ENGINE ASSEMBLY INSTALLATION

CAUTION / NOTICE / HINT

Note

w/ DPF:

When fuel lines are disconnected, air may enter the fuel lines, leading to engine starting trouble. Therefore, perform forced regeneration and bleed the air from the fuel lines Click here.

PROCEDURE


  1. INSTALL FRONT ENGINE MOUNTING INSULATOR LH

    Click here

  2. INSTALL FRONT ENGINE MOUNTING INSULATOR RH

    Click here

  3. INSTALL NO. 1 AND NO. 2 ENGINE HANGER

    Click here

  4. REMOVE ENGINE STAND


    1. Attach an engine sling device and hang the engine with a chain block.

    2. Lift the engine, and remove it from the engine stand.

      Note


      • With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine while it is suspended, as doing so is dangerous.

      • Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.

  5. INSTALL DRIVE PLATE AND RING GEAR SUB-ASSEMBLY (for Automatic Transmission)


    1. Using a wrench, hold the crankshaft.

    2. B001ZIR

      Install the rear crankshaft balancer weight.

      Text in Illustration
      B001XPG Engine Side

      Tech Tips


      • Align the pin hole of the rear crankshaft balancer weight with the pin of the crankshaft.

      • As the rear crankshaft balancer weight is not reversible, be sure to install it so that it is facing in the direction shown in the illustration.

    3. B001XG2E01
      Text in Illustration
      *1 Drive Plate and Ring Gear
      *2 Rear Drive Plate Spacer
      B001XPG Automatic Transmission Side

      Install the drive plate and ring gear and rear drive plate spacer with 8 new bolts.

      Tech Tips

      As the drive plate and ring gear and rear drive plate spacer are not reversible, be sure to install them so that they are facing in the direction shown in the illustration.

    4. B001ZNZE02

      Install and uniformly tighten the 8 bolts in the sequence shown in the illustration.

      Torque:
      182 N*m  { 1856 kgf*cm, 134 ft.*lbf }

  6. INSTALL FLYWHEEL SUB-ASSEMBLY (for Manual Transmission)


    1. B001ZJ0E02

      Temporarily install the flywheel with 8 new bolts.

      Note


      • Align the crankshaft knock pin and flywheel knock pin hole.

      • Do not strike or damage the flywheel installation bolts. Be sure to handle them carefully.

      • Make sure there is no oil on the bolts.

    2. Using a wrench, hold the crankshaft.

    3. Uniformly install and tighten the 8 bolts in the sequence shown in the illustration.

      Torque:
      182 N*m  { 1856 kgf*cm, 134 ft.*lbf }

  7. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission)

    Click here

  8. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission)

    Click here

  9. INSTALL ENGINE ASSEMBLY


    1. Slowly lower the engine into the engine compartment.

    2. Install the 4 bolts to the front mounting insulator RH and LH.

      Torque:
      58 N*m  { 591 kgf*cm, 43 ft.*lbf }

    3. Remove the 4 bolts and No. 1 and No. 2 engine hangers.

  10. INSTALL CLUTCH RELEASE CYLINDER TO FLEXIBLE HOSE TUBE (for Manual Transmission)


    1. Install the clutch release cylinder to flexible hose tube with the bolt.

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

  11. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY

    Click here

  12. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

    Click here

  13. INSTALL NO. 2 INTAKE MANIFOLD

    Click here

  14. INSTALL NO. 1 INTAKE MANIFOLD

    Click here

  15. INSTALL NO. 1 FUEL PIPE CLAMP (w/ DPF)

    Click here

  16. INSTALL FUEL HOSE BRACKET (w/ DPF)

    Click here

  17. INSTALL NO. 1 NOZZLE LEAKAGE PIPE (w/ DPF)

    Click here

  18. INSTALL NO. 2 NOZZLE LEAKAGE PIPE (w/ DPF)

    Click here

  19. INSTALL NO. 1 WATER BY-PASS PIPE

    Click here

  20. INSTALL FUEL TUBE SUB-ASSEMBLY (w/ DPF)

    Click here

  21. INSTALL FUEL COOLER ASSEMBLY (w/o DPF)

    Click here

  22. CONNECT NO. 6 WATER BY-PASS HOSE (w/o DPF)

  23. INSTALL NO. 4 NOZZLE LEAKAGE PIPE (w/o DPF)

    Click here

  24. INSTALL NO. 3 NOZZLE LEAKAGE PIPE (w/o DPF)

    Click here

  25. INSTALL EGR COOLER INSULATOR (w/ EGR System)

  26. INSTALL EGR VALVE ASSEMBLY WITH EGR COOLER (w/ EGR System)

    Click here

  27. INSTALL EGR PIPE INSULATOR (w/ EGR System)

    Click here

  28. INSTALL INTAKE MANIFOLD INSULATOR (w/ EGR System)

  29. INSTALL NO. 3 INTAKE MANIFOLD

    Click here

  30. CONNECT NO. 2 ENGINE WIRE

    Click here

  31. INSTALL INTAKE PIPE

    Click here

  32. INSTALL NO. 3 NOZZLE LEAKAGE PIPE (w/ DPF)

    Click here

  33. INSTALL CONNECTING WIRE (w/ DPF)

    Click here

  34. INSTALL NO. 2 INTAKE MANIFOLD INSULATOR (w/ Intercooler)

  35. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR (w/ Intercooler)

  36. INSTALL COMMON RAIL ASSEMBLY RH

    Click here

  37. INSTALL INJECTION PIPE RH

    Click here

  38. INSTALL NO. 1 PROTECTOR FUEL INJECTOR (w/ DPF)

    Click here

  39. INSTALL NO. 2 PROTECTOR FUEL INJECTOR (w/ DPF)

    Click here

  40. INSTALL CYLINDER HEAD COVER SILENCER RH (w/ DPF)

  41. INSTALL NO. 5 INJECTION PIPE SUB-ASSEMBLY

    Click here

  42. CONNECT FUEL PUMP MOTOR WIRE

    Click here

  43. INSTALL FUEL FILTER TO INJECTION PUMP FUEL PIPE SUB-ASSEMBLY

    Click here

  44. INSTALL COMMON RAIL ASSEMBLY LH

    Click here

  45. INSTALL NO. 5 NOZZLE LEAKAGE PIPE (w/ DPF)

    Click here

  46. INSTALL INJECTION PIPE LH

    Click here

  47. INSTALL NO. 4 NOZZLE LEAKAGE PIPE (w/ DPF)

    Click here

  48. INSTALL CYLINDER HEAD COVER SILENCER LH (w/ DPF)

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

    Click here

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

    Click here

  51. INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY (w/o DPF)

    Click here

  52. CONNECT NO. 6 INJECTION PIPE SUB-ASSEMBLY

    Click here

  53. CONNECT ENGINE WIRE


    1. Rear Side:


      1. Install the glow plug wire harness with the nut and screw grommet.

        Torque:
        4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

      2. w/ DPF:

        Connect the 3 connectors.

      3. w/o DPF:

        Connect the connector.

      4. Install the engine wire harness protector with the 2 bolts.

      5. Install the 2 ground wires with the 2 bolts.

        Torque:
        8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    2. LH Side:


      1. Install the engine wire protector with the 2 bolts.

      2. Connect the 8 connectors.

      3. Attach the wire harness clamp.

      4. Install the engine wire harness bracket with the bolt.

      5. for RHD:

        Connect the wire harness with the wire harness clamp holder.

      6. Attach the 3 wire harness clamps and connect the 2 connectors.

      7. w/ DPF:

        Connect the 7 connectors to the injection driver.

      8. w/o DPF:

        Connect the 4 connectors to the injection driver.

      9. Install the ground wire with the bolt.

        Torque:
        8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

      10. Connect the wire harness holder to the relay block.

      11. Connect the 4 connectors to the relay block.

      12. Connect the wire harness with the wire harness clamp holder.

      13. for RHD:

        Connect the wire harness with the wire harness clamp holder.

      14. for RHD:

        Connect the ECM connector to the ECM.

      15. for RHD:

        Attach the wire harness tab to the relay block.

      16. Connect the 4 connectors to the relay block.

      17. Connect the generator positive (+) cable to the body panel with the 2 clamps.

      18. Attach the generator positive (+) cable holder to the relay block, and install the cable to the relay block with the nut.

        Torque:
        10 N*m  { 102 kgf*cm, 7 ft.*lbf }

      19. Connect the wire harness with the wire harness clamp holder, and attach the ground wire clamp to the relay block side.

      20. Install the ground wire to the body panel with the bolt.

        Torque:
        8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

    3. RH Side:


      1. w/ Winch:

        Install the ground wire with the bolt.

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

      2. Install the engine wire harness protector with the 3 bolts.

      3. Connect the 7 connectors.

      4. Install the wire harness bracket with the bolt.

      5. Install the glow plug wire harness with the nut and screw grommet.

        Torque:
        4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

      6. for RHD:

        Install the wire harness holder with the bolt.

      7. for RHD:

        Connect the wire harness with the wire harness holder.

      8. for LHD:

        Connect the wire harness with the wire harness clamp holder.

      9. for LHD:

        Connect the ECM connector to the ECM.

      10. for LHD:

        Attach the wire harness tab to the relay block.

      11. for LHD:

        Connect the 4 connectors to the relay block.

  54. INSTALL NO. 4 WATER BY-PASS PIPE

    Click here

  55. INSTALL NO. 3 WATER BY-PASS PIPE (w/o Viscous Heater)

    Click here

  56. CONNECT FUEL HOSE

  57. INSTALL NO. 1 AIR CLEANER PIPE SUB-ASSEMBLY

    Click here

  58. INSTALL HEATER WATER PIPE SUB-ASSEMBLY (w/ Viscous Heater)

    Click here

  59. INSTALL NO. 2 INTAKE AIR CONNECTOR PIPE


    1. B001YLDE02
      Text in Illustration
      *1 Hose Stopper
      *a No Gap

      Install the No. 2 intake air connector pipe to the No. 2 inlet compressor elbow.

      Note

      Make sure there is no gap between the air pipe and hose stopper on the elbow side.

    2. Install the bolt of the No. 2 intake air connector pipe.

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

      Note

      Do not excessively pull the air pipe towards the front of the engine.

    3. Tighten the hose clamp on the elbow side.

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

      Tech Tips


      • Align the 2 protrusions of the air pipe and elbow.

      • Install the air pipe so that the protrusion on the pipe side is within the range of the protrusion on the elbow side.

      • After tightening, a gap between the air pipe and hose stopper on the elbow side is acceptable.

      • Make sure the direction of the hose clamp is as shown in the illustration.

      B001YSME03
      Text in Illustration
      *1 Protrusion

    4. w/ Intercooler:

      Connect the vacuum hose.

  60. ADJUST COMPRESSOR OIL

    Click here

  61. INSTALL COOLER COMPRESSOR ASSEMBLY


    1. B001VRBE02

      Temporarily install the cooler compressor with the 4 bolts.

    2. Tighten the 4 bolts in the order shown in the illustration.

      Torque:
      25 N*m  { 250 kgf*cm, 18 ft.*lbf }

    3. Attach the 3 wire harness clamps and connect the 4 connectors.

  62. INSTALL SUCTION HOSE SUB-ASSEMBLY

    Click here

  63. INSTALL NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

  64. INSTALL NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY

    Click here

  65. INSTALL NO. 2 AIR TUBE ASSEMBLY


    1. Apply a light coat of washer fluid to a new O-ring, and install it to the No. 2 air tube.

    2. Install the No. 2 air tube with the bolt.

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

  66. INSTALL NO. 4 AIR TUBE

    Click here

  67. INSTALL NO. 2 AIR HOSE

    Click here

  68. INSTALL NO. 1 AIR TUBE ASSEMBLY


    1. Apply a light coat of washer fluid to a new O-ring, and install it to the No. 1 air tube.

    2. Install the No. 1 air tube with the bolt.

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

  69. INSTALL NO. 3 AIR TUBE

    Click here

  70. INSTALL NO. 1 AIR HOSE

    Click here

  71. INSTALL DIESEL THROTTLE BODY ASSEMBLY LH

    Click here

  72. INSTALL NO. 3 INTERCOOLER SUPPORT BRACKET

    Click here

  73. INSTALL NO. 1 GAS FILTER

    Click here

  74. INSTALL TUBE CONNECTOR TO FLEXIBLE HOSE TUBE (for Manual Transmission)

    Click here

  75. INSTALL AIR TUBE SUB-ASSEMBLY LH

    Click here

  76. INSTALL CLUTCH HOSE (for Manual Transmission)

    Click here

  77. INSTALL DIESEL THROTTLE BODY ASSEMBLY RH

    Click here

  78. INSTALL AIR TUBE SUB-ASSEMBLY RH

    Click here

  79. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  80. CONNECT WATER HOSE SUB-ASSEMBLY

  81. INSTALL NO. 2 COOL AIR INLET (w/o Intercooler)

    Click here

  82. INSTALL NO. 1 COOL AIR INLET (w/o Intercooler)

    Click here

  83. CONNECT FUEL TUBE


    1. Install new No. 1 and No. 3 fuel tube clamps.

    2. w/ DPF:

      Connect the 2 fuel tubes to the clamps.

    3. w/o DPF:

      Connect the 3 fuel tubes to the clamps.

  84. CONNECT FRONT DIFFERENTIAL BREATHER TUBE

  85. ADD ENGINE OIL

    Click here

  86. INSTALL RADIATOR ASSEMBLY

    Click here

  87. CONNECT RADIATOR SIDE DEFLECTOR LH

    Click here

  88. CONNECT RADIATOR SIDE DEFLECTOR RH (for Manual Transmission)

    Click here

  89. INSTALL TRANSMISSION OIL COOLER AIR DUCT (for Automatic Transmission)

    Click here

  90. INSTALL FRONT BUMPER COVER

    Click here

  91. INSTALL RADIATOR GRILLE

    Click here

  92. INSTALL FRONT BUMPER WINCH COVER (w/ Winch)

    Click here

  93. INSTALL FAN PULLEY

  94. INSTALL FAN SHROUD WITH FAN

    Click here

  95. INSTALL OIL COOLER TUBE (for Automatic Transmission)

    Click here

  96. INSTALL V-RIBBED BELT

    Click here

  97. INSTALL NO. 3 IDLER PULLEY (w/ Viscous Heater)

    Click here

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

    Click here

  99. INSTALL V-RIBBED BELT (w/ Viscous Heater)

    Click here

  100. CONNECT NO. 2 RADIATOR HOSE

  101. CONNECT NO. 1 RADIATOR HOSE

  102. INSTALL VANE PUMP ASSEMBLY


  103. INSTALL RADIATOR RESERVOIR ASSEMBLY

    Click here

  104. INSTALL NO. 1 OIL RESERVOIR BRACKET

    Click here

  105. INSTALL VANE PUMP OIL RESERVOIR ASSEMBLY

    Click here

  106. INSTALL AIR CLEANER CASE


    1. Install the air cleaner case with the 3 bolts.

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

    2. Attach the wire harness clamp to the air cleaner case.

  107. INSTALL AIR CLEANER FILTER ELEMENT

  108. INSTALL INTAKE AIR CONNECTOR

    Click here

  109. TEMPORARILY INSTALL NO. 1 AIR CLEANER HOSE

    Click here

  110. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  111. INSTALL INTERCOOLER ASSEMBLY (w/ Intercooler)

    Click here

  112. INSTALL SUB-BATTERY

  113. INSTALL MAIN BATTERY

  114. INSTALL NO. 3 ENGINE ROOM WIRE

    Click here

  115. INSTALL FRONT WHEEL

  116. BLEED CLUTCH LINE

    Click here

  117. CHECK FOR CLUTCH FLUID LEAK

  118. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.


    1. Connect the cables to the negative (-) main battery and sub-battery terminals.

  119. BLEED AIR FROM FUEL SYSTEM

    Click here

  120. ADD ENGINE COOLANT

    Click here

  121. INSPECT FOR FUEL LEAK

    Click here

  122. INSPECT FOR OIL LEAK

    Click here

  123. INSPECT FOR COOLANT LEAK

    Click here

  124. INSPECT FOR EXHAUST GAS LEAK

  125. CHARGE REFRIGERANT

    Click here

  126. WARM UP ENGINE

    Click here

  127. CHECK FOR REFRIGERANT GAS LEAK

    Click here

  128. INSTALL FRONT FENDER APRON SEAL REAR LH


    1. Install the front fender apron seal rear LH with the 4 clips.

  129. INSTALL FRONT FENDER APRON SEAL FRONT LH


    1. w/o KDSS:

      Install the front fender apron seal front LH with the 4 clips.

    2. w/ KDSS:

      Install the front fender apron seal front LH with the 3 clips.

  130. INSTALL FRONT FENDER APRON SEAL REAR RH


    1. Install the front fender apron seal rear RH with the 4 clips.

  131. INSTALL FRONT FENDER APRON SEAL FRONT RH


    1. Install the front fender apron seal front RH with the 3 clips.

  132. INSTALL OIL PAN PROTECTOR ASSEMBLY

    Click here

  133. INSTALL NO. 2 ENGINE UNDER COVER


    1. Install the No. 2 engine under cover with the 2 bolts.

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

  134. INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY


    1. Install the No. 1 engine under cover with the 10 bolts.

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

  135. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH


    1. Install the front fender splash shield RH with the clip, and then install the 3 bolts and 2 screws.

  136. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH


    1. Install the front fender splash shield LH with the clip, and then install the 3 bolts and screw.

  137. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  138. INSTALL HOOD SUB-ASSEMBLY


    1. Install the hood with the 4 bolts.

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

    2. Install the 2 hood supports with the 2 bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

      Note


      • As much as possible avoid touching the stroke portions of the rod to prevent foreign matter from attaching to it. Be sure to hold the cylinders while servicing.

      • Do not wear cotton gloves or other similar materials when handling the rod. Fibers may attach to the rod and result in gas leaks.

      • Do not apply any load to the cylinders in the horizontal direction in order to prevent the rod from being deformed.

      • Install the hood support while supporting the hood by hand.

  139. ADJUST HOOD SUB-ASSEMBLY

    Click here

  140. INSPECT ENGINE OIL LEVEL

    Click here

  141. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR

    Click here

  142. INSPECT ENGINE IDLE SPEED

    Click here

  143. INSPECT MAXIMUM ENGINE SPEED

    Click here

  144. INSTALL UPPER RADIATOR SUPPORT SEAL

    Click here

  145. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY (w/ Intercooler)

    Click here

  146. PERFORM CRANK TIME COMPENSATION RESET FUNCTION

    Click here