ENGINE UNIT INSTALLATION

CAUTION / NOTICE / HINT

PROCEDURE

1. Click here

   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.

      68 N*m

      693 kgf*cm

      50 ft.*lbf

2. Click here

   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.

      68 N*m

      693 kgf*cm

      50 ft.*lbf

3. Click here

   INSTALL ENGINE COOLANT TEMPERATURE SENSOR

   Click here

4. Click here

   INSTALL CAMSHAFT POSITION SENSOR

   Click here

5. Click here

   INSTALL CRANKSHAFT POSITION SENSOR

   Click here

6. Click here

   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.

      39 N*m

      398 kgf*cm

      29 ft.*lbf

7. Click here

   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.

      20.6 N*m

      210 kgf*cm

      15 ft.*lbf

8. Click here

   INSTALL OIL COOLER COVER SUB-ASSEMBLY

   Click here

9. Click here

   INSTALL GLOW PLUG ASSEMBLY

   Click here

10. Click here

    INSTALL NO. 2 EGR HOLE COVER PLATE

    
    

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

       13 N*m

       133 kgf*cm

       10 ft.*lbf

11. Click here

    INSTALL INTAKE MANIFOLD

    Click here

12. Click here

    INSTALL FUEL SUPPLY PUMP ASSEMBLY

    Click here

13. Click here

    INSTALL COMMON RAIL ASSEMBLY

    Click here

14. Click here

    INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Click here

15. Click here

    INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

16. Click here

    INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

17. Click here

    INSTALL NO. 4 INJECTION PIPE SUB-ASSEMBLY

    Click here

18. Click here

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

    Click here

19. Click here

    INSTALL OIL FILTER SUB-ASSEMBLY

    Click here

20. Click here

    INSTALL INTAKE AIR CONNECTOR

    Click here

21. Click here

    INSTALL NO. 2 INTAKE AIR CONNECTOR BRACKET

    Click here

22. Click here

    INSTALL MANIFOLD STAY

    Click here

23. Click here

    INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Click here

24. Click here

    INSTALL VACUUM SWITCHING VALVE BRACKET

    Click here

25. Click here

    INSTALL WATER OUTLET

    
    
    1. 

       *a

       Claw

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

       19 N*m

       194 kgf*cm

       14 ft.*lbf

       Tip:

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

26. Click here

    INSTALL THERMOSTAT

    Click here

27. Click here

    INSTALL WATER INLET

    Click here

28. Click here

    INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET

    
    

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

       45 N*m

       459 kgf*cm

       33 ft.*lbf

29. Click here

    INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

    
    
    1. 

       *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.

       21 N*m

       214 kgf*cm

       15 ft.*lbf

       Tip:

       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. Click here

    INSTALL GENERATOR BRACKET

    
    

    1. Install the generator bracket with the bolt.

       25 N*m

       255 kgf*cm

       18 ft.*lbf

31. Click here

    INSTALL GENERATOR ASSEMBLY

    Click here

32. Click here

    INSTALL NO. 2 IDLE PULLEY ASSEMBLY

    Click here

33. Click here

    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.

       40 N*m

       408 kgf*cm

       30 ft.*lbf

34. Click here

    INSTALL TURBINE OUTLET ELBOW

    Click here

35. Click here

    CONNECT NO. 1 TURBO WATER HOSE

    Click here

36. Click here

    INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

37. Click here

    INSTALL NO. 1 TURBO INSULATOR

    Click here

38. Click here

    INSTALL VENTILATION PIPE

    Click here

39. Click here

    INSTALL INTERCOOLER SUPPORT BRACKET

    
    

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

       32 N*m

       326 kgf*cm

       24 ft.*lbf

40. Click here

    INSTALL NO. 2 INTERCOOLER SUPPORT BRACKET

    
    

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

       32 N*m

       326 kgf*cm

       24 ft.*lbf

41. Click here

    INSTALL CRANKSHAFT PULLEY SUB-ASSEMBLY

    Click here

42. Click here

    INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY

    Click here

43. Click here

    INSTALL TIMING BELT

    Click here

44. Click here

    INSTALL NO. 1 TIMING BELT COVER

    Click here