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, No. 3 injection pipe sub-assembly, No. 4 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)

    • Common rail assembly

    • Cylinder head sub-assembly

    • No. 1 injection pipe sub-assembly

    • No. 2 injection pipe sub-assembly

    • No. 3 injection pipe sub-assembly

    • No. 4 injection pipe sub-assembly

    • Supply pump assembly

    • Common rail assembly

    • Cylinder block sub-assembly

    • Cylinder head sub-assembly

    • Cylinder head gasket

    • Timing Gear Case Assembly

    		 Fuel inlet pipe sub-assembly

  • After removing the No. 1 injection pipe sub-assembly, No. 2 injection pipe sub-assembly, No. 3 injection pipe sub-assembly, No. 4 injection pipe sub-assembly and fuel inlet pipe sub-assembly, clean them with a brush and compressed air.

PROCEDURE


  1. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET LH


    1. Install the front No. 1 engine mounting bracket LH to the cylinder block sub-assembly with the 4 bolts.

      Torque:
      68 N*m  { 693 kgf*cm, 50 ft.*lbf }

  2. INSTALL FRONT NO. 1 ENGINE MOUNTING BRACKET RH


    1. Install the front No. 1 engine mounting bracket RH to the cylinder block sub-assembly with the 4 bolts.

      Torque:
      68 N*m  { 693 kgf*cm, 50 ft.*lbf }

  3. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  4. INSTALL CAMSHAFT POSITION SENSOR

    Click here

  5. INSTALL CRANKSHAFT POSITION SENSOR

    Click here

  6. INSTALL VANE PUMP ASSEMBLY


    1. Install a new O-ring to the vane pump assembly.

    2. Install the vane pump assembly to the timing gear case assembly with the 2 nuts.

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

  7. INSTALL VACUUM PUMP ASSEMBLY


    1. Install 2 new O-rings to the vacuum pump assembly.

    2. Install the vacuum pump assembly to the timing gear cover with the 2 nuts.

      Torque:
      20.6 N*m  { 210 kgf*cm, 15 ft.*lbf }

  8. INSTALL OIL COOLER COVER SUB-ASSEMBLY

    Click here

  9. INSTALL GLOW PLUG ASSEMBLY

    Click here

  10. INSTALL NO. 2 EGR HOLE COVER PLATE


    1. Install a new gasket and the No. 2 EGR hole cover plate with the 2 nuts.

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

  11. INSTALL INTAKE MANIFOLD

    Click here

  12. INSTALL FUEL SUPPLY PUMP ASSEMBLY

    Click here

  13. INSTALL COMMON RAIL ASSEMBLY

    Click here

  14. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  15. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  16. INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  17. INSTALL NO. 4 INJECTION PIPE SUB-ASSEMBLY

    Click here

  18. INSTALL NO. 1, NO. 2 AND NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Click here

  19. INSTALL OIL FILTER SUB-ASSEMBLY

    Click here

  20. INSTALL INTAKE AIR CONNECTOR

    Click here

  21. INSTALL NO. 2 INTAKE AIR CONNECTOR BRACKET

    Click here

  22. INSTALL MANIFOLD STAY

    Click here

  23. INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Click here

  24. INSTALL VACUUM SWITCHING VALVE BRACKET

    Click here

  25. INSTALL WATER OUTLET


    1. B003SF8C01
      *a Claw

      Install a new gasket and the water outlet to the cylinder head sub-assembly with the 2 bolts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

      Tech Tips

      Make sure the claws of the gasket face the water outlet.

  26. INSTALL THERMOSTAT

    Click here

  27. INSTALL WATER INLET

    Click here

  28. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET


    1. Install the No. 1 compressor mounting bracket to the cylinder block sub-assembly with the 4 bolts.

      Torque:
      45 N*m  { 459 kgf*cm, 33 ft.*lbf }

  29. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. B003OHEC01
      *1 Cylinder Block Sub-assembly
      *2 V-ribbed Belt Tensioner

      Install the V-ribbed belt tensioner assembly to the cylinder block sub-assembly with the 4 bolts.

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

      Tech Tips

      Firmly press and hold the V-ribbed belt tensioner assembly against the cylinder block sub-assembly to eliminate any gaps in the areas labeled A in the illustration. Then uniformly tighten the 4 bolts.

  30. INSTALL GENERATOR BRACKET


    1. Install the generator bracket with the bolt.

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

  31. INSTALL GENERATOR ASSEMBLY

    Click here

  32. INSTALL NO. 2 IDLE PULLEY ASSEMBLY

    Click here

  33. INSTALL EXHAUST MANIFOLD WITH TURBOCHARGER


    1. Install a new gasket and the exhaust manifold with turbocharger to the cylinder head sub-assembly with the 8 spacers, 8 collars and 8 new nuts.

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

  34. INSTALL TURBINE OUTLET ELBOW

    Click here

  35. CONNECT NO. 1 TURBO WATER HOSE

    Click here

  36. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  37. INSTALL NO. 1 TURBO INSULATOR

    Click here

  38. INSTALL VENTILATION PIPE

    Click here

  39. INSTALL INTERCOOLER SUPPORT BRACKET


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

      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

  40. INSTALL NO. 2 INTERCOOLER SUPPORT BRACKET


    1. Install the No. 2 intercooler support bracket to the cylinder head sub-assembly with the 2 bolts.

      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

  41. INSTALL CRANKSHAFT PULLEY SUB-ASSEMBLY

    Click here

  42. INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY

    Click here

  43. INSTALL TIMING BELT

    Click here

  44. INSTALL NO. 1 TIMING BELT COVER

    Click here