ENGINE UNIT(w/o Glow Plug Controller) INSTALLATION

PROCEDURE


  1. INSTALL STUD BOLT


    1. Using an 8 mm socket wrench, install the 2 stud bolts to the engine mounting bracket RH.

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

  2. INSTALL OIL PAN COVER


    1. Install the oil pan cover with the 2 bolts and 2 washer plates.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  3. INSTALL NO. 2 OIL PAN COVER SILENCER


    1. Install the No. 2 oil pan cover silencer with the 2 bolts and 2 washer plates.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  4. INSTALL NO. 5 ENGINE COVER


    1. Install the No. 5 engine cover with the 2 bolts and 2 washer plates.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

  5. INSTALL HARNESS BRACKET


    1. Install the 2 harness brackets with the 2 bolts.

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

  6. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. Install the V-ribbed belt tensioner assembly with the 2 bolts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  7. INSTALL CAMSHAFT POSITION SENSOR


    1. A01T9W0C02
      *A w/o Stop And Start System
      *B w/ Stop And Start System
      *a O-ring

      Apply a light coat of engine oil to the O-ring of the camshaft position sensor.

      Note

      If reusing the camshaft position sensor, be sure to inspect the O-ring.

    2. Install the camshaft position sensor with the bolt.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

      Note


      • If the camshaft position sensor has been dropped or subjected to a strong impact, replace it.

      • Make sure that the O-ring is not cracked or moved out of place during installation.

  8. INSTALL HOLE PLUG


    1. A01TBBFC01
      *1 O-ring

      Apply a light coat of engine oil to the O-ring of the hole plug.

      Note

      If reusing the hole plug, be sure to inspect the O-ring.

    2. Install the hole plug with the bolt.

      Torque:
      7.0 N*m  { 71 kgf*cm, 62 in.*lbf }

      Note

      Make sure that the O-ring is not cracked or moved out of place during installation.

  9. INSTALL VACUUM PUMP ASSEMBLY


    1. A01TB9HC01
      A01TCE3 Engine Oil

      Apply engine oil to 2 new O-rings, and install them to the vacuum pump assembly.

    2. A01TD6XC02
      *a Coupling Teeth
      *b Groove

      Install the vacuum pump assembly so that the coupling teeth of the vacuum pump assembly and groove of the camshaft can engage.

      Note

      Ensure that the vacuum pump assembly is installed securely.

    3. Install 2 new bolts.

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

      Note

      After tightening the bolts, ensure that the contact surface of the vacuum pump assembly is flush with the cylinder head sub-assembly.

  10. INSTALL INLET WATER PIPE


    1. Install the inlet water pipe with the 2 bolts.

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

  11. INSTALL INLET WATER HOSE LH


    1. A01TCHTC01
      *a View A
      *b Upper
      *c LH

      Install the inlet water hose LH.

      Tech Tips

      The clip at the inlet water housing can be installed in any orientation, as long as it does not contact any of the surrounding parts.

  12. INSTALL INLET WATER HOSE RH


    1. A01T8TRC01
      *a View A
      *b View B
      *c Upper
      *d LH
      *e Rear

      Install the inlet water hose RH.

  13. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Install a new O-ring to the water by-pass pipe sub-assembly.

      Note

      Apply water to the O-ring contacting surface of the water inlet housing before installing the water by-pass pipe sub-assembly.

    2. A01TCLTN01

      Install the water by-pass pipe sub-assembly with the 2 bolts, in the order shown in the illustration.

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

    3. Install the 2 hose clamps to the water by-pass pipe sub-assembly.

  14. INSTALL WATER BY-PASS HOSE


    1. A01TCINC01
      *a View A
      *b View B
      *c Upper
      *d Front
      *e RH

      Install the water by-pass hose to the water by-pass pipe sub-assembly.

  15. INSTALL NO. 2 WATER BY-PASS HOSE


    1. A01T9XXC01
      *a View A
      *b Upper
      *c LH

      Install the No. 2 water by-pass hose to the water by-pass pipe sub-assembly.

  16. INSTALL NO. 3 WATER BY-PASS HOSE


    1. A01TA6SC01
      *a View A
      *b Front
      *c LH

      Install the No. 3 water by-pass hose.

  17. INSTALL NO. 4 WATER BY-PASS HOSE


    1. A01TC8HC01
      *a View A
      *b Upper
      *c Rear

      Install the No. 4 water by-pass hose to the inlet water pipe.

  18. INSTALL NO. 2 OIL COOLER HOSE


    1. A01T902C01
      *a View A
      *b Front
      *c LH

      Connect the 2 hose clamps and install the No. 2 oil cooler hose.

      Note

      Align the paint mark of the No. 2 oil cooler hose with the center of the clamp.

    2. Install the 2 hose clamps.

      Note

      Align the paint mark of the No. 2 oil cooler hose with the center of the clamp.

  19. INSTALL OIL COOLER HOSE


    1. A01TBD9C01
      *a View A
      *b Front
      *c LH

      Install the oil cooler hose.

  20. INSTALL NO. 2 CYLINDER HEAD COVER


    1. Install the No. 2 cylinder head cover.

  21. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR


    1. Install the No. 1 intake manifold insulator.

  22. INSTALL COMMON RAIL ASSEMBLY


    1. Install the common rail assembly to the cylinder head sub-assembly with the 2 bolts.

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

  23. INSTALL NO. 1 SUPPLY PUMP DRIVE COUPLING

    Click here

  24. TEMPORARILY INSTALL SUPPLY PUMP ASSEMBLY

    Note

    Clean the seal surfaces of the inlet fuel pipe sub-assembly, supply pump assembly and common rail assembly before installation.


    1. Apply a light coat of engine oil to a new O-ring.

    2. Install the O-ring to the supply pump assembly.

    3. Temporarily install the supply pump assembly with the 3 bolts.

    4. A01TCWRC01
      *a Upper
      *b LH

      Connect the No. 1 fuel hose to the supply pump assembly.

  25. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Note


    • When replacing the supply pump assembly, the fuel inlet pipe sub-assembly must also be replaced.

    • Replace the fuel inlet pipe sub-assembly with a new one when the fuel inlet pipe sub-assembly has been removed and reinstalled more than 5 times.


    1. A01TAACC01
      *a CORRECT
      *b INCORRECT

      Temporarily install the fuel inlet pipe sub-assembly to the supply pump assembly and common rail assembly.

      Note

      Install the fuel inlet pipe sub-assembly and union nut with their centers aligned.

    2. Install the supply pump assembly with the 3 bolts.

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

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

      Torque:
      28 N*m  { 286 kgf*cm, 21 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.

    4. Using a 17 mm wrench, hold the supply pump assembly nut, and using a 17 mm union nut wrench, tighten the fuel inlet pipe sub-assembly union nut on the supply pump assembly side.

      Torque:
      28 N*m  { 286 kgf*cm, 21 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.

  26. INSTALL NO. 2 FUEL HOSE


    1. Install the No. 2 fuel hose.

  27. INSTALL INJECTION NOZZLE SEAT

    Click here

  28. INSTALL INJECTOR ASSEMBLY

    Click here

  29. INSTALL NOZZLE HOLDER CLAMP SEAT

    Click here

  30. INSTALL NO. 1 NOZZLE HOLDER CLAMP

    Click here

  31. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY


    1. A01TC4R

      Install the nozzle leakage pipe assembly to each injector assembly.


      1. Make sure that the lock bush is at the top position.

      2. Connect the rest arm to the injector assembly and push both sides of the return plug until the rest arm engages the injector assembly, as shown in the illustration.

        A01T8LWC03
        *1 Injector - -
        *a Push *b Lock Bush
        *c Return Plug *d Rest Arm

        Tech Tips

        Push the nozzle leakage pipe assembly until it makes a click sound.

      3. Push the lock bush until it fits with the return plug, as shown in the illustration.

    2. Connect the nozzle leakage pipe assembly and install a new retainer spring to the supply pump assembly.

  32. INSTALL NOZZLE LEAKAGE PIPE SET CLAMP


    1. Install the 3 nozzle leakage pipe set clamps to the nozzle leakage pipe assembly.

  33. INSTALL NO. 2 INTAKE MANIFOLD INSULATOR

    Click here

  34. INSTALL GLOW PLUG ASSEMBLY


    1. Clean the cylinder head sub-assembly glow plug assembly installation holes.

    2. Install the 4 glow plug assemblies.

      Torque:
      12.5 N*m  { 127 kgf*cm, 9 ft.*lbf }

  35. INSTALL NO. 1 GLOW PLUG CONNECTOR


    1. Install the No. 1 glow plug connector with the 4 nuts.

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

    2. Install the 4 screw grommets.

  36. INSTALL NO. 1 INJECTION PIPE SUB-ASSEMBLY

    Click here

  37. INSTALL NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Click here

  38. INSTALL NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Click here

  39. INSTALL INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY


    1. Install a new intake air connector gasket to the cylinder head sub-assembly.

    2. Install the intake air connector with diesel throttle body with the 2 bolts and 2 nuts.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

    3. Connect the vacuum transmitting hose to the hose clamp.

  40. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Install a new O-ring to the engine oil level dipstick guide.

    2. Install the engine oil level dipstick guide with the bolt.

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

  41. INSTALL ENGINE OIL LEVEL DIPSTICK


    1. Install the engine oil level dipstick.

  42. INSTALL EGR VALVE (ELECTRIC EGR CONTROL VALVE ASSEMBLY)

    Click here

  43. INSTALL HARNESS BRACKET

    Click here

  44. INSTALL NO. 1 EGR COOLER BRACKET


    1. Install the No. 1 EGR cooler bracket to the cylinder head sub-assembly with the 2 bolts.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

  45. INSTALL EGR WITH COOLER PIPE ASSEMBLY


    1. Install 2 new gaskets to the cylinder head sub-assembly and electric EGR control valve assembly.

    2. Install the EGR with cooler pipe assembly with the 4 bolts and 2 nuts.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
    3. A01TASDC01
      *a View A
      *b View B
      *c Rear
      *d LH

      Connect the No. 2 water by-pass hose to the EGR with cooler pipe assembly.

    4. Connect the No. 2 oil cooler hose to the EGR with cooler pipe assembly.

    5. Connect the vacuum hose to the EGR with cooler pipe assembly.

    6. Connect the 3 vacuum transmitting hoses to the vacuum switching valve assembly and turbo pressure sensor.

  46. INSTALL GENERATOR BRACKET


    1. Install the generator bracket to the cylinder block sub-assembly with the 2 bolts.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  47. INSTALL GENERATOR ASSEMBLY


    1. A01TAC5N01

      Install the generator assembly with the 2 bolts.

      Torque:
      Bolt A
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }
      Bolt B
      54 N*m  { 551 kgf*cm, 40 ft.*lbf }

  48. INSTALL ENGINE COVER BRACKET (w/ No. 1 Engine Cover)


    1. Install the engine cover bracket to the engine mounting bracket RH with the bolt.

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