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:
      41 N*m  { 418 kgf*cm, 30 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 FUEL SUPPLY PUMP ASSEMBLY

    Click here

  10. INSTALL COMMON RAIL ASSEMBLY

    Click here

  11. INSTALL OIL FILTER SUB-ASSEMBLY

    Click here

  12. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  13. INSTALL GLOW PLUG ASSEMBLY

    Click here

  14. INSTALL NO. 2 EGR HOLE COVER PLATE


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

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

  15. INSTALL INTAKE MANIFOLD

    Click here

  16. INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Click here

  17. 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.

  18. INSTALL THERMOSTAT

    Click here

  19. INSTALL WATER INLET

    Click here

  20. 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 }

  21. 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.

  22. INSTALL GENERATOR BRACKET


    1. Install the generator bracket with the bolt.

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

  23. INSTALL GENERATOR ASSEMBLY

    Click here

  24. INSTALL NO. 2 IDLE PULLEY ASSEMBLY

    Click here

  25. INSTALL EXHAUST MANIFOLD WITH TURBOCHARGER

    Click here

  26. INSTALL VENTILATION HOSE HEAT INSULATOR


    1. Install the ventilation hose heat insulator to the cylinder head sub-assembly with the 2 bolts.

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

  27. INSTALL CRANKSHAFT PULLEY SUB-ASSEMBLY

    Click here

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

    Click here

  29. INSTALL TIMING BELT

    Click here

  30. INSTALL NO. 1 TIMING BELT COVER

    Click here