GLOW PLUG INSTALLATION

PROCEDURE


  1. INSTALL GLOW PLUG

    Note


    • Measure the resistance of the glow plug when reinstalling it. If the result is not as specified, replace the glow plug with a new one.

    • Replace the glow plug with a new one when it has been dropped or subjected to a physical impact.

    • Remove any carbon deposits from the glow plug hole when reinstalling the glow plug.


    1. Clean the glow plug hole.


      1. Wrap tape around a drill bit with a diameter of 4.4 mm (0.173 in.), 118.5 mm (4.665 in.) from its tip.

      2. Insert the drill bit 118.5 mm (4.665 in.) into the glow plug hole (up to the tape) and remove any carbon deposits by turning the drill bit by hand.

      3. Insert a drill bit with a diameter of 4 mm (0.157 in.) into the glow plug hole and remove any carbon deposits from the end of the glow plug hole by turning the drill bit by hand.

      4. Using a 12 mm deep socket wrench, install the glow plug assembly.

        Torque:
        18 N*m  { 178 kgf*cm, 13 ft.*lbf }

        Note

        Do not use any tools, such as air tools, which are liable to cause an impact to the glow plugs when installing them.

    2. Install the 4 glow plugs.

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

      Note

      Do not use any tools, such as air tools, which are liable to cause an impact to the glow plugs when installing them.

  2. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR

  3. INSTALL NO. 1 GLOW PLUG CONNECTOR


    1. Temporarily install the No. 1 glow plug connector with the 4 nuts.

    2. Tighten the 4 nuts.

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

    3. Install the 4 screw grommets.

    4. Connect the wire harness to the No. 1 glow plug connector with the nut.

      Torque:
      2.6 N*m  { 27 kgf*cm, 23 in.*lbf }

    5. Install the screw grommet.

  4. INSTALL NO. 2 MANIFOLD STAY


    1. Install the No. 2 manifold stay with the bolt.

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

  5. INSTALL INTAKE PIPE STAY

    Click here

  6. INSTALL INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY ASSEMBLY (w/o EGR System)


    1. B001EZH

      Set a new gasket on the intake manifold.

      Note

      Make sure the claw of the gasket face the intake manifold as shown in the illustration.

    2. B001FBYE01

      Install the intake air connector with diesel throttle body with the 3 bolts.

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

      Note

      Tighten the bolts in the order shown in the illustration.

    3. Connect the throttle position sensor connector.

  7. INSTALL AIR CONNECTOR STAY (w/o EGR System)


    1. B001HJYE02

      Temporarily install the air connector stay with the 3 bolts.

    2. Tighten the bolt labeled A.

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

    3. Tighten the 2 bolts labeled B.

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

  8. CONNECT ENGINE WIRE (w/o EGR System)


    1. B001FOME02

      for LHD:

      Connect the engine wire with the clamp and install the 2 bolts.

      Torque:
      for bolt A
      13 N*m  { 131 kgf*cm, 9 ft.*lbf }
      for bolt B
      22 N*m  { 220 kgf*cm, 16 ft.*lbf }
    2. B001F9X

      for RHD:

      Connect the engine wire with the bolt.

      Torque:
      13 N*m  { 131 kgf*cm, 9 ft.*lbf }

  9. INSTALL NO. 1 NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY (w/o EGR System)

    Click here

  10. INSTALL THROTTLE BODY BRACKET (w/o EGR System)


    1. Install the throttle body bracket with the 2 bolts.

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

    2. Install the gas filter with gas filter bracket with the bolt.

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

    3. Connect the vacuum hose.

  11. INSTALL NO. 1 INTAKE PIPE (w/o EGR System)

    Click here

  12. INSTALL NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY (w/o EGR System)

    Click here

  13. INSTALL INLET HEATER WATER HOSE (w/o EGR System)

    Click here

  14. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System)


    1. Install the electric EGR control valve Click here.

  15. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

  16. BLEED AIR FROM FUEL SYSTEM

    Click here

  17. INSPECT FOR FUEL LEAK

    Click here

  18. INSPECT FOR COOLANT LEAK

    Click here