ENGINE UNIT INSTALLATION

CAUTION / NOTICE / HINT

Note


  • When replacing the parts in the following chart (A), replace the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly with new ones.

    Replaced Parts (A) Pipes Requiring New Replacement
    Injector assembly (including shuffling the injector assemblies between the cylinders)

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing chain case assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • Fuel inlet pipe sub-assembly
    Supply pump assembly Fuel inlet pipe sub-assembly

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly and/or fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

  • The injector assembly is a precision instrument. Do not use the injector assembly if it is struck or dropped.

  • The supply pump assembly is a precision instrument. Do not use the supply pump assembly if it is struck or dropped.

  • The common rail assembly is a precision instrument. Do not use the common rail assembly if it is struck or dropped.

  • Hold the supply pump assembly itself during removal and installation. Do not hold the pre-stroke control valve or fuel pipe, etc.

  • Hold the common rail assembly itself during removal and installation. Do not hold the pressure discharge valve or fuel pressure sensor, etc.

  • Make sure foreign matter does not enter the fuel path.

PROCEDURE


  1. INSTALL NO. 1 WATER HOSE CLAMP BRACKET (w/ DPF)


    1. Install the No. 1 water hose clamp bracket with the bolt to the timing chain case assembly.

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

  2. INSTALL CRANKSHAFT PULLEY

    Click here

  3. INSTALL CRANKSHAFT PULLEY COVER

    Click here

  4. INSTALL VISCOUS HEATER CRANKSHAFT PULLEY (w/ Viscous Heater)

    Click here

  5. INSTALL CAMSHAFT OIL SEAL RETAINER

    Note

    If the camshaft oil seal retainer is dropped, replace it with a new one.


    1. Before installing a new camshaft oil seal retainer, clean the installation surface of the No. 3 camshaft bearing cap and cylinder head sub-assembly and remove any foreign matter.

    2. B003PRPC01
      *1 Camshaft Oil Seal Retainer
      *a Depth

      Using SST and a hammer, tap in a new camshaft oil seal retainer to the No. 3 camshaft bearing cap and cylinder head sub-assembly as shown in the illustration.

      SST
      09223-46011
      Standard depth
      -0.5 to 0.8 mm (-0.0197 to 0.0315 in.)

  6. INSTALL VACUUM PUMP ASSEMBLY


    1. B003RUI

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

    2. B003KURN01

      Install the vacuum pump assembly so that the coupling teeth of the vacuum pump assembly labeled A and the groove of the No. 2 camshaft labeled B can engage.

    3. Install the vacuum pump assembly with the 3 bolts to the cylinder head sub-assembly.

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

  7. INSTALL NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. Install the No. 1 vacuum transmitting pipe sub-assembly with the 3 bolts to the cylinder head sub-assembly.

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

    2. w/ EGR Cooler:

      Connect the No. 1 vacuum transmitting hose to the vacuum pump assembly.

  8. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

    Click here

  9. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY

    Click here

  10. INSTALL THERMOSTAT

    Click here

  11. INSTALL WATER INLET


    1. Install the water inlet with the 3 bolts to the timing chain cover sub-assembly.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  12. INSTALL WATER OUTLET SUB-ASSEMBLY


    1. Install a new gasket and the water outlet sub-assembly with the 4 bolts and 2 nuts to the timing chain cover sub-assembly.

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

  13. INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Install the No. 2 water by-pass pipe sub-assembly with the 2 bolts to the engine water pump assembly and water inlet.

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

    2. Connect the No. 3 water by-pass hose to the water outlet sub-assembly, and slide the clamp to secure the hose.

  14. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  15. TEMPORARILY INSTALL TURBO OIL INLET PIPE SUB-ASSEMBLY

    Click here

  16. TEMPORARILY INSTALL EXHAUST MANIFOLD WITH TURBOCHARGER SUB-ASSEMBLY

    Click here

  17. INSTALL TURBO OIL OUTLET PIPE

    Click here

  18. TEMPORARILY INSTALL TURBOCHARGER STAY

    Click here

  19. TIGHTEN EXHAUST MANIFOLD WITH TURBOCHARGER SUB-ASSEMBLY

    Click here

  20. TIGHTEN TURBOCHARGER STAY

    Click here

  21. INSTALL NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (w/ Viscous Heater)


    1. B003RF0N01

      Temporarily install the No. 1 viscous heater bracket sub-assembly with the 4 bolts to the cylinder block sub-assembly and timing chain cover sub-assembly.

    2. Tighten the 4 bolts in the sequence shown in the illustration to install the No. 1 viscous heater bracket sub-assembly.

      Torque:
      24.5 N*m  { 250 kgf*cm, 18 ft.*lbf }

  22. CONNECT NO. 1 AND NO. 2 TURBO WATER HOSE

    Click here

  23. INSTALL NO. 1 WATER BY-PASS PIPE


    1. Install a new gasket and the No. 1 water by-pass pipe with the 3 bolts to the timing chain cover sub-assembly.

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

      Tech Tips

      Make sure that the claw of the gasket faces the No. 1 water by-pass pipe.

  24. INSTALL NO. 3 WATER BY-PASS PIPE

    Click here

  25. INSTALL PCV HOSE (except Cold Area Specification Vehicles)

    Click here

  26. INSTALL TURBINE OUTLET ELBOW (w/o EGR Cooler)


    1. Set a new gasket and the turbine outlet elbow to the turbocharger sub-assembly.

    2. Temporarily install the exhaust pipe support stay to the cylinder block sub-assembly and turbine outlet elbow with the 3 bolts.

    3. B003RABC01
      *1 Exhaust Pipe Clamp
      *2 Turbine Outlet Elbow
      *3 Turbocharger Sub-assembly
      *4 Gasket

      Install a new exhaust pipe clamp to the turbine outlet elbow with a new nut.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    4. Tighten the 3 bolts and install the exhaust pipe support stay to the cylinder block sub-assembly and turbine outlet elbow.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  27. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (w/ EGR Cooler)


  28. INSTALL NO. 2 EXHAUST PIPE SUPPORT STAY (w/o EGR Cooler)


    1. Install the No. 2 exhaust pipe support stay to the cylinder block sub-assembly and turbine outlet elbow with 2 new nuts and the bolt.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  29. INSTALL NO. 2 EXHAUST PIPE SUPPORT STAY (w/ EGR Cooler)


  30. INSTALL NO. 1 TURBO INSULATOR (w/o EGR Cooler)


    1. Install the No. 1 turbo insulator to the exhaust manifold and turbocharger sub-assembly with the 3 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  31. INSTALL NO. 1 TURBO INSULATOR (w/ EGR Cooler)


  32. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (w/o EGR Cooler)


    1. Install the No. 1 exhaust manifold heat insulator to the exhaust manifold with the 3 bolts.

      Torque:
      12 N*m  { 122 kgf*cm, 9 ft.*lbf }

  33. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (w/ EGR Cooler)


  34. INSTALL AIR FUEL RATIO SENSOR (w/ DPF)

    Click here

  35. INSTALL NO. 2 EXHAUST MANIFOLD HEAT INSULATOR (w/ DPF)

    Click here

  36. INSTALL NO. 1 INJECTOR HOLDER (w/ DPF)

    Click here

  37. CONNECT NO. 4 WATER BY-PASS HOSE (w/ DPF)


    1. Connect the No. 4 water by-pass hose to the No. 1 injector holder, and slide the clamp to secure the hose.

  38. INSTALL NO. 5 WATER BY-PASS HOSE (w/ DPF)


    1. Attach the clamp and install the No. 5 water by-pass hose to the No. 1 water hose clamp bracket.

    2. Connect the No. 5 water by-pass hose to the No. 1 injector holder and water outlet sub-assembly, and slide the 2 clamps to secure the hose.

  39. INSTALL PCV PIPE (for Cold Area Specification Vehicles)

    Click here

  40. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  41. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET

    Note

    Install the No. 1 compressor mounting bracket exactly as described in the procedures below to properly secure and prevent damage to the fan and generator V belt.


    1. B003OFQ

      Temporarily install the No. 1 compressor mounting bracket with the 2 bolts to the cylinder block sub-assembly.

      Tech Tips

      Temporarily install the No. 1 compressor mounting bracket with the 2 bolts so that the No. 1 compressor mounting bracket can be moved by hand.

    2. B003JMKC01
      *a No Clearance
      *b Push
      *c Front

      Push the No. 1 compressor mounting bracket toward the cylinder block sub-assembly as shown in the illustration and tighten bolt A.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

      Tech Tips

      Make sure there is no clearance between the cylinder block sub-assembly and No. 1 compressor mounting bracket as shown in the illustration.

    3. B003QCIN01

      Uniformly tighten the 3 bolts in the order shown in the illustration.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

  42. INSTALL NO. 5 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Install a new gasket and the No. 5 water by-pass pipe sub-assembly with the 3 bolts to the cylinder block sub-assembly.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Tech Tips

      Make sure that the claw of the gasket faces the No. 5 water by-pass pipe sub-assembly.

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


    1. Install the No. 3 nozzle leakage pipe with the 2 nuts to the cylinder block sub-assembly.

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

  44. INSTALL DIESEL FUEL FILTER ASSEMBLY (w/ DPF)


    1. Install the diesel fuel filter assembly with the 2 nuts to the cylinder block sub-assembly.

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

  45. INSTALL HOSE BRACKET


    1. Install the hose bracket with the 2 bolts to the cylinder head sub-assembly.

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

  46. INSTALL GLOW PLUG ASSEMBLY

    Click here

  47. INSTALL NO. 1 GLOW PLUG CONNECTOR

    Click here

  48. INSTALL COMMON RAIL ASSEMBLY

    Click here

  49. TEMPORARILY INSTALL NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Click here

  50. TIGHTEN INJECTOR ASSEMBLY

    Click here

  51. TIGHTEN NO. 1 AND NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Click here

  52. INSTALL WIRING HARNESS CLAMP BRACKET


    1. B003K6MN01

      Install the 2 wiring harness clamp brackets with the 2 bolts to the cylinder head cover sub-assembly.

      Torque:
      for bolt A
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for bolt B
      8.4 N*m  { 86 kgf*cm, 74 in.*lbf }

  53. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  54. INSTALL NO. 1 FUEL PIPE (w/ DPF)

    Click here

  55. INSTALL WIRING HARNESS CLAMP BRACKET

    Click here

  56. INSTALL INTAKE MANIFOLD

    Click here

  57. INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  58. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  59. INSTALL NO. 3 FUEL PIPE (w/ DPF)

    Click here

  60. INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY (w/ DPF)

    Click here

  61. INSTALL NO. 1 FUEL HOSE

    Click here

  62. INSTALL NO. 2 FUEL HOSE

    Click here

  63. INSTALL FUEL PUMP MOTOR WIRE

    Click here

  64. INSTALL FUEL INJECTION PUMP COVER SUB-ASSEMBLY

    Click here

  65. INSTALL MANIFOLD STAY

    Click here

  66. INSTALL WIRING HARNESS CLAMP BRACKET

    Click here

  67. INSTALL NO. 2 FUEL PIPE


    1. Install the No. 2 fuel pipe with the bolt to the manifold stay.

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

    2. Connect the No. 1 fuel hose to the No. 2 fuel pipe, and slide the clamp to secure the hose.

  68. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  69. INSTALL EGR HOLE COVER PLATE (w/o EGR System)


    1. Using an E8 "TORX" socket wrench, install 2 new stud bolts to the exhaust manifold.

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

    2. Install 2 new gaskets and the 2 EGR cooler hole plates to the intake manifold and exhaust manifold with 4 new nuts.

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

  70. INSTALL EGR VALVE ADAPTER SUB-ASSEMBLY (w/o EGR System)


    1. Temporarily install the EGR valve adapter sub-assembly to the intake manifold with the 4 bolts.

    2. B003J2EN01

      Tighten the 4 bolts in the order shown in the illustration.

      Note

      Make sure to tighten the bolts in the order.

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

  71. INSTALL EGR VALVE ADAPTER SUB-ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System without EGR Cooler)


    1. B003MRVN01

      Temporarily install the EGR valve adapter sub-assembly with electric EGR control valve assembly to the intake manifold with the 4 bolts.

    2. Tighten the 4 bolts in the order shown in the illustration.

      Note

      Make sure to tighten the bolts in the order.

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

  72. INSTALL NO. 1 EGR COOLER AND NO. 2 EGR VALVE ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System with EGR Cooler)

    Click here

  73. INSTALL NO. 4 WATER BY-PASS PIPE SUB-ASSEMBLY


    1. Install the No. 4 water by-pass pipe sub-assembly with the 2 bolts to the intake manifold.

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

    2. Connect the water hose to the No. 2 EGR valve assembly, and slide the clamp to secure the hose.

    3. Connect the No. 7 water by-pass hose to the No. 4 water by-pass pipe sub-assembly, and slide the clamp to secure the hose.

    4. Connect the No. 6 water by-pass hose to the No. 4 water by-pass pipe sub-assembly, and slide the clamp to secure the hose.

  74. INSTALL VACUUM CONTROL VALVE SET

    Click here

  75. INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY


    1. Using an E8 "TORX" socket wrench, install 2 new stud bolts to the exhaust manifold.

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

    2. Install 2 new gaskets and the No. 1 EGR pipe sub-assembly with the bolt and 4 new nut to the exhaust manifold, electric EGR control valve assembly and No. 1 vacuum transmitting pipe sub-assembly.

      Torque:
      for bolt
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for nut
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

  76. INSTALL CONNECTING WIRE


    1. Attach the 2 clamps and install the connecting wire to the hose bracket.

    2. Connect the connector to the common rail assembly.

  77. INSTALL NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY

    Click here

  78. INSTALL NO. 2 EGR PIPE

    Click here

  79. INSTALL EGR VALVE BRACKET

    Click here

  80. INSTALL DIESEL TURBO PRESSURE SENSOR

    Click here

  81. INSTALL GAS FILTER

    Click here

  82. INSTALL ENGINE COVER BRACKET


    1. Install the engine cover bracket with the 2 bolts to the cylinder head cover sub-assembly and hose bracket.

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

  83. INSTALL PIPE CLAMP (w/ DPF)

    Click here

  84. TEMPORARILY INSTALL NO. 2 VACUUM PIPE (w/ DPF)

    Click here

  85. TEMPORARILY INSTALL NO. 1 VACUUM PIPE (w/ DPF)

    Click here

  86. TIGHTEN NO. 2 VACUUM PIPE (w/ DPF)

    Click here

  87. TIGHTEN NO. 1 VACUUM PIPE (w/ DPF)

    Click here

  88. INSTALL EXHAUST GAS TEMPERATURE SENSOR (w/ DPF)

    Click here

  89. INSTALL DIFFERENTIAL PRESSURE SENSOR (w/ DPF)

    Click here

  90. INSTALL NO. 2 WATER BY-PASS PIPE

    Click here

  91. INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Click here

  92. INSTALL INTERCOOLER AIR TUBE

    Click here

  93. INSTALL ENGINE WIRE

  94. INSTALL NO. 2 ENGINE COVER BRACKET

    Click here

  95. INSTALL NO. 2 HOSE TO HOSE TUBE


    1. Install the No. 2 hose to hose tube to the cylinder head cover sub-assembly and hose bracket with the 2 bolts.

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

    2. Connect the union to check valve hose to the vacuum pump assembly, and slide the clamp to secure the hose.