БЛОК ДВИГАТЕЛЯ УСТАНОВКА
CAUTION / NOTICE / HINT
Note
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When replacing the injectors (including shuffling the injectors between the cylinders), common rail assembly, intake manifold or cylinder head sub-assembly, it is necessary to replace the injection pipes with new ones.
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When replacing the fuel 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 COOLER WITH PIPE 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 WIRING 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 FUEL SUPPLY PUMP ASSEMBLY
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Apply a light coat of engine oil to a new O-ring.
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Install a new O-ring to the fuel supply pump assembly.
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Install the No. 1 supply pump drive coupling.
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.
Tech Tips
Line up the No. 1 supply pump drive coupling with the groove in the camshaft end.
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Install the fuel supply pump assembly with the 2 bolts.
- Torque:
- 21 N*m { 209 kgf*cm, 15 ft.*lbf }
Tech Tips
Line up the end of the supply pump drive shaft with the No. 1 supply pump drive coupling.
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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 NO. 2 WATER BY-PASS PIPE
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INSTALL NO. 4 WATER BY-PASS HOSE
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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 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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INSTALL 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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INSTALL NO. 7 WATER BY-PASS HOSE
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INSTALL DIESEL THROTTLE BODY ASSEMBLY
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INSTALL VACUUM PUMP ASSEMBLY
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INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
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INSTALL ENGINE MOUNTING BRACKET
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INSTALL NO. 4 WATER BY-PASS PIPE
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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 NO. 2 IDLER PULLEY SUB-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 sub-assembly.
- Torque:
- 35 N*m { 357 kgf*cm, 26 ft.*lbf }
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INSTALL COOLER COMPRESSOR ASSEMBLY WITH PULLEY
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INSTALL FAN AND GENERATOR V BELT
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CONNECT ENGINE WIRE