ENGINE ASSEMBLY INSTALLATION

PROCEDURE


  1. INSTALL FRONT ENGINE MOUNTING INSULATOR


    1. Install the 2 front engine mounting insulators to the 2 front engine mounting brackets with the 2 bolts.

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

  2. INSTALL FRONT ENGINE MOUNTING INSULATOR RH


    1. Install the front engine mounting insulator RH to the front engine mounting insulator sub-assembly with the bolt.

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

  3. INSTALL ENGINE WIRE


    1. Install the engine wire to the engine assembly.

  4. INSTALL ENGINE HANGER

    Click here

  5. REMOVE ENGINE ASSEMBLY TO ENGINE STAND

    Note


    • Pay attention to the angle of the sling device as the engine assembly or engine hangers may be damaged or deformed if the angle is incorrect.

    • With the exception of installing the engine assembly to an engine stand or removing the engine assembly from an engine stand, do not perform any work on the engine assembly while it is suspended, as doing so is dangerous.


    1. Attach the engine sling device and hang the engine assembly with the chain block.

    2. Remove the engine assembly from the engine stand.

  6. INSTALL ENGINE ASSEMBLY


    1. Slowly lower the engine assembly into the engine compartment.

    2. Install the engine assembly to the body with the 4 bolt and 4 nuts.

      Torque:
      42 N*m  { 428 kgf*cm, 31 ft.*lbf }

      Tech Tips


      • Make sure to tighten the side with the nut.

      • When installing a bolt with a claw (stopper), make sure that the claw (stopper) does not damage the body of the vehicle.

    3. Remove the 3 bolts, No. 1 engine hanger upper and No. 2 engine hanger.

  7. INSTALL REAR END PLATE


    1. Install the rear end plate to the cylinder block with the bolt.

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

  8. INSTALL FLYWHEEL SUB-ASSEMBLY


    1. Clean the bolt holes.

    2. B003R0YN01

      Using SST, hold the crankshaft pulley.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021

    3. for Manual Transmission:

      Install the flywheel sub-assembly to the crankshaft with the 8 bolts.

      Torque:
      178 N*m  { 1815 kgf*cm, 131 ft.*lbf }

      Note

      Do not start the engine for at least 1 hour after installation.

    4. B003NK9C01
      *1 Flywheel Sub-assembly
      *2 Pump Impeller Drive Plate
      *3 Rear Drive Plate Spacer
      *a Engine Side
      *b Transmission Side

      for Automatic Transmission:

      Install the flywheel sub-assembly, the pump impeller drive plate and the rear drive plate spacer to the crankshaft with the 8 bolts.

      Note


      • Align either hole in the pump impeller drive plate and either hole in the rear drive plate spacer with the knock pin of the flywheel sub-assembly, and then install the flywheel sub-assembly, the pump impeller drive plate and the rear drive plate spacer to the crankshaft.

      • Do not start the engine for at least 1 hour after installation.

      Tech Tips

      As the rear drive plate spacer and pump impeller drive plate are not reversible, be sure to install them in the direction shown in the illustration.

    5. B003JAVN01

      for Automatic Transmission:

      Install and uniformly tighten and tighten the 8 bolts in several steps in the sequence shown in the illustration.

      Torque:
      178 N*m  { 1815 kgf*cm, 131 ft.*lbf }

    6. Install the crankshaft pulley cover to the crankshaft pulley with the 4 bolts.

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

  9. INSTALL CLUTCH DISC ASSEMBLY (for Manual Transmission)

    Click here

  10. INSTALL CLUTCH COVER ASSEMBLY (for Manual Transmission)

    Click here

  11. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY (for Manual Transmission)

    Click here

  12. INSTALL AUTOMATIC TRANSMISSION ASSEMBLY (for Automatic Transmission)


  13. INSTALL DRIVE PLATE AND TORQUE CONVERTER CLUTCH SETTING BOLT (for Automatic Transmission)

    Click here

  14. INSTALL MANUAL TRANSMISSION UNIT ASSEMBLY (for Manual Transmission)


  15. INSTALL PROPELLER WITH CENTER BEARING SHAFT ASSEMBLY

    Click here

  16. INSTALL FRONT PROPELLER SHAFT ASSEMBLY (for 4WD)

    Click here

  17. INSTALL FRONT EXHAUST PIPE ASSEMBLY

    Click here

  18. CONNECT COOLER COMPRESSOR ASSEMBLY


    1. Temporarily install the cooler compressor assembly to the compressor mounting bracket with the 2 stud bolts.

    2. Using an E8 "TORX" socket wrench, tighten the 2 stud bolts.

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

    3. Install the 2 bolts and 2 nuts.

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

    4. Connect the connector to the cooler compressor assembly.

    5. Connect the suction hose sub-assembly to the water inlet and timing chain cover with the 2 bolts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  19. INSTALL GENERATOR ASSEMBLY

    Click here

  20. CONNECT UNION TO CONNECTOR TUBE HOSE


    1. Connect the union to connector tube hose to the No. 1 hose to hose tube, and slide the clamp to secure the hose.

  21. CONNECT VANE PUMP ASSEMBLY


    1. Connect the vane pump assembly to the generator bracket with the 2 bolts.

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

    2. Connect the connector to the power steering oil pressure switch.

  22. CONNECT WATER HOSE SUB-ASSEMBLY


    1. Connect the water hose sub-assembly to the air conditioning unit assembly, slide the 2 clamps secure the 2 hoses.

  23. INSTALL BATTERY TRAY

  24. INSTALL BATTERY

  25. INSTALL BATTERY CLAMP SUB-ASSEMBLY


    1. Install the battery clamp sub-assembly to the battery with the 2 nuts.

      Torque:
      5.4 N*m  { 55 kgf*cm, 48 in.*lbf }

  26. CONNECT WIRE HARNESS


    1. Connect the engine room main wire to the battery positive cable with the nut.

      Torque:
      7.1 N*m  { 72 kgf*cm, 63 in.*lbf }

    2. Attach the clamp and connect the No. 2 engine wire with the 2 bolts.

      Torque:
      14 N*m  { 143 kgf*cm, 10 ft.*lbf }

    3. Connect the 2 connectors to the engine room relay block sub-assembly.

    4. Connect the wire to wire to the engine room relay block sub-assembly with the nut.

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

    5. Attach the 2 clips and install the No. 1 relay block cover side to the engine room relay block sub-assembly.

    6. Attach the 3 clips and install the No. 1 relay block cover upper to the engine room relay block sub-assembly.

  27. CONNECT NO. 2 FUEL HOSE


    1. Connect the No. 2 fuel hose to the No. 3 nozzle leakage pipe assembly, and slide the clamp to secure the hose.

    2. Attach the clamp to the No. 2 fuel hose.

  28. CONNECT NO. 1 FUEL HOSE


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

    2. Attach the clamp to the No. 1 fuel hose.

  29. INSTALL FUEL FILTER ASSEMBLY

    Click here

  30. INSTALL INTERCOOLER AIR TUBE


    1. Install the intercooler air tube to the diesel throttle body assembly, and slide the clamp to secure the hose.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

    2. Connect the connector to the intake air temperature sensor.

  31. INSTALL NO. 4 AIR TUBE


    1. Install the No. 4 air hose to the No. 2 air tube and intercooler air tube, and slide the 2 clamps to secure the hose.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

    2. Connect the oil return hose to the engine oil level dipstick guide assembly, and slide the clamp to secure the hose.

  32. INSTALL NO. 1 AIR HOSE


    1. Install the No. 1 air hose to the compressor outlet elbow and No. 1 air tube, and slide the 2 clamps to secure the 2 hoses.

      Torque:
      6.5 N*m  { 66 kgf*cm, 58 in.*lbf }

  33. INSTALL AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY

  34. INSTALL AIR CLEANER CAP AND HOSE


    1. Attach the 4 clips and install the air cleaner cap and hose.

    2. Tighten the hose clamp.

      Torque:
      4.0 N*m  { 41 kgf*cm, 35 in.*lbf }

    3. Attach the 2 clamp and connect the connector to the mass air flow meter.

  35. CONNECT ENGINE WIRE


    1. Pass the engine wire into the cabin.

    2. Attach the grommet to the body.

      Tech Tips

      Make sure the direction of grommet is shown in the illustration.

      B003LFEN01

    3. Attach the clamp to connect the engine wire to the bracket.

    4. Attach the clamp and connect the 4 connectors to the glow plug controller.

    5. Connect the connector to the engine room main wire.

    6. Attach the 2 clamps and connect the 3 connectors to the instrument panel wire.

    7. Install the ECM.

      Click here

  36. INSTALL RADIATOR ASSEMBLY

    Click here

  37. INSTALL HOOD SUB-ASSEMBLY


    1. Install the hood sub-assembly to the 2 hood hinge assemblies with the 4 bolts.

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

    2. Connect the washer nozzle hose to the hood sub-assembly.

  38. ADD ENGINE OIL

    Click here

  39. ADD MANUAL TRANSMISSION OIL (for Manual Transmission)


  40. ADD AUTOMATIC TRANSMISSION FLUID (for Automatic Transmission)


  41. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected.

    Click here

  42. BLEED AIR FROM FUEL SYSTEM

    Click here

  43. ADD ENGINE COOLANT

    Click here

  44. INSPECT FOR COOLANT LEAK

    Click here

  45. INSPECT ENGINE OIL LEVEL

    Click here

  46. INSPECT ENGINE IDLE SPEED AND MAXIMUM SPEED

    Click here

  47. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY

    Click here

  48. INSTALL NO. 2 ENGINE UNDER COVER

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

  49. INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

    Torque:
    for M6 bolt
    11.5 N*m  { 117 kgf*cm, 8 ft.*lbf }
    for M8 bolt
    28 N*m  { 286 kgf*cm, 21 ft.*lbf }