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 ENGINE HANGER 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


    1. Using a wrench, hold the crankshaft.

    2. B00193C

      Install the rear crankshaft balancer weight.

      Text in Illustration
      B0018FC 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. B001ARYE01
      Text in Illustration
      *1 Drive Plate and Ring Gear Sub-assembly
      *2 Rear Drive Plate Spacer
      B0018FC Automatic Transmission Side

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

      Tech Tips

      As the drive plate and ring gear sub-assembly 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. B001B0DE02

      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 ENGINE ASSEMBLY


    1. Slowly lower the engine into the engine compartment.

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

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

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

  7. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY

    Click here

  8. INSTALL NO. 2 INTAKE MANIFOLD

    Click here

  9. INSTALL INTAKE MANIFOLD

    Click here

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

    Click here

  11. INSTALL FUEL HOSE BRACKET (w/ DPF)

    Click here

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

    Click here

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

    Click here

  14. INSTALL NO. 1 WATER BY-PASS PIPE

    Click here

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

    Click here

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

    Click here

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

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

    Click here

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

    Click here

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

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

    Click here

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

    Click here

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

  24. INSTALL NO. 3 INTAKE MANIFOLD

    Click here

  25. CONNECT NO. 2 ENGINE WIRE

    Click here

  26. INSTALL INTAKE PIPE

    Click here

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

    Click here

  28. INSTALL CONNECTING WIRE (w/ DPF)

    Click here

  29. INSTALL NO. 2 INTAKE MANIFOLD INSULATOR

  30. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR

  31. INSTALL COMMON RAIL ASSEMBLY RH

    Click here

  32. INSTALL INJECTION PIPE SUB-ASSEMBLY RH

    Click here

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

    Click here

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

    Click here

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

  36. INSTALL NO. 5 INJECTION PIPE SUB-ASSEMBLY

    Click here

  37. CONNECT FUEL PUMP MOTOR WIRE

    Click here

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

    Click here

  39. INSTALL COMMON RAIL ASSEMBLY LH

    Click here

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

    Click here

  41. INSTALL INJECTION PIPE SUB-ASSEMBLY LH

    Click here

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

    Click here

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

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

    Click here

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

    Click here

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

    Click here

  47. CONNECT NO. 6 INJECTION PIPE SUB-ASSEMBLY

    Click here

  48. 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 2 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. Install the engine wire harness protector with the 3 bolts.

      2. Connect the 7 connectors.

      3. Install the wire harness bracket with the bolt.

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

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

      5. for RHD:

        Install the wire harness holder with the bolt.

      6. for RHD:

        Connect the wire harness with the wire harness holder.

      7. for LHD:

        Connect the wire harness with the wire harness clamp holder.

      8. for LHD:

        Connect the ECM connector to the ECM.

      9. for LHD:

        Attach the wire harness tab to the relay block.

      10. for LHD:

        Connect the 4 connectors to the relay block.

  49. INSTALL NO. 4 WATER BY-PASS PIPE

    Click here

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

    Click here

  51. CONNECT FUEL HOSE

  52. INSTALL AIR CLEANER PIPE

    Click here

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

    Click here

  54. INSTALL NO. 2 INTAKE AIR CONNECTOR PIPE


    1. B001AAXE02
      Text in Illustration
      *a Hose Stopper
      B0018FC 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 No. 2 intake air connector 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 No. 2 intake air connector 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 No. 2 intake air connector pipe and elbow.

      • Install the No. 2 intake air connector pipe so that the protrusion on the No. 2 intake air connector pipe side is within the range of the protrusion on the elbow side.

      • After tightening, a gap between the No. 2 intake air connector pipe and hose stopper on the elbow side is acceptable.

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

      B0018YQE04
      Text in Illustration
      *a Protrusion

    4. Connect the vacuum hose.

  55. ADJUST COMPRESSOR OIL

    Click here

  56. INSTALL COOLER COMPRESSOR ASSEMBLY


    1. B00188ZE02

      Temporarily install the cooler compressor assembly 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.

  57. INSTALL SUCTION HOSE SUB-ASSEMBLY

    Click here

  58. INSTALL NO. 1 COOLER REFRIGERANT DISCHARGE HOSE

    Click here

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

    Click here

  60. 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 assembly.

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

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

  61. INSTALL NO. 4 AIR TUBE

    Click here

  62. INSTALL NO. 2 AIR HOSE

    Click here

  63. 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 assembly.

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

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

  64. INSTALL NO. 3 AIR TUBE

    Click here

  65. INSTALL NO. 1 AIR HOSE

    Click here

  66. INSTALL DIESEL THROTTLE BODY ASSEMBLY LH

    Click here

  67. INSTALL NO. 3 INTERCOOLER SUPPORT BRACKET

    Click here

  68. INSTALL NO. 1 GAS FILTER

    Click here

  69. INSTALL AIR TUBE SUB-ASSEMBLY LH

    Click here

  70. INSTALL DIESEL THROTTLE BODY ASSEMBLY RH

    Click here

  71. INSTALL AIR TUBE SUB-ASSEMBLY RH

    Click here

  72. INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  73. CONNECT WATER HOSE SUB-ASSEMBLY

  74. CONNECT FUEL TUBE


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

    2. w/ DPF:

      Connect the No. 1 fuel main tube and fuel return tube to the No. 1 fuel tube clamp and No. 3 fuel tube clamp.

    3. w/o DPF:

      Connect the No. 1 fuel main tube and 2 fuel return tubes to the No. 1 fuel tube clamp and No. 3 fuel tube clamp.

  75. CONNECT FRONT DIFFERENTIAL BREATHER TUBE

  76. ADD ENGINE OIL

    Click here

  77. INSTALL RADIATOR ASSEMBLY

    Click here

  78. CONNECT RADIATOR SIDE DEFLECTOR LH

    Click here

  79. INSTALL TRANSMISSION OIL COOLER AIR DUCT

    Click here

  80. INSTALL FRONT BUMPER COVER

    Click here

  81. INSTALL FAN PULLEY

  82. INSTALL FAN SHROUD WITH FAN

    Click here

  83. INSTALL OIL COOLER TUBE

    Click here

  84. INSTALL V-RIBBED BELT

    Click here

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

    Click here

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

    Click here

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

    Click here

  88. CONNECT NO. 2 RADIATOR HOSE

  89. CONNECT NO. 1 RADIATOR HOSE

  90. INSTALL VANE PUMP ASSEMBLY

    Click here

  91. INSTALL RADIATOR RESERVOIR TANK ASSEMBLY

    Click here

  92. INSTALL NO. 1 OIL RESERVOIR BRACKET

    Click here

  93. INSTALL VANE PUMP OIL RESERVOIR ASSEMBLY

    Click here

  94. 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.

  95. INSTALL AIR CLEANER FILTER ELEMENT

  96. INSTALL INTAKE AIR CONNECTOR

    Click here

  97. TEMPORARILY INSTALL NO. 1 AIR CLEANER HOSE

    Click here

  98. INSTALL AIR CLEANER CAP SUB-ASSEMBLY

    Click here

  99. INSTALL INTERCOOLER ASSEMBLY

    Click here

  100. INSTALL SUB-BATTERY

  101. INSTALL MAIN BATTERY

  102. INSTALL NO. 3 ENGINE ROOM WIRE

    Click here

  103. INSTALL FRONT WHEEL

  104. 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.

  105. BLEED AIR FROM FUEL SYSTEM

    Click here

  106. ADD ENGINE COOLANT

    Click here

  107. INSPECT FOR FUEL LEAK

    Click here

  108. INSPECT FOR OIL LEAK

    Click here

  109. INSPECT FOR COOLANT LEAK

    Click here

  110. INSPECT FOR EXHAUST GAS LEAK

  111. CHARGE REFRIGERANT

    Click here

  112. WARM UP ENGINE

    Click here

  113. CHECK FOR REFRIGERANT GAS LEAK

    Click here

  114. INSTALL FRONT FENDER APRON SEAL REAR LH


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

  115. INSTALL FRONT FENDER APRON SEAL FRONT LH


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

  116. INSTALL FRONT FENDER APRON SEAL REAR RH


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

  117. INSTALL FRONT FENDER APRON SEAL FRONT RH


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

  118. INSTALL OIL PAN PROTECTOR ASSEMBLY RH (w/ DPF)

    Click here

  119. INSTALL OIL PAN PROTECTOR ASSEMBLY LH (w/ DPF)

    Click here

  120. INSTALL OIL PAN PROTECTOR ASSEMBLY (w/o DPF)

    Click here

  121. 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 }

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


    1. Install the No. 1 engine under cover sub-assembly with the 10 bolts.

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

  123. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH


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

  124. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH


    1. Install the front fender splash shield sub-assembly LH with the clip, and then install the 3 bolts and 2 screws.

  125. INSTALL COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY

    Click here

  126. INSTALL HOOD SUB-ASSEMBLY


    1. Install the hood sub-assembly 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 sub-assembly by hand.

  127. ADJUST HOOD SUB-ASSEMBLY

    Click here

  128. INSPECT ENGINE OIL LEVEL

    Click here

  129. INSPECT ENGINE COOLANT LEVEL IN RESERVOIR

    Click here

  130. INSPECT ENGINE IDLE SPEED

    Click here

  131. INSPECT MAXIMUM ENGINE SPEED

    Click here

  132. INSTALL UPPER RADIATOR SUPPORT SEAL

    Click here

  133. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

    Click here

  134. PERFORM CRANK TIME COMPENSATION RESET FUNCTION

    Click here