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ENGINE UNIT INSTALLATION

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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
    Supply pump assembly Fuel inlet 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

  • 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.

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PROCEDURE


  1. Click here

    INSTALL NO. 1 WATER HOSE CLAMP BRACKET (w/ DPF)


    1. Install the No. 1 water hose clamp bracket with the bolt to the timing chain case assembly.

      10 N*m 102 kgf*cm 7 ft.*lbf
  2. Click here

    INSTALL CRANKSHAFT PULLEY

    Click here

  3. Click here

    INSTALL CRANKSHAFT PULLEY COVER

    Click here

  4. Click here

    INSTALL VISCOUS HEATER CRANKSHAFT PULLEY (w/ Viscous Heater)

    Click here

  5. Click here

    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. B0024AKC01
      *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.

      09223-46011
      Standard depth
      0 to 0.8 mm (0 to 0.0315 in.)
  6. Click here

    INSTALL VACUUM PUMP ASSEMBLY


    1. B0025YB

      Coat 2 new O-rings with engine oil, and install them to the vacuum pump assembly.

    2. B0025U3N01

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

      21 N*m 214 kgf*cm 15 ft.*lbf
  7. Click here

    INSTALL NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


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

      10 N*m 102 kgf*cm 7 ft.*lbf

    2. w/ EGR Cooler:

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

  8. Click here

    INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

    Click here

  9. Click here

    INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY

    Click here

  10. Click here

    INSTALL THERMOSTAT

    Click here

  11. Click here

    INSTALL WATER INLET


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

      13 N*m 133 kgf*cm 10 ft.*lbf
  12. Click here

    INSTALL WATER OUTLET SUB-ASSEMBLY


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

      10 N*m 102 kgf*cm 7 ft.*lbf
  13. Click here

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


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

      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.

  14. Click here

    INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  15. Click here

    TEMPORARILY INSTALL TURBO OIL INLET PIPE SUB-ASSEMBLY

    Click here

  16. Click here

    TEMPORARILY INSTALL EXHAUST MANIFOLD WITH TURBOCHARGER SUB-ASSEMBLY

    Click here

  17. Click here

    INSTALL TURBO OIL OUTLET PIPE

    Click here

  18. Click here

    TEMPORARILY INSTALL TURBOCHARGER STAY

    Click here

  19. Click here

    TIGHTEN EXHAUST MANIFOLD WITH TURBOCHARGER SUB-ASSEMBLY

    Click here

  20. Click here

    TIGHTEN TURBOCHARGER STAY

    Click here

  21. Click here

    INSTALL NO. 1 VISCOUS HEATER BRACKET SUB-ASSEMBLY (w/ Viscous Heater)


    1. B0026G4N01

      Temporarily install the No. 1 viscous heater bracket sub-assembly with the 4 bolts to the cylinder block sub-assembly and timing chain cover sub-assembly.

    2. Tighten the 4 bolts in the sequence shown in the illustration to install the No. 1 viscous heater bracket sub-assembly.

      24.5 N*m 250 kgf*cm 18 ft.*lbf
  22. Click here

    CONNECT NO. 1 AND NO. 2 TURBO WATER HOSE

    Click here

  23. Click here

    INSTALL NO. 1 WATER BY-PASS PIPE


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

      10 N*m 102 kgf*cm 7 ft.*lbf
      Tip:

      Make sure that the claw of the gasket faces the No. 1 water by-pass pipe.

  24. Click here

    INSTALL NO. 3 WATER BY-PASS PIPE

    Click here

  25. Click here

    INSTALL PCV HOSE (except Cold Area Specification Vehicles)

    Click here

  26. Click here

    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. B00274QC01
      *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.

      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.

      38 N*m 387 kgf*cm 28 ft.*lbf
  27. Click here

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


  28. Click here

    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.

      38 N*m 387 kgf*cm 28 ft.*lbf
  29. Click here

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


  30. Click here

    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.

      12 N*m 122 kgf*cm 9 ft.*lbf
  31. Click here

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


  32. Click here

    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.

      12 N*m 122 kgf*cm 9 ft.*lbf
  33. Click here

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


  34. Click here

    INSTALL AIR FUEL RATIO SENSOR (w/ DPF)

    Click here

  35. Click here

    INSTALL NO. 1 INJECTOR HOLDER (w/ DPF)

    Click here

  36. Click here

    CONNECT NO. 4 WATER BY-PASS HOSE (w/ DPF)


    1. Connect the No. 4 water by-pass hose to the No. 1 injector holder, and slide the clamp to secure the hose.

  37. Click here

    INSTALL NO. 5 WATER BY-PASS HOSE (w/ DPF)


    1. Attach the clamp and install the No. 5 water by-pass hose to the No. 1 water hose clamp bracket.

    2. Connect the No. 5 water by-pass hose to the No. 1 injector holder and water outlet sub-assembly, and slide the 2 clamps to secure the hose.

  38. Click here

    INSTALL PCV PIPE (for Cold Area Specification Vehicles)

    Click here

  39. Click here

    INSTALL ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  40. Click here

    INSTALL IDLER PULLEY ASSEMBLY (w/o Air Conditioning System)

    Note:

    Install the idler pulley assembly exactly as described in the procedures below to properly secure and prevent damage to the fan and generator V belt.


    1. B0025H2

      Temporarily install the idler pulley assembly with the 2 bolts to the cylinder block sub-assembly.

      Tip:

      Temporarily install the idler pulley assembly with the 2 bolts so that the idler pulley assembly can be moved by hand.

    2. B0027S9C01
      *a No Clearance
      *b Push
      *c Front

      Push the idler pulley assembly toward the cylinder block sub-assembly as shown in the illustration and tighten bolt A.

      39 N*m 398 kgf*cm 29 ft.*lbf
      Tip:

      Make sure there is no clearance between the cylinder block sub-assembly and idler pulley assembly as shown in the illustration.

    3. B0026WWN01

      Uniformly tighten the 2 bolts in the order shown in the illustration.

      39 N*m 398 kgf*cm 29 ft.*lbf
  41. Click here

    INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET (w/ Air Conditioning System)

    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. B0027N4

      Temporarily install the No. 1 compressor mounting bracket with the 2 bolts to the cylinder block sub-assembly.

      Tip:

      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. B0026WEC01
      *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.

      39 N*m 398 kgf*cm 29 ft.*lbf
      Tip:

      Make sure there is no clearance between the cylinder block sub-assembly and No. 1 compressor mounting bracket as shown in the illustration.

    3. B0026UYN01

      Uniformly tighten the 3 bolts in the order shown in the illustration.

      39 N*m 398 kgf*cm 29 ft.*lbf
  42. Click here

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


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

      25 N*m 255 kgf*cm 18 ft.*lbf
      Tip:

      Make sure that the claw of the gasket faces the No. 5 water by-pass pipe sub-assembly.

  43. Click here

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


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

      21 N*m 214 kgf*cm 15 ft.*lbf
  44. Click here

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


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

      21 N*m 214 kgf*cm 15 ft.*lbf
  45. Click here

    INSTALL HOSE BRACKET


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

      10 N*m 102 kgf*cm 7 ft.*lbf
  46. Click here

    INSTALL GLOW PLUG ASSEMBLY

    Click here

  47. Click here

    INSTALL NO. 1 GLOW PLUG CONNECTOR

    Click here

  48. Click here

    INSTALL COMMON RAIL ASSEMBLY

    Click here

  49. Click here

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

    Click here

  50. Click here

    TIGHTEN INJECTOR ASSEMBLY

    Click here

  51. Click here

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

    Click here

  52. Click here

    INSTALL WIRING HARNESS CLAMP BRACKET


    1. B0026T5N01

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

      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
  53. Click here

    INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  54. Click here

    INSTALL NO. 1 FUEL PIPE (w/ DPF)

    Click here

  55. Click here

    INSTALL WIRING HARNESS CLAMP BRACKET

    Click here

  56. Click here

    INSTALL INTAKE MANIFOLD

    Click here

  57. Click here

    INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  58. Click here

    INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Click here

  59. Click here

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

    Click here

  60. Click here

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

    Click here

  61. Click here

    INSTALL NO. 1 FUEL HOSE

    Click here

  62. Click here

    INSTALL NO. 2 FUEL HOSE

    Click here

  63. Click here

    INSTALL FUEL PUMP MOTOR WIRE

    Click here

  64. Click here

    INSTALL FUEL INJECTION PUMP COVER SUB-ASSEMBLY

    Click here

  65. Click here

    INSTALL MANIFOLD STAY

    Click here

  66. Click here

    INSTALL WIRING HARNESS CLAMP BRACKET

    Click here

  67. Click here

    INSTALL NO. 2 FUEL PIPE


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

      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.

  68. Click here

    INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  69. Click here

    INSTALL EGR HOLE COVER PLATE (w/o EGR System)


    1. Using an E8 "TORX" socket wrench, install 2 new stud bolts to the exhaust manifold.

      10 N*m 102 kgf*cm 7 ft.*lbf

    2. Install 2 new gaskets and the 2 EGR cooler hole plates to the intake manifold and exhaust manifold with 4 new nuts.

      29 N*m 296 kgf*cm 21 ft.*lbf
  70. Click here

    INSTALL EGR VALVE ADAPTER SUB-ASSEMBLY (w/o EGR System)


    1. B0024WYN01

      Temporarily install the EGR valve adapter sub-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.

      21 N*m 214 kgf*cm 15 ft.*lbf
  71. Click here

    INSTALL EGR VALVE ADAPTER SUB-ASSEMBLY WITH ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR System without EGR Cooler)


    1. B0027MON01

      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.

      21 N*m 214 kgf*cm 15 ft.*lbf
  72. Click here

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

    Click here

  73. Click here

    INSTALL EGR PIPE WITH COOLER SUB-ASSEMBLY (w/ DPF)


    1. Using an E8 "TORX" socket wrench, install 2 new stud bolts to the exhaust manifold.

      10 N*m 102 kgf*cm 7 ft.*lbf

    2. Install 2 new gaskets and the EGR pipe with cooler sub-assembly with the bolt and 4 new nut to the exhaust manifold, electric EGR control valve assembly and No. 1 vacuum transmitting pipe sub-assembly.

      for bolt
      10 N*m 102 kgf*cm 7 ft.*lbf
      for nut
      29 N*m 296 kgf*cm 21 ft.*lbf
  74. Click here

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


    1. w/ DPF:


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

        10 N*m 102 kgf*cm 7 ft.*lbf

      2. for Cold Area Specification Vehicles:

        Attach the clamp and connect the No. 11 water by-pass hose to the No. 2 fuel pipe.

      3. Connect the No. 17 water by-pass hose to the EGR pipe with cooler sub-assembly, and slide the clamp to secure the hose.

      4. Connect the water hose to the No. 2 EGR valve assembly, and slide the clamp to secure the hose.

      5. 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.

      6. 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 DPF:


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

        10 N*m 102 kgf*cm 7 ft.*lbf

      2. for Cold Area Specification Vehicles:

        Attach the clamp and connect the No. 11 water by-pass hose to the No. 2 fuel pipe.

      3. Connect the water hose to the No. 2 EGR valve assembly, and slide the clamp to secure the hose.

      4. 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.

      5. 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.

  75. Click here

    INSTALL VACUUM CONTROL VALVE SET (w/ EGR Cooler)

    Click here

  76. Click here

    INSTALL NO. 1 EGR PIPE SUB-ASSEMBLY (w/ EGR System)


    1. Using an E8 "TORX" socket wrench, install 2 new stud bolts to the exhaust manifold.

      10 N*m 102 kgf*cm 7 ft.*lbf

    2. Install 2 new gaskets and the No. 1 EGR pipe sub-assembly with the bolt and 4 new nut to the exhaust manifold, electric EGR control valve assembly and No. 1 vacuum transmitting pipe sub-assembly.

      for bolt
      10 N*m 102 kgf*cm 7 ft.*lbf
      for nut
      29 N*m 296 kgf*cm 21 ft.*lbf
  77. Click here

    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.

  78. Click here

    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.

      10 N*m 102 kgf*cm 7 ft.*lbf

    2. w/ EGR System:

      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.

  79. Click here

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

    Click here

  80. Click here

    INSTALL NO. 2 EGR PIPE

    Click here

  81. Click here

    INSTALL EGR VALVE BRACKET

    Click here

  82. Click here

    INSTALL DIESEL TURBO PRESSURE SENSOR

    Click here

  83. Click here

    INSTALL GAS FILTER

    Click here

  84. Click here

    INSTALL ENGINE COVER BRACKET


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

      21 N*m 214 kgf*cm 15 ft.*lbf
  85. Click here

    INSTALL PIPE CLAMP (w/ DPF)

    Click here

  86. Click here

    TEMPORARILY INSTALL NO. 2 VACUUM PIPE (w/ DPF)

    Click here

  87. Click here

    TEMPORARILY INSTALL NO. 1 VACUUM PIPE (w/ DPF)

    Click here

  88. Click here

    TIGHTEN NO. 2 VACUUM PIPE (w/ DPF)

    Click here

  89. Click here

    TIGHTEN NO. 1 VACUUM PIPE (w/ DPF)

    Click here

  90. Click here

    INSTALL EXHAUST GAS TEMPERATURE SENSOR (w/ DPF)

    Click here

  91. Click here

    INSTALL DIFFERENTIAL PRESSURE SENSOR (w/ DPF)

    Click here

  92. Click here

    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.

  93. Click here

    INSTALL NO. 2 WATER BY-PASS PIPE

    Click here

  94. Click here

    INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Click here

  95. Click here

    INSTALL INTERCOOLER AIR TUBE

    Click here

  96. Click here

    INSTALL ENGINE WIRE

  97. Click here

    INSTALL NO. 2 ENGINE COVER BRACKET

    Click here

  98. Click here

    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.

      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.