ENGINE UNIT INSTALLATION

CAUTION / NOTICE / HINT

Note


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

  • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket or timing gear case, it is necessary to replace the fuel inlet pipe with a new one.

PROCEDURE


  1. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. Install the 2 engine mounting brackets with the 8 bolts.

      Torque:
      68 N*m  { 694 kgf*cm, 50 ft.*lbf }

  2. INSTALL NO. 2 CYLINDER BLOCK INSULATOR


    1. Install the No. 2 cylinder block insulator.

  3. INSTALL NO. 1 VACUUM PIPE


    1. Install the No. 1 vacuum pipe with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 70 in.*lbf }

  4. INSTALL NO. 1 OIL PAN COVER SUB-ASSEMBLY


    1. Install the No. 1 oil pan cover with the 4 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  5. INSTALL NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. Install the No. 1 vacuum transmitting pipe with the bolt and nut.

      Torque:
      for bolt
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      for nut
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  6. INSTALL OIL COOLER COVER SUB-ASSEMBLY


    1. Install the oil cooler cover with the 13 bolts.

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

  7. INSTALL NO. 2 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. Install the No. 2 vacuum transmitting pipe with the 2 nuts.

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

    2. Connect the vacuum hose.

  8. INSTALL NO. 3 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. Install the No. 3 vacuum transmitting pipe with the bolt.

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

    2. Connect the vacuum hose.

  9. INSTALL OIL FILTER SUB-ASSEMBLY

    Click here

  10. INSTALL NO. 1 INJECTION PUMP PROTECTOR


    1. Install the No. 1 injection pump protector with the 2 bolts.

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

  11. INSTALL SUPPLY PUMP ASSEMBLY


    1. B001EMC

      Check that the injection gear in the timing gear case moves back and forth smoothly.

    2. Install the pump drive shaft pulley and No. 2 camshaft timing pulley flange with the 4 bolts.

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }
    3. B001I3U

      Move the pump drive shaft pulley back and forth to check the thrust clearance of the injection pump drive shaft.

      Standard thrust clearance
      0.15 to 0.55 mm (0.00590 to 0.0217 in.)

      If the clearance is not within the specified range, disassemble and reassemble the supply pump and pump drive shaft pulley. Then repeat the step above.

  12. INSTALL COMMON RAIL ASSEMBLY


    1. Install the common rail with the 2 bolts.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  13. INSTALL FUEL INLET PIPE SUB-ASSEMBLY


    1. Temporarily install the fuel inlet pipe with the union nuts.

      Note


      • When replacing the fuel supply pump, it is necessary to replace the fuel inlet pipe with a new one.

      • Keep the fuel inlet pipe free of foreign matter.

    2. A01XJL6E03
      Text in Illustration
      *a for Common Rail Side
      *b for Fuel Supply Pump Side

      Using a 17 mm union nut wrench, tighten the fuel inlet pipe union nut on the common rail side.

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

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

    3. Using a 17 mm union nut wrench, tighten the fuel inlet pipe union nut on the fuel supply pump side.

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

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

  14. INSTALL NO. 2 INTAKE MANIFOLD INSULATOR


    1. Install the No. 2 intake manifold insulator.

  15. INSTALL INTAKE MANIFOLD

    Click here

  16. INSTALL INTAKE MANIFOLD INSULATOR

    Click here

  17. INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  18. INSTALL NO. 4 INJECTION PIPE SUB-ASSEMBLY

    Click here

  19. INSTALL VACUUM CONTROL VALVE SET

    Click here

  20. INSTALL INTAKE PIPE STAY

    Click here

  21. INSTALL MANIFOLD STAY WITH VACUUMSWITCHING VALVE


    1. A01XGWRE02
      Text in Illustration
      *A w/o EGR System
      *B w/ EGR System
      *1 Blue Mark
      *2 White Mark

      Install the manifold stay with vacuum switching valve with the 2 bolts and connect the No. 3 vacuum transmitting hose assembly and No. 4 vacuum transmitting hose assembly.

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

      Note

      Make sure the vacuum hose color matches the connection area color.

    2. w/ EGR Cooler:

      Connect the No. 3 vacuum transmitting hose.

    3. A01XML6E01
      Text in Illustration
      *1 Yellow Mark
      *2 Pink Mark

      w/ EGR System:

      Connect the No. 2 vacuum transmitting hose and No. 3 vacuum transmitting hose assembly.

      Note


      • Make sure the vacuum hose color matches the connection area color.

      • Push on the hose until it reaches the bent part of the pipe.

    4. Connect the No. 1 vacuum transmitting hose.

  22. INSTALL GLOW PLUG ASSEMBLY


    1. Using a 12 mm socket wrench, install the 4 glow plugs.

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

  23. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR


    1. Install the No. 1 intake manifold insulator.

  24. INSTALL NO. 1 GLOW PLUG CONNECTOR


    1. Install the glow plug connector with the 4 nuts. Uniformly tighten the nuts.

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

    2. Install the 4 screw grommets.

  25. INSTALL WATER OUTLET


    1. Install a new gasket and the water outlet with the 2 bolts.

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

  26. INSTALL NO. 2 EGR HOLE COVER PLATE (w/o EGR System)


    1. Install a new gasket and the No. 2 EGR hole cover plate with the 2 nuts.

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

  27. INSTALL NO. 2 INTAKE AIR CONNECTOR (w/o EGR System)


    1. A01XJSZE01
      Text in Illustration
      *1 No. 2 Intake Air Connector
      *2 No. 1 Intake Air Connector
      *3 Intake Air Connector
      *4 Gasket

      Install the No. 2 intake air connector, No. 1 intake air connector, intake air connector and 2 new gaskets with the 3 nuts as shown in the illustration.

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

  28. INSTALL INTAKE AIR CONNECTOR (w/o EGR System)


    1. A01XFNW

      Set a new gasket on the intake manifold.

      Note

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

    2. A01XI0EE01

      Install the intake air connector 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.

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


    1. A01XI19E01

      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 }

  30. INSTALL INJECTION PIPE (w/o EGR System)

    Click here

  31. 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.

  32. INSTALL NO. 2 EGR VALVE ASSEMBLY (w/ EGR Cooler)

    Click here

  33. INSTALL EGR COOLER WITH PIPE (w/ EGR System with EGR Cooler)

    Click here

  34. TEMPORARILY INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System with EGR Cooler)

    Click here

  35. TIGHTEN ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System with EGR Cooler)

    Click here

  36. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY (w/ EGR System without EGR Cooler)

    Click here

  37. TEMPORARILY INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System without EGR Cooler)

    Click here

  38. TIGHTEN ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System without EGR Cooler)

    Click here

  39. INSTALL AIR CONNECTOR STAY (w/ EGR System)

    Click here

  40. INSTALL ELECTRIC VACUUM REGULATING VALVE ASSEMBLY (w/ EGR System)

    Click here

  41. INSTALL EGR VALVE BRACKET (w/ EGR System)

    Click here

  42. INSTALL INJECTION PIPE (w/ EGR System)

    Click here

  43. CONNECT NO. 4 WATER BY-PASS HOSE (w/ EGR System with EGR Cooler)

    Click here

  44. CONNECT NO. 3 WATER BY-PASS HOSE (w/ EGR System with EGR Cooler)

    Click here

  45. INSTALL CRANKSHAFT PULLEY

    Click here

  46. INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY

    Click here

  47. INSTALL TIMING BELT

    Click here

  48. INSTALL NO. 1 TIMING BELT COVER

    Click here

  49. INSTALL CRANKSHAFT POSITION SENSOR


    1. Attach the clamp and install the crankshaft position sensor with the bolt.

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

  50. INSTALL CAMSHAFT POSITION SENSOR


    1. Install the camshaft position sensor with the bolt.

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

  51. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  52. INSTALL VANE PUMP ASSEMBLY


    1. Install a new O-ring and the vane pump with the 2 nuts.

      Torque:
      41 N*m  { 418 kgf*cm, 30 ft.*lbf }

  53. INSTALL VACUUM PUMP ASSEMBLY


    1. Install 2 new O-rings to the vacuum pump.

    2. Install the vacuum pump with the 2 nuts.

      Torque:
      21 N*m  { 210 kgf*cm, 15 ft.*lbf }

  54. INSTALL TIMING GEAR COVER INSULATOR


    1. Install the timing gear cover insulator with the bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  55. INSTALL ENGINE OIL LEVEL SENSOR


    1. Install a new gasket and the engine oil level sensor with the 4 bolts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 ft.*lbf }

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


    1. Install the No. 2 water by-pass pipe with the 2 bolts and 2 nuts.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 ft.*lbf }

    2. Connect the 2 hoses.

  57. INSTALL THERMOSTAT


    1. Install a new gasket to the thermostat.

      Note

      When installing the gasket to the thermostat, be careful not to deform the gasket. Make sure that the gasket is properly installed to the thermostat, as shown in the illustration.

    2. A01XGPHE01
      Text in Illustration
      *1 CORRECT
      *2 INCORRECT
      *3 Gasket
      *4 Jiggle Valve
      *a Upward

      Install the thermostat to the cylinder block with the jiggle valve facing straight upward.

      Tech Tips

      The jiggle valve may be set within 30° of either side of the prescribed position.

  58. INSTALL WATER INLET


    1. Install the water inlet with the 3 bolts.

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

  59. INSTALL COMPRESSOR ELBOW STAY


    1. Install the compressor elbow stay with the 2 bolts.

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

  60. INSTALL NO. 2 CYLINDER HEAD COVER SUB-ASSEMBLY


    1. A01XFHVE01

      Install the No. 2 cylinder head cover with the 4 bolts.

      Torque:
      for bolt A
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }
      for bolt B
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

  61. INSTALL EXHAUST MANIFOLD WITH TURBOCHARGER

    Click here

  62. INSTALL TURBINE OUTLET ELBOW

    Click here

  63. CONNECT NO. 1 TURBO WATER HOSE

    Click here

  64. INSTALL NO. 1 EXHAUST MANIFOLD HEATINSULATOR

    Click here

  65. INSTALL NO. 1 TURBO INSULATOR

    Click here

  66. INSTALL COMPRESSOR INLET ELBOW

    Click here

  67. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  68. INSTALL VENTILATION PIPE

    Click here

  69. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET


    1. Install the No. 1 compressor mounting bracket with the 5 bolts.

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

  70. INSTALL GENERATOR BRACKET


    1. Install the generator bracket with the bolts.

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

  71. INSTALL GENERATOR ASSEMBLY


    1. A01XGK5E01

      Install the generator with the 2 bolts.

      Torque:
      for bolt A
      62 N*m  { 632 kgf*cm, 46 ft.*lbf }
      for bolt B
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }