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 CRANKSHAFT PULLEY

    Click here

  2. 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.)

  3. 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 to the cylinder head sub-assembly with the 3 bolts.

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

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


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

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

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

  5. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

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  6. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY

    Click here

  7. INSTALL THERMOSTAT

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  8. INSTALL WATER INLET


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

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

  9. INSTALL WATER OUTLET SUB-ASSEMBLY


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

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

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


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

      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.

  11. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

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  12. TEMPORARILY INSTALL TURBO OIL INLET PIPE SUB-ASSEMBLY

    Click here

  13. TEMPORARILY INSTALL EXHAUST MANIFOLD WITH TURBOCHARGER SUB-ASSEMBLY

    Click here

  14. INSTALL TURBO OIL OUTLET PIPE

    Click here

  15. TEMPORARILY INSTALL TURBOCHARGER STAY

    Click here

  16. TIGHTEN EXHAUST MANIFOLD WITH TURBOCHARGER SUB-ASSEMBLY

    Click here

  17. TIGHTEN TURBOCHARGER STAY

    Click here

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

    Click here

  19. INSTALL NO. 1 WATER BY-PASS PIPE


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

      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.

  20. INSTALL NO. 3 WATER BY-PASS PIPE

    Click here

  21. INSTALL PCV HOSE

    Click here

  22. 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 }

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

    Click here

  24. 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 }

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

    Click here

  26. 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 }

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

    Click here

  28. 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 }

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

    Click here

  30. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  31. 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 to the cylinder block sub-assembly with the 2 bolts.

      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 }

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


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

      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.

  33. INSTALL NO. 3 NOZZLE LEAKAGE PIPE (w/o Pressurized Fuel Filter)


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

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

  34. INSTALL DIESEL FUEL FILTER ASSEMBLY (w/ Pressurized Fuel Filter)


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

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

  35. INSTALL HOSE BRACKET


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

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

  36. INSTALL GLOW PLUG ASSEMBLY

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  37. INSTALL NO. 1 GLOW PLUG CONNECTOR

    Click here

  38. INSTALL COMMON RAIL ASSEMBLY

    Click here

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

    Click here

  40. TIGHTEN INJECTOR ASSEMBLY

    Click here

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

    Click here

  42. INSTALL WIRING HARNESS CLAMP BRACKET


    1. B003K6MN01

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

      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 }

  43. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  44. INSTALL WIRING HARNESS CLAMP BRACKET

    Click here

  45. INSTALL INTAKE MANIFOLD

    Click here

  46. INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  47. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  48. INSTALL NO. 3 FUEL PIPE (w/ Pressurized Fuel Filter)

    Click here

  49. INSTALL NO. 4 FUEL PIPE SUB-ASSEMBLY (w/ Pressurized Fuel Filter)

    Click here

  50. INSTALL NO. 1 FUEL HOSE

    Click here

  51. INSTALL NO. 2 FUEL HOSE

    Click here

  52. INSTALL FUEL PUMP MOTOR WIRE

    Click here

  53. INSTALL FUEL INJECTION PUMP COVER SUB-ASSEMBLY

    Click here

  54. INSTALL MANIFOLD STAY

    Click here

  55. INSTALL WIRING HARNESS CLAMP BRACKET

    Click here

  56. INSTALL NO. 2 FUEL PIPE


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

      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.

  57. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  58. INSTALL EGR VALVE ADAPTER SUB-ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/o 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 }

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

    Click here

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


    1. w/ EGR Cooler:


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

        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.

    2. w/o EGR Cooler:


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

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

      2. Connect the No. 2 turbo water hose to the EGR valve adapter sub-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.

  61. INSTALL VACUUM CONTROL VALVE SET (w/ EGR Cooler)

    Click here

  62. 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 to the exhaust manifold, electric EGR control valve assembly and No. 1 vacuum transmitting pipe sub-assembly with the bolt and 4 new nuts.

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

  63. 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.

  64. INSTALL NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY (w/o EGR Cooler)


    1. Install the No. 3 water by-pass pipe sub-assembly to the EGR valve adapter sub-assembly with the 2 bolts.

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

    2. Connect the No. 8 water by-pass hose to the No. 3 water by-pass pipe sub-assembly, and slide the clamp to secure the hose.

    3. Connect the No. 4 fuel hose to the No. 3 water by-pass pipe sub-assembly.

  65. INSTALL NO. 3 WATER BY-PASS PIPE SUB-ASSEMBLY (w/ EGR Cooler)

    Click here

  66. INSTALL NO. 2 EGR PIPE

    Click here

  67. INSTALL EGR VALVE BRACKET

    Click here

  68. INSTALL DIESEL TURBO PRESSURE SENSOR

    Click here

  69. INSTALL GAS FILTER

    Click here

  70. INSTALL WATER BY-PASS PLUG (w/o Heater)


    1. Install the water by-pass plug to the water outlet sub-assembly, and slide the clamp to secure the plug.

  71. INSTALL ENGINE COVER BRACKET


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

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

  72. INSTALL NO. 2 WATER BY-PASS PIPE

    Click here

  73. INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Click here

  74. INSTALL INTERCOOLER AIR TUBE

    Click here

  75. INSTALL ENGINE WIRE

  76. INSTALL NO. 2 ENGINE COVER BRACKET

    Click here

  77. 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.