БЛОК ДВИГАТЕЛЯ УСТАНОВКА
CAUTION / NOTICE / HINT
Note
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When replacing the injector sub-assemblies (including exchanging the injector sub-assemblies between the cylinders), common rail assembly, intake manifold or cylinder head sub-assembly, it is necessary to replace the injection pipe sub-assemblies with new ones.
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When replacing the fuel tube sub-assembly, supply pump assembly, common rail assembly, intake manifold or cylinder head sub-assembly, it is necessary to replace the fuel inlet pipe sub-assembly with a new one.
PROCEDURE
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INSTALL DRIVE SHAFT BEARING BRACKET
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Install the drive shaft bearing bracket with the 3 bolts.
- Torque:
- 63.7 N*m { 650 kgf*cm, 47 ft.*lbf }
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INSTALL TURBOCHARGER SUB-ASSEMBLY
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INSTALL EGR PIPE WITH COOLER SUB-ASSEMBLY
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INSTALL NO. 2 WATER BY-PASS HOSE
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INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
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INSTALL MANIFOLD CONVERTER INSULATOR SUB-ASSEMBLY
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INSTALL NO. 4 MANIFOLD CONVERTER INSULATOR
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INSTALL NO. 1 WIRE HARNESS CLAMP BRACKET
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INSTALL VACUUM TRANSMITTING HOSE ASSEMBLY
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INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY
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INSTALL NO. 1 TURBO OIL PIPE
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INSTALL NO. 3 WATER BY-PASS PIPE
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INSTALL SUPPLY PUMP ASSEMBLY
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Install a new O-ring to the supply pump assembly.
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Install the No. 1 supply pump drive coupling.
Tech Tips
Line up the No. 1 supply pump drive coupling with the groove in the camshaft end.
Note
When reusing the No. 1 supply pump drive coupling, it must be installed in the same orientation (top/bottom, front/back) as when it was removed,
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Install the supply pump assembly with the 2 bolts.
- Torque:
- 20.5 N*m { 209 kgf*cm, 15 ft.*lbf }
Tech Tips
Line up the end of the supply pump assembly drive shaft with the No. 1 supply pump drive coupling.
Note
Apply engine oil to the O-ring of the supply pump assembly.
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INSTALL NO. 3 FUEL HOSE
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INSTALL FUEL INJECTOR SEAL
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INSTALL EXHAUST FUEL ADDITION INJECTOR ASSEMBLY
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INSTALL FUEL TUBE SUB-ASSEMBLY
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INSTALL FUEL HOSE PROTECTOR
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Install the fuel hose protector to the cylinder head sub-assembly with the bolt.
- Torque:
- 20.5 N*m { 209 kgf*cm, 15 ft.*lbf }
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INSTALL NO. 4 WATER BY-PASS HOSE
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INSTALL NO. 2 WATER BY-PASS PIPE
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INSTALL NO. 8 WATER BY-PASS HOSE
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INSTALL NO. 6 WATER BY-PASS HOSE
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INSTALL WATER BY-PASS HOSE
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INSTALL NO. 1 CYLINDER BLOCK INSULATOR
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INSTALL GLOW PLUG ASSEMBLY
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Using a 10 mm deep socket wrench, install the 4 glow plug assemblies.
- Torque:
- 12.3 N*m { 125 kgf*cm, 9 ft.*lbf }
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Install the No. 1 glow plug connector with the 4 nuts.
- Torque:
- 2.2 N*m { 22 kgf*cm, 19 in.*lbf }
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Install the 4 glow plug screw grommets.
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INSTALL INTAKE MANIFOLD
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CONNECT NO. 2 INTAKE MANIFOLD
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INSTALL ENGINE COVER BRACKET
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INSTALL GAS FILTER BRACKET
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INSTALL NO. 1 GAS FILTER
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INSTALL DIESEL TURBO PRESSURE SENSOR
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INSTALL INTAKE MANIFOLD INSULATOR
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INSTALL COMMON RAIL ASSEMBLY
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INSTALL NO. 4 FUEL HOSE
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INSTALL INJECTION PIPE SUB-ASSEMBLY
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INSTALL FUEL INLET PIPE SUB-ASSEMBLY
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INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
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INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY
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INSTALL NO. 2 EGR PIPE SUB-ASSEMBLY
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INSTALL EGR VALVE BRACKET
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CONNECT NO. 8 WATER BY-PASS HOSE
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CONNECT NO. 7 WATER BY-PASS HOSE
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INSTALL DIESEL THROTTLE BODY ASSEMBLY
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INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
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INSTALL ENGINE MOUNTING BRACKET
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INSTALL STUD BOLT
Tech Tips
Perform this procedure only when replacement of the stud bolt is necessary.
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Using an 8 mm socket wrench, install the stud bolt to the engine mounting bracket.
- Torque:
- 10 N*m { 102 kgf*cm, 7 ft.*lbf }
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INSTALL NO. 4 WATER BY-PASS PIPE
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INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
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INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY
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INSTALL IDLER PULLEY COVER PLATE
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INSTALL VACUUM PUMP ASSEMBLY
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INSTALL GENERATOR ASSEMBLY
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INSTALL COMPRESSOR STAY
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Install the compressor stay to the cylinder block.
- Torque:
- 35 N*m { 357 kgf*cm, 26 ft.*lbf }
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