator body.

   7. Using a 26 mm wrench, install a new gasket and the oil pressure regulator.

      86 N*m

      877 kgf*cm

      63 ft.*lbf

7. Click here

   INSTALL OIL FILTER BRACKET DRAIN COCK ASSEMBLY

   
   
   1. 

      Install the drain cock.

      20 N*m

      204 kgf*cm

      15 ft.*lbf

   2. Using a 17 mm wrench, rotate the drain cock clockwise (360°) and align the position of the drain hole so that it is within the range shown in the illustration after tightening the drain cock to the specified torque.

      Note:
      

      • As the oil filter bracket may be damaged, the maximum tightening torque should be 80 N*m (816 kgf*cm, 59 ft.*lbf) or less.

      • Do not rotate the drain cock more than 1 revolution (360°) after tightening the drain cock with the specified torque.

      • Do not expose the drain cock to coolant within 1 hour after installation.

   3. Install the oil filter drain cock plug.

      13 N*m

      130 kgf*cm

      9 ft.*lbf

8. Click here

   INSTALL OIL TANK BRACKET

   
   

   1. Install the oil tank bracket with the bolt.

      10 N*m

      102 kgf*cm

      7 ft.*lbf

9. Click here

   INSTALL NO. 2 CYLINDER BLOCK INSULATOR

10. Click here

    INSTALL ENGINE MOUNTING BRACKET LH

    
    

    1. Install the engine mounting bracket LH with the 4 bolts.

       80 N*m

       816 kgf*cm

       59 ft.*lbf

11. Click here

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

    
    
    1. 

       Temporarily install a new gasket and No. 2 water by-pass pipe with the union bolt and 2 bolts.

    2. Tighten the union bolt and 2 bolts of the No. 2 water by-pass pipe in the order shown in the illustration.

       for union bolt
       35 N*m	357 kgf*cm	26 ft.*lbf
       for bolt
       10 N*m	102 kgf*cm	7 ft.*lbf

12. Click here

    INSTALL NO. 3 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY

    
    

    1. Install the No. 3 vacuum transmitting pipe with the 2 bolts.

       6.0 N*m

       61 kgf*cm

       53 in.*lbf

    2. w/ Intercooler:

       Connect the vacuum hose.

13. Click here

    INSTALL TURBOCHARGER WIRE

    
    

    1. Install the turbocharger wire with the 2 bolts.

       21 N*m

       214 kgf*cm

       15 ft.*lbf

    2. Attach the 3 wire harness clamps.

14. Click here

    INSTALL NO. 2 INTAKE AIR CONNECTOR BRACKET

    
    

    1. Install the No. 2 intake air connector bracket with the bolt.

       21 N*m

       214 kgf*cm

       15 ft.*lbf

    2. Attach the 2 wire clamps.

15. Click here

    INSTALL NO. 1 CYLINDER BLOCK INSULATOR

16. Click here

    INSTALL ENGINE MOUNTING BRACKET RH

    
    

    1. Install the engine mounting bracket RH with the 4 bolts.

       80 N*m

       816 kgf*cm

       59 ft.*lbf

17. Click here

    INSTALL NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/ Intercooler)

    
    

    1. Install the No. 4 vacuum transmitting pipe with the 2 bolts.

       6.0 N*m

       61 kgf*cm

       53 in.*lbf

    2. Connect the vacuum hose.

18. Click here

    INSTALL NO. 1 WATER BY-PASS PIPE SUB-ASSEMBLY

    
    

    1. Temporarily install a new gasket and the No. 1 water by-pass pipe with the union bolt and bolt.

    2. 

       Tighten the union bolt and bolt of the No. 1 water by-pass pipe in the order shown in the illustration.

       for union bolt
       35 N*m	357 kgf*cm	26 ft.*lbf
       for bolt
       10 N*m	102 kgf*cm	7 ft.*lbf

19. Click here

    INSTALL AIR TUBE SUPPORT

    
    

    1. Install the air tube support with the 2 bolts.

       21 N*m

       214 kgf*cm

       15 ft.*lbf

20. Click here

    INSTALL NO. 1 INTAKE AIR CONNECTOR BRACKET

    
    

    1. Install the No. 1 intake air connector bracket with the 2 bolts.

       21 N*m

       214 kgf*cm

       15 ft.*lbf

21. Click here

    INSTALL REAR CYLINDER HEAD PLATE LH (w/o EGR System)

    
    

    1. Install a new gasket and the rear cylinder head plate LH with the 2 bolts.

       29 N*m

       296 kgf*cm

       21 ft.*lbf

       Tip:

       The gasket claw should face toward the plate.

22. Click here

    INSTALL REAR CYLINDER HEAD PLATE RH (w/o EGR System)

    
    

    1. Install a new gasket and the rear cylinder head plate RH with the 2 bolts.

       29 N*m

       296 kgf*cm

       21 ft.*lbf

       Tip:

       The gasket claw should face toward the plate.

23. Click here

    INSTALL CYLINDER HEAD COVER SILENCER LH (w/o DPF)

    
    

    1. w/ Intercooler:

       Install the cylinder head cover silencer LH with the 3 bolts.

       5.0 N*m

       51 kgf*cm

       44 in.*lbf

24. Click here

    INSTALL CYLINDER HEAD COVER SILENCER RH (w/o DPF)

    
    

    1. w/ Intercooler:

       Install the cylinder head cover silencer RH with the 3 bolts.

       5.0 N*m

       51 kgf*cm

       44 in.*lbf

25. Click here

    INSTALL NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/o DPF)

    Click here

26. Click here

    INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY (w/o DPF)

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27. Click here

    INSTALL FAN BRACKET SUB-ASSEMBLY

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28. Click here

    INSTALL NO. 2 IDLER PULLEY BRACKET (w/ Viscous Heater)

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29. Click here

    INSTALL NO. 2 IDLER PULLEY (w/ Viscous Heater)

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30. Click here

    INSTALL NO. 3 ENGINE HANGER

    
    

    1. Install the No. 3 engine hanger with the 2 bolts.

       43 N*m

       438 kgf*cm

       32 ft.*lbf

31. Click here

    INSTALL NO. 1 INTERCOOLER SUPPORT BRACKET

    
    

    1. Install the No. 1 intercooler support bracket with the 2 bolts.

       21 N*m

       214 kgf*cm

       15 ft.*lbf

32. Click here

    INSTALL FUEL PUMP MOTOR WIRE

    
    
    1. 

       Install the fuel pump wire with the bolt.

       6.0 N*m

       61 kgf*cm

       53 in.*lbf

       Tip:

       Attach the claw of the bracket to the timing gear case when installing the bracket.

33. Click here

    INSTALL GLOW PLUG ASSEMBLY

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34. Click here

    INSTALL NO. 1 GLOW PLUG CONNECTOR

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35. Click here

    INSTALL CLUTCH FLEXIBLE HOSE BRACKET (for Manual Transmission)

    
    

    1. Install the clutch flexible hose bracket with the 2 bolts.

       20 N*m

       204 kgf*cm

       15 ft.*lbf

36. Click here

    INSTALL NO. 1 AND NO. 2 WATER OUTLET PIPES AND WATER BY-PASS OUTLET

    
    

    1. Align the painted mark of the No. 1 water hose joint with the protrusion of the water by-pass outlet and connect the water by-pass outlet to the No. 1 water hose joint.

    2. Align the painted mark of the No. 1 water hose joint with the painted mark of the No. 2 water outlet pipe and connect the No. 2 water outlet pipe to the No. 1 water hose joint.

    3. Connect a new gasket and the No. 1 and No. 2 water outlet pipes with the 2 bolts.

       21 N*m

       214 kgf*cm

       15 ft.*lbf

       Tip:

       The gasket claws can face the No. 1 or No. 2 water outlet pipe.

37. Click here

    INSTALL WATER OUTLET PIPE

    
    

    1. Install 2 new gaskets and the water outlet pipe with the 4 bolts.

       21 N*m

       214 kgf*cm

       15 ft.*lbf

       Tip:

       The gasket claw should face toward the water outlet pipe.

38. Click here

    INSTALL WATER OUTLET

    
    

    1. Install a new gasket and the water outlet with the 2 bolts, and then connect the water outlet to the No. 2 water hose joint.

       21 N*m

       214 kgf*cm

       15 ft.*lbf

39. Click here

    INSTALL NO. 2 INTERCOOLER SUPPORT BRACKET

    
    

    1. Install the No. 2 intercooler support bracket with the 2 bolts.

       43 N*m

       438 kgf*cm

       32 ft.*lbf

40. Click here

    INSTALL DIESEL ENGINE COOLANT TEMPERATURE SENSOR

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41. Click here

    CONNECT INLET WATER HOSE

42. Click here

    INSTALL STARTER HOSE BRACKET

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43. Click here

    INSTALL STARTER ASSEMBLY

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44. Click here

    INSTALL TIMING GEAR COVER INSULATOR (w/ Intercooler)

    
    

    1. w/o Viscous Heater:

       Install the timing gear cover insulator with the 2 bolts.

       21 N*m

       214 kgf*cm

       15 ft.*lbf

    2. w/ Viscous Heater:

       Install the timing gear cover insulator.

45. Click here

    INSTALL THERMOSTAT

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46. Click here

    INSTALL WATER INLET

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47. Click here

    INSTALL NO. 1 IDLER PULLEY BRACKET (w/ Viscous Heater)

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48. Click here

    INSTALL VISCOUS HEATER ASSEMBLY WITH MAGNET CLUTCH (w/ Viscous Heater)

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49. Click here

    INSTALL NO. 2 TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD LH

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50. Click here

    INSTALL NO. 2 VENTILATION TUBE SUB-ASSEMBLY

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51. Click here

    INSTALL NO. 2 TURBOCHARGER STAY

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52. Click here

    CONNECT NO. 2 OUTLET TURBO OIL HOSE

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53. Click here

    INSTALL NO. 2 TURBO WATER PIPE SUB-ASSEMBLY

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54. Click here

    INSTALL FRONT WATER BY-PASS JOINT

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55. Click here

    INSTALL NO. 3 TURBO WATER PIPE SUB-ASSEMBLY

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56. Click here

    INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

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57. Click here

    INSTALL NO. 2 TURBO WATER HOSE

58. Click here

    INSTALL BREATHER PLUG LH

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59. Click here

    INSTALL NO. 3 VENTILATION HOSE

60. Click here

    INSTALL NO. 1 TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD RH

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61. Click here

    INSTALL NO. 1 VENTILATION TUBE SUB-ASSEMBLY

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62. Click here

    INSTALL NO. 1 TURBOCHARGER STAY

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63. Click here

    INSTALL NO. 1 TURBO WATER PIPE SUB-ASSEMBLY

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64. Click here

    CONNECT NO. 1 OUTLET TURBO OIL HOSE

65. Click here

    INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

66. Click here

    INSTALL NO. 2 TURBO WATER HOSE

67. Click here

    INSTALL BREATHER PLUG RH

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68. Click here

    INSTALL NO. 2 VENTILATION HOSE

69. Click here

    INSTALL GENERATOR ASSEMBLY

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70. Click here

    INSTALL NO. 1 INTAKE AIR CONNECTOR PIPE

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71. Click here

    INSTALL NO. 1 ENGINE OIL LEVEL DIPSTICK GUIDE

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72. Click here

    INSTALL VACUUM PUMP ASSEMBLY (w/ Intercooler)

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