INTAKE MANIFOLD INSTALLATION

CAUTION / NOTICE / HINT

Note

When replacing the injector assemblies (including shuffling the injector assemblies between the cylinders), common rail assembly, cylinder head sub-assembly, or intake manifold, it is necessary to replace the injection pipe sub-assemblies with new ones.
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

INSTALL RING PIN

Note

It is not necessary to remove a ring pin unless it is being replaced.
1. for Intake Manifold and No. 2 Intake Manifold:
  1. Text in Illustration
    
    *a Protrusion Height
    
    Using a plastic-faced hammer, tap in the ring pins to the intake manifold and No. 2 intake manifold.
    
    Standard protrusion height
    
    4.4 to 5.6 mm (0.173 to 0.222 in.)

Text in Illustration
*a	Protrusion Height

Standard protrusion height
4.4 to 5.6 mm (0.173 to 0.222 in.)

INSTALL STUD BOLT

Note

If a stud bolt is deformed or its threads are damaged, replace it.

for Intake Pipe Side:

Text in Illustration
*a	42 mm (1.65 in.)
*b	20 mm (0.787 in.)
*c	13 mm (0.512 in.)

Using an E8 "TORX" wrench, install the stud bolts to the intake pipe.

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

for No. 3 Intake Manifold Side:

Using an E8 "TORX" wrench, install the stud bolts labeled A to the No. 3 intake manifold.

Torque:

6.0 N*m { 61 kgf*cm, 53 in.*lbf }
Using an E6 "TORX" wrench, install the stud bolts labeled B to the No. 3 intake manifold.

Torque:

5.0 N*m { 51 kgf*cm, 44 in.*lbf }
Using an E6 "TORX" wrench, install the stud bolts labeled C to the No. 3 intake manifold.

Torque:

4.5 N*m { 46 kgf*cm, 40 in.*lbf }

Using an E6 "TORX" wrench, install the stud bolt labeled D to the No. 3 intake manifold.

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

Text in Illustration
*a	42 mm (1.65 in.)	*b	20 mm (0.787 in.)
*c	13 mm (0.512 in.)	*d	24 mm (0.945 in.)
*e	9.0 mm (0.354 in.)	*f	39 mm (1.54 in.)
*g	21 mm (0.827 in.)	-	-

INSTALL NO. 2 INTAKE MANIFOLD
1. Install a new gasket and the No. 2 intake manifold to the cylinder head sub-assembly LH with the 9 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL INTAKE MANIFOLD
1. Install a new gasket and the intake manifold to the cylinder head sub-assembly with the 9 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL NO. 1 FUEL PIPE CLAMP (w/ DPF)
1. Install the 2 No. 1 fuel pipe clamps to the cylinder head sub-assembly and cylinder head sub-assembly LH with the 2 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL FUEL HOSE BRACKET (w/ DPF)
1. Install the fuel hose bracket to the cylinder head sub-assembly LH with the bolt.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL NO. 1 WATER BY-PASS PIPE
1. Text in Illustration
  
  *A w/ DPF
  
  *B w/o DPF
  
  Temporarily install a new gasket and the No. 1 water by-pass pipe to the cylinder block sub-assembly with the union bolt and bolt.
2. Tighten the union bolt and bolt in the order shown in the illustration.
  
  Torque:
  
  for union bolt
  
  59 N*m { 600 kgf*cm, 43 ft.*lbf }
  
  for bolt
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
INSTALL FUEL TUBE SUB-ASSEMBLY (w/ DPF)
1. Attach the 3 clamps to the 2 No. 1 fuel pipe clamps and fuel hose bracket.
2. Connect the 3 fuel tube connectors to the supply pump assembly and 2 exhaust fuel addition injector assemblies Click here.
INSTALL FUEL COOLER ASSEMBLY (w/o DPF)

Click here
INSTALL NO. 6 WATER BY-PASS HOSE (w/o DPF)
1. Install the No. 6 water by-pass hose to the fuel cooler assembly and No. 1 water by-pass pipe, and slide the 2 clamps to secure the hose.
INSTALL NO. 4 NOZZLE LEAKAGE PIPE (w/o DPF)
1. Temporarily install a new gasket and the No. 4 nozzle leakage pipe to the cylinder head sub-assembly LH and No. 2 intake manifold with the union bolt and bolt.
2. Tighten the union bolt and bolt in the order shown in the illustration.
  
  Torque:
  
  for union bolt
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  
  for bolt
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
3. Connect the No. 2 fuel hose to the fuel cooler assembly, and slide the clamp to secure the hose.
INSTALL NO. 3 NOZZLE LEAKAGE PIPE (w/o DPF)
1. Temporarily install a new gasket and the No. 3 nozzle leakage pipe to the cylinder head sub-assembly and intake manifold with the union bolt and bolt.
2. Tighten the union bolt and bolt in the order shown in the illustration.
  
  Torque:
  
  for union bolt
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  
  for bolt
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
3. Connect the No. 1 fuel hose to the fuel cooler assembly, and slide the clamp to secure the hose.
INSTALL EGR COOLER INSULATOR (w/ EGR System)
1. Install the EGR cooler insulator to the starter assembly.
INSTALL EGR VALVE ASSEMBLY WITH EGR COOLER ASSEMBLY (w/ EGR System)
1. Connect the No. 5 water by-pass hose to the water by-pass outlet sub-assembly, and slide the clamp to secure the hose.
2. Install 2 new gaskets and the EGR valve assembly with EGR cooler assembly to the intake manifold, No. 2 intake manifold, cylinder head sub-assembly and cylinder head sub-assembly LH with the 6 bolts labeled A and 4 bolts labeled B shown in the illustration.
  
  Torque:
  
  for bolt A
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  
  for bolt B
  
  29 N*m { 296 kgf*cm, 21 ft.*lbf }
  
  Tech Tips
  
  The gasket claws should face toward the No. 1 EGR pipe sub-assembly and No. 2 EGR pipe sub-assembly.
INSTALL EGR PIPE INSULATOR (w/ EGR System)
1. Install the EGR pipe insulator to the No. 2 EGR pipe sub-assembly and No. 1 EGR pipe sub-assembly with the 2 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  
  Note
  
  If the No. 1 EGR pipe sub-assembly and No. 2 EGR pipe sub-assembly insulator installation stay is deformed, or the bolt holes of the EGR pipe insulator do not align, replace the No. 1 EGR pipe sub-assembly and No. 2 EGR pipe sub-assembly as a set.
INSTALL INTAKE MANIFOLD INSULATOR (w/ EGR System)
1. Install the intake manifold insulator to the EGR cooler assembly.

Text in Illustration
*A	w/ DPF
*B	w/o DPF

INSTALL NO. 3 INTAKE MANIFOLD

Install 2 new gaskets to the intake manifold and No. 2 intake manifold.

Install the No. 3 intake manifold to the intake manifold and No. 2 intake manifold with the 16 bolts.

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

Bolt Length
Item	Length
Bolt A	25 mm (0.984 in.)
Bolt B	70 mm (2.76 in.)

Text in Illustration
	for bolt A
	for bolt B

CONNECT NO. 2 ENGINE WIRE
1. Connect the No. 2 engine wire with the 3 bolts.
  
  Torque:
  
  for bolt A
  
  13 N*m { 133 kgf*cm, 10 ft.*lbf }
  
  for bolt B
  
  32 N*m { 326 kgf*cm, 24 ft.*lbf }
2. Attach the 2 wire harness clamps.
INSTALL INTAKE PIPE
1. w/ EGR System:
  1. Install 2 new gaskets and the intake pipe to the No. 3 intake manifold and No. 3 EGR pipe sub-assembly with the 6 bolts and 2 nuts.
    
    Torque:
    
    21 N*m { 214 kgf*cm, 15 ft.*lbf }
2. w/o EGR System:
  1. Install a new gasket and the intake pipe to the No. 3 intake manifold with the 4 bolts and 2 nuts.
    
    Torque:
    
    21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL NO. 2 INTAKE MANIFOLD INSULATOR
1. Install the No. 2 intake manifold insulator to the No. 3 intake manifold.
INSTALL NO. 1 INTAKE MANIFOLD INSULATOR
1. Install the No. 1 intake manifold insulator to the No. 3 intake manifold.
INSTALL NO. 1 NOZZLE LEAKAGE PIPE (w/ DPF)

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

Click here
INSTALL NO. 3 NOZZLE LEAKAGE PIPE (w/ DPF)
1. Temporarily install 2 new gaskets and the No. 3 nozzle leakage pipe to the No. 2 nozzle leakage pipe, No. 1 nozzle leakage pipe, fuel hose bracket and intake pipe with the 2 injector hollow screws and 3 bolts.
2. Tighten the 2 injector hollow screws and 3 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
  
  Tech Tips
  
  Tighten the injector hollow screws first, and then tighten the bolts.
INSTALL CONNECTING WIRE (w/ DPF)
1. Attach the 2 clamps to install the connecting wire No. 3 nozzle leakage pipe.
INSTALL COMMON RAIL ASSEMBLY RH

Click here
INSTALL INJECTION PIPE SUB-ASSEMBLY RH
1. Text in Illustration
  
  *a Torque Wrench Fulcrum Length
  
  Using a 17 mm union nut wrench, install 4 new injection pipe sub-assemblies to the common rail assembly RH and injector assembly RH.
  
  Torque:
  
  Specified tightening torque
  
  34 N*m { 347 kgf*cm, 25 ft.*lbf }
  Tech Tips
  - Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.
  - When using a union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 29 N*m (297 kgf*cm, 21 ft.*lbf)
2. Install the 4 injection pipe clamps with the 2 nuts.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
INSTALL NO. 1 FUEL INJECTOR PROTECTOR (w/ DPF)

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

Click here
INSTALL CYLINDER HEAD COVER SILENCER (w/ DPF)

Click here
INSTALL NO. 5 INJECTION PIPE SUB-ASSEMBLY
1. Temporarily install a new No. 5 injection pipe sub-assembly to the common rail assembly RH and supply pump assembly by hand.
  
  Note
  
  Make sure there is no damage or foreign matter on the seal surfaces.
2. w/ DPF:
  1. Temporarily install the used gasket and fuel filter to injection pump fuel pipe sub-assembly to the cylinder head cover sub-assembly LH with the nut, bolt and union bolt.
3. w/o DPF:
  1. Temporarily install the used gasket and No. 2 fuel pipe sub-assembly to the No. 3 intake manifold and cylinder head cover sub-assembly with the nut, bolt and union bolt.
4. Text in Illustration
  
  *A w/ DPF
  
  *B w/o DPF
  
  Install the No. 2 injection pipe clamp with the bolt.
  
  Torque:
  
  4.0 N*m { 41 kgf*cm, 35 in.*lbf }
5. Text in Illustration
  
  *a Torque Wrench Fulcrum Length
  
  Using a 17 mm union nut wrench, tighten the No. 5 injection pipe sub-assembly ends.
  
  Torque:
  
  Specified tightening torque
  
  34 N*m { 347 kgf*cm, 25 ft.*lbf }
  Tech Tips
  
  Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.
  
  When using a union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 29 N*m (297 kgf*cm, 21 ft.*lbf)
6. Remove the bolt and No. 2 injection pipe clamp.
7. Remove the union bolt and gasket.
8. w/ DPF:
  1. Remove the bolt, nut, fuel filter to injection pump fuel pipe sub-assembly and gasket from the No. 3 intake manifold and cylinder head cover sub-assembly LH.
9. w/o DPF:
  1. Remove the bolt, nut and No. 2 fuel pipe sub-assembly from the No. 3 intake manifold and cylinder head cover sub-assembly.
CONNECT FUEL PUMP MOTOR WIRE
1. Install the fuel pump motor wire to the No. 3 intake manifold with the bolt.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Connect the connector.
INSTALL FUEL FILTER TO INJECTION PUMP FUEL PIPE SUB-ASSEMBLY

Note

Check for damage and foreign matter on the fuel filter to injection pump fuel pipe sub-assembly installation surface of the supply pump assembly.

If there is foreign matter, remove it from the installation surface.

If the installation surface is damaged, replace the supply pump assembly.
1. w/ DPF:
  1. Temporarily install a new gasket and fuel filter to injection pump fuel pipe sub-assembly to the No. 3 intake manifold and cylinder head cover sub-assembly LH with the nut, bolt and union bolt.
  2. Install the No. 2 injection pipe clamp with the bolt.
    
    Torque:
    
    4.0 N*m { 41 kgf*cm, 35 in.*lbf }
  3. Tighten the union bolt, bolt and nut.
    
    Torque:
    
    for union bolt
    
    12 N*m { 125 kgf*cm, 9 ft.*lbf }
    
    for bolt and nut
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
  4. Connect the fuel pump hose to the fuel filter to injection pump fuel pipe sub-assembly, and slide the clamp to secure the hose.
2. w/o DPF:
  1. Install the fuel filter to injection pump fuel pipe sub-assembly to the cylinder head cover sub-assembly LH with the bolt.
    
    Torque:
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
  2. Connect the No. 3 fuel hose to the fuel filter to injection pump fuel pipe sub-assembly, and slide the clamp to secure the hose.
  3. Connect the fuel pump hose to the No. 1 fuel pipe, and slide the clamp to secure the hose.
INSTALL COMMON RAIL ASSEMBLY LH

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

Click here
INSTALL NO. 2 FUEL PIPE (w/ DPF)

Click here
INSTALL INJECTION PIPE SUB-ASSEMBLY LH
1. Text in Illustration
  
  *a Torque Wrench Fulcrum Length
  
  Using a 17 mm union nut wrench, install the 4 new injection pipe sub-assemblies to the common rail assembly LH and injector assembly LH.
  
  Torque:
  
  Specified tightening torque
  
  34 N*m { 347 kgf*cm, 25 ft.*lbf }
  Tech Tips
  - Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.
  - When using a union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 29 N*m (297 kgf*cm, 21 ft.*lbf)
2. Install the 4 injection pipe clamps with the 2 nuts.
  
  Torque:
  
  5.0 N*m { 51 kgf*cm, 44 in.*lbf }
INSTALL NO. 4 NOZZLE LEAKAGE PIPE (w/ DPF)
1. Temporarily install a new gasket and No. 4 nozzle leakage pipe to the No. 2 nozzle leakage pipe with the check valve.
2. Tighten the check valve.
  
  Torque:
  
  32 N*m { 321 kgf*cm, 23 ft.*lbf }
3. Connect the No. 5 fuel hose to the fuel filter to injection pump fuel pipe sub-assembly, and slide the clamp to secure the hose.
INSTALL CYLINDER HEAD COVER SILENCER LH (w/ DPF)

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

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

Click here
CONNECT NO. 6 INJECTION PIPE SUB-ASSEMBLY
1. w/ EGR System:
  1. Temporarily install a new No. 6 injection pipe sub-assembly to the common rail assembly LH and common rail assembly RH.
    
    Note
    
    Make sure there is no damage or foreign matter on the seal surfaces.
  2. Install the 2 No. 2 injection pipe clamps with the 2 nuts.
    
    Torque:
    
    5.0 N*m { 51 kgf*cm, 44 in.*lbf }
  3. Text in Illustration
    
    *a Torque Wrench Fulcrum Length
    
    Using a 17 mm union nut wrench, tighten the No. 6 injection pipe sub-assembly ends.
    
    Torque:
    
    Specified tightening torque
    
    34 N*m { 347 kgf*cm, 25 ft.*lbf }
    Tech Tips
    
    Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.
    
    When using a union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 29 N*m (297 kgf*cm, 21 ft.*lbf)
2. w/o EGR System:
  1. Temporarily install a new No. 6 injection pipe sub-assembly to the common rail assembly LH, common rail assembly RH and No. 3 intake manifold.
    
    Note
    
    Make sure there is no damage or foreign matter on the seal surfaces.
  2. Install the No. 6 injection pipe sub-assembly bracket to the No. 3 intake manifold with the bolt.
    
    Torque:
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
  3. Install the No. 2 injection pipe clamp with the nut.
    
    Torque:
    
    5.0 N*m { 51 kgf*cm, 44 in.*lbf }
  4. Text in Illustration
    
    *a Torque Wrench Fulcrum Length
    
    Using a 17 mm union nut wrench, tighten the No. 6 injection pipe sub-assembly ends.
    
    Torque:
    
    Specified tightening torque
    
    34 N*m { 347 kgf*cm, 25 ft.*lbf }
    Tech Tips
    
    Calculate the torque wrench reading when changing the fulcrum length of the torque wrench Click here.
    
    When using a union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 29 N*m (297 kgf*cm, 21 ft.*lbf)
INSTALL NO. 2 FUEL PIPE SUB-ASSEMBLY (w/o DPF)
Note

Check for damage and foreign matter on the No. 2 fuel pipe sub-assembly installation surface of the supply pump assembly.

If there is foreign matter, remove it from the installation surface. If the installation surface is damaged, replace the supply pump assembly.
1. Temporarily install a new gasket and the No. 2 fuel pipe sub-assembly to the No. 3 intake manifold and cylinder head cover sub-assembly with the union bolt, nut and bolt.
2. Tighten the union bolt, nut and bolt in the order shown in the illustration.
  
  Torque:
  
  for union bolt
  
  12 N*m { 125 kgf*cm, 9 ft.*lbf }
  
  for bolt and nut
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
3. Install the No. 2 injection pipe clamp with the bolt.
  
  Torque:
  
  4.0 N*m { 41 kgf*cm, 35 in.*lbf }
4. Connect the No. 1 fuel hose to the No. 5 nozzle leakage pipe, and slide the clamp to secure the hose.
CONNECT ENGINE WIRE
1. 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. Attach the 3 wire harness clamps and connect the 4 connectors.
2. RH Side:
  1. Install the engine wire harness protector with the 3 bolts.
  2. Connect the 7 connectors.
  3. Attach the wire harness clamp.
  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 clamp holder with the bolt.
  7. for RHD:
    
    Connect the wire harness with the wire harness clamp holder.
3. 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 { 87 kgf*cm, 74 in.*lbf }
  6. Attach the wire harness clamp.
INSTALL NO. 4 WATER BY-PASS PIPE
1. w/ EGR System:
  1. w/o DPF:
    
    Connect the No. 7 water by-pass hose to the No. 4 water by-pass pipe, and slide the clamp to secure the hose.
  2. Connect the water inlet hose to the No. 4 water by-pass pipe, and slide the clamp to secure the hose.
  3. Connect the water hose to the water by-pass pipe, and slide the clamp to secure the hose.
  4. Connect the No. 4 water by-pass hose to the No. 3 water by-pass pipe, and slide the clamp to secure the hose.
  5. Install the No. 4 water by-pass pipe to the No. 3 intake manifold with the 2 bolts and nut.
    
    Torque:
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
    
    Tech Tips
    
    First tighten the 2 bolts and then tighten the nut.
2. w/o EGR System:
  1. Connect the No. 7 water by-pass hose to the No. 4 water by-pass pipe, and slide the clamp to secure the hose.
  2. Connect the water inlet hose to the No. 4 water by-pass pipe, and slide the clamp to secure the hose.
  3. Connect the water hose to the water by-pass pipe, and slide the clamp to secure the hose.
  4. Install the No. 4 water by-pass pipe to the No. 3 intake manifold with the 2 bolts and nut.
    
    Torque:
    
    10 N*m { 102 kgf*cm, 7 ft.*lbf }
    
    Tech Tips
    
    First tighten the 2 bolts and then tighten the nut.
INSTALL NO. 3 WATER BY-PASS PIPE (w/o Viscous Heater)
1. Install the No. 3 water by-pass pipe to the cylinder head cover sub-assembly with the 2 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
2. Connect the water hose and No. 2 water by-pass hose to the No. 4 water by-pass pipe, and slide the 2 clamps to secure the hose.
CONNECT FUEL HOSE
1. w/ DPF:
  1. Connect the 2 fuel hoses to the fuel filter to injection pump fuel pipe sub-assembly, and slide the 2 clamps to secure the hose.
2. w/o DPF:
  1. Connect the 2 fuel hoses to the fuel filter to injection pump fuel pipe sub-assembly, and slide the 2 clamps to secure the hose.
  2. Connect the fuel hose to fuel pipe sub-assembly, and slide the clamp to secure the hose.
INSTALL AIR CLEANER PIPE
1. Connect the air cleaner pipe to the intake air connector pipe.
2. Install the air cleaner pipe to the No. 3 intake manifold with the bolt.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
3. Tighten the hose clamp.
  
  Torque:
  
  6.3 N*m { 64 kgf*cm, 56 in.*lbf }
INSTALL HEATER WATER PIPE SUB-ASSEMBLY (w/ Viscous Heater)
1. Install the heater water pipe sub-assembly to the air cleaner pipe and cylinder head cover sub-assembly with the 4 bolts.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }
2. Connect the 4 water hoses to the viscous with magnet clutch heater assembly, No. 4 water by-pass pipe and No. 2 water by-pass pipe, and slide the 4 clamps to secure the hose.
INSTALL NO. 2 AIR CLEANER PIPE SUB-ASSEMBLY
1. Connect the No. 2 air cleaner pipe sub-assembly to the No. 2 intake air connector pipe.
2. Connect the ventilation hose to the oil separator assembly.
3. Install the No. 2 air cleaner pipe sub-assembly to the No. 3 intake manifold with the bolt.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
4. Tighten the hose clamp.
  
  Torque:
  
  6.3 N*m { 64 kgf*cm, 56 in.*lbf }
INSTALL NO. 4 AIR TUBE
1. Text in Illustration
  
  *a Paint Mark
  
  *b Top
  
  Install the No. 4 air tube to the air tube support with the bolt.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
2. Tighten the hose clamp.
  
  Torque:
  
  6.3 N*m { 64 kgf*cm, 56 in.*lbf }
  
  Tech Tips
  
  Make sure the direction of the hose clamp is as shown in the illustration.
3. Install the suction hose sub-assembly to the No. 4 air tube with the bolt.
  
  Torque:
  
  9.8 N*m { 100 kgf*cm, 87 in.*lbf }

Text in Illustration
*a	Torque Wrench Fulcrum Length

Text in Illustration
*A	w/ DPF
*B	w/o DPF

Text in Illustration
*a	Torque Wrench Fulcrum Length

Text in Illustration
*a	Torque Wrench Fulcrum Length

Text in Illustration
*a	Torque Wrench Fulcrum Length

Text in Illustration
*a	Torque Wrench Fulcrum Length

Text in Illustration
*a	Paint Mark
*b	Top

INSTALL NO. 2 AIR HOSE

Text in Illustration
*a	Protrusion
*b	Paint Mark
*c	Top

Connect the No. 2 air hose to the No. 4 air tube with the hose clamp.

Torque:: 6.3 N*m { 64 kgf*cm, 56 in.*lbf }

Tech Tips

Align the paint mark of the No. 2 air hose with the protrusion and push on the No. 2 air hose so that distance B is 0 to 3.0 mm (0 to 0.118 in.).
Position the clamp so that distance A is 2.0 to 6.0 mm (0.0787 to 0.236 in.).
Make sure the direction of the hose clamp is as shown in the illustration.

INSTALL NO. 3 AIR TUBE
1. Text in Illustration
  
  *a Paint Mark
  
  *b Top
  
  Install the No. 3 air tube to the intake air connector bracket with the bolt.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
2. Tighten the hose clamp.
  
  Torque:
  
  6.3 N*m { 64 kgf*cm, 56 in.*lbf }
  
  Tech Tips
  
  Make sure the direction of the hose clamp is as shown in the illustration.
3. Install the wire harness bracket with the bolt.
4. Install the ground wire with the nut, and attach the wire harness clamp.
  
  Torque:
  
  8.4 N*m { 85 kgf*cm, 74 in.*lbf }

Text in Illustration
*a	Paint Mark
*b	Top

INSTALL NO. 1 AIR HOSE

Text in Illustration
*a	Protrusion
*b	Paint Mark
*c	Top

Connect the No. 1 air hose to the No. 3 air tube with the hose clamp.

Torque:: 6.3 N*m { 64 kgf*cm, 56 in.*lbf }

Tech Tips

Align the paint mark of the No. 1 air hose with the protrusion and push on the No. 1 air hose so that distance B is 0 to 3.0 mm (0 to 0.118 in.).
Position the clamp so that distance A is 2.0 to 6.0 mm (0.0787 to 0.236 in.).
Make sure the direction of the hose clamp is as shown in the illustration.

INSTALL INTAKE AIR CONNECTOR
1. Connect the intake air connector to the air cleaner pipe and No. 2 air cleaner pipe sub-assembly.
2. Install the intake air connector to the timing chain cover sub-assembly with the 2 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
3. Tighten the 2 hose clamps.
  
  Torque:
  
  6.3 N*m { 64 kgf*cm, 56 in.*lbf }
4. Attach the 3 wire harness clamps.
5. w/o Viscous Heater:
  1. Connect the connector to the water temperature sensor.
6. w/ Viscous Heater:
  1. Connect the 2 connectors to the water temperature sensor and viscous with magnet clutch heater assembly.
TEMPORARILY INSTALL NO. 1 AIR CLEANER HOSE
1. Temporarily install the No. 1 air cleaner hose to the intake air connector.
INSTALL AIR CLEANER CAP SUB-ASSEMBLY
1. Connect the air cleaner cap sub-assembly to the No. 1 air cleaner hose, and install the air cleaner cap sub-assembly with the 4 clamps.
2. Connect the mass air flow meter sub-assembly connector and attach the wire harness clamp to the air cleaner cap sub-assembly.
3. Align the protrusion of the air cleaner cap sub-assembly and the concave portion of the No. 1 air cleaner hose.
4. Tighten the 2 hose clamps.
  
  Torque:
  
  2.5 N*m { 25 kgf*cm, 22 in.*lbf }
INSTALL DIESEL THROTTLE BODY ASSEMBLY LH

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INSTALL NO. 3 INTERCOOLER SUPPORT BRACKET

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INSTALL NO. 1 GAS FILTER

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INSTALL AIR TUBE SUB-ASSEMBLY LH

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INSTALL DIESEL THROTTLE BODY ASSEMBLY RH

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INSTALL AIR TUBE SUB-ASSEMBLY RH

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INSTALL NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE
1. Apply a light coat of engine oil to a new O-ring.
2. Install the O-ring to the No. 2 engine oil level dipstick guide.
3. Install the No. 2 engine oil level dipstick guide to the cylinder head cover sub-assembly and air tube sub-assembly RH with the 2 bolts.
  
  Torque:
  
  10 N*m { 102 kgf*cm, 7 ft.*lbf }
4. Connect the engine oil level dipstick guide oil hose to the cylinder head cover sub-assembly.
5. Connect the wire harness clamp to the No. 2 engine oil level dipstick guide.
CONNECT WATER HOSE SUB-ASSEMBLY
1. w/ Viscous Heater:
  1. Connect the 6 water hose sub-assemblies to the heater water pipe sub-assembly, heater pipe and air conditioning radiator assembly, and slide the 6 clamps to secure the hoses.
2. w/o Viscous Heater:
  1. Connect the 6 water hose sub-assemblies to the No. 3 water by-pass pipe, heater pipe and air conditioning radiator assembly, and slide the 6 clamps to secure the hoses.
INSTALL INTERCOOLER ASSEMBLY

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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.
ADD ENGINE COOLANT

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INSPECT FOR FUEL LEAK
- w/ DPF: Click here
- w/o DPF: Click here
INSPECT FOR COOLANT LEAK

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INSPECT FOR OIL LEAK

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INSTALL UPPER RADIATOR SUPPORT SEAL

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INSTALL NO. 1 ENGINE UNDER COVER SUB-ASSEMBLY

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INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH

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INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY LH

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