БЛОК ДВИГАТЕЛЯ УСТАНОВКА

INSTALL EGR COOLER WITH PIPE ASSEMBLY

INSTALL NO. 2 WATER BY-PASS HOSE

1. for CCo:

   Install the No. 2 water by-pass hose to the EGR cooler and No. 5 water by-pass hose, and slide the 2 clamps to secure it.

2. for DPF:

   Install the No. 2 water by-pass hose to the EGR cooler and turbo oil outlet pipe, and slide the 2 clamps to secure it.

INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (for CCo)

INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (for DPF)

INSTALL NO. 1 MANIFOLD CONVERTER INSULATOR (for CCo)

1. Install the No. 1 manifold converter insulator with the 4 bolts.

   Torque:

   29 N*m  { 291 kgf*cm, 21 ft.*lbf }

INSTALL MANIFOLD CONVERTER INSULATOR SUB-ASSEMBLY (for DPF)

1. Install the manifold converter insulator sub-assembly with the bolt.

   Torque:

   29 N*m  { 291 kgf*cm, 21 ft.*lbf }

   Note

   Make sure that the ceramic wool inside the manifold converter insulator sub-assembly does not fall out and is not bent.

INSTALL NO. 4 MANIFOLD CONVERTER INSULATOR (for DPF)

1. Install the No. 4 manifold converter insulator with the 4 bolts.

   Torque:

   29 N*m  { 291 kgf*cm, 21 ft.*lbf }

INSTALL WIRE HARNESS CLAMP BRACKET (for DPF)

1. Install the No. 1 wiring harness clamp bracket with the bolt.

   Torque:

   9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

INSTALL VACUUM TRANSMITTING HOSE ASSEMBLY

1. 

   Text in Illustration

   *a	CORRECT
   *b	INCORRECT
   	Paint Mark

   for CCo:

   Attach the 10 clamps to install the 2 vacuum transmitting hoses.

   Tech Tips

   
   

   • Make sure that the paint marks of the vacuum transmitting hoses at the locations labeled A in the illustration are aligned as shown in the illustration. Any of the "CORRECT" alignments are acceptable for each location.

   • Make sure that the paint marks of the vacuum transmitting hoses at the locations labeled B in the illustration are aligned as shown in the illustration. Any of the "CORRECT" alignments are acceptable for each location.

2. 

   Text in Illustration

   *a	CORRECT
   *b	INCORRECT
   	Paint Mark

   for DPF:

   Attach the 8 clamps to install the 2 vacuum transmitting hoses.

   Tech Tips

   
   

   • Make sure that the paint marks of the vacuum transmitting hoses at the locations labeled A in the illustration are aligned as shown in the illustration. Any of the "CORRECT" alignments are acceptable for each location.

   • Make sure that the paint marks of the vacuum transmitting hoses at the locations labeled B in the illustration are aligned as shown in the illustration. Any of the "CORRECT" alignments are acceptable for each location.

INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

1. Using a 4 mm hexagon socket wrench, install the VSV with the 2 bolts.

   Torque:

   5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

2. Connect the 2 vacuum hoses.

3. Connect the VSV connector.

INSTALL VACUUM REGULATING VALVE ASSEMBLY (for CCo)

1. Install the vacuum regulating valve with the 2 bolts.

   Torque:

   9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

2. Connect the 2 vacuum hoses.

3. Connect the vacuum regulating valve connector.

INSTALL NO. 3 FUEL HOSE

1. 

   Text in Illustration

   *a	2 to 3 mm (0.0787 to 0.118 in.)
   *b	2 to 6 mm (0.0787 to 0.236 in.)

   Using pliers, grip the claws of the 2 clips and slide the 2 clips to install the No. 3 fuel hose to the fuel supply pump assembly and No. 2 nozzle leakage pipe.

   Tech Tips

   
   

   • Push on the No. 3 fuel hose so that the clearance is 2 to 3 mm (0.0787 to 0.118 in.).

   • Position the clamp so that the distance from the end of the No. 3 hose is 2 to 6 mm (0.0787 to 0.236 in.).

INSTALL FUEL INJECTOR SEAL (for DPF)

1. Install a new fuel injector seal to the exhaust fuel addition injector assembly.

INSTALL EXHAUST FUEL ADDITION INJECTOR ASSEMBLY (for DPF)

INSTALL FUEL TUBE SUB-ASSEMBLY (for DPF)

INSTALL FUEL HOSE PROTECTOR (for DPF)

1. Install the fuel hose protector with the bolt.

   Torque:

   21 N*m  { 209 kgf*cm, 15 ft.*lbf }

INSTALL NO. 2 FUEL PIPE (for CCo)

1. Temporarily install the No. 2 fuel pipe and 2 new gaskets with the check valve and union bolt.

2. Tighten the check valve.

   Torque:

   32 N*m  { 321 kgf*cm, 23 ft.*lbf }

3. Tighten the union bolt.

   Torque:

   23 N*m  { 235 kgf*cm, 17 ft.*lbf }

INSTALL NO. 2 WATER BY-PASS PIPE

1. Install a new O-ring to the No. 2 water by-pass pipe.

2. Install the No. 2 water by-pass pipe with the 2 bolts.

   Torque:

   11 N*m  { 112 kgf*cm, 8 ft.*lbf }

INSTALL NO. 4 WATER BY-PASS HOSE

1. Install the No. 4 water by-pass hose to the water inlet housing and cylinder head sub-assembly, and slide the 2 clamps to secure it.

INSTALL NO. 8 WATER BY-PASS HOSE

1. Install the No. 8 water by-pass hose to the No. 3 water by-pass pipe, and slide the clamp to secure it.

INSTALL NO. 6 WATER BY-PASS HOSE

1. Install the No. 6 water by-pass hose to the water outlet, and slide the clamp to secure it.

INSTALL WATER BY-PASS HOSE

INSTALL NO. 1 CYLINDER BLOCK INSULATOR

INSTALL INTAKE MANIFOLD

INSTALL NO. 2 INTAKE MANIFOLD

1. Install a new gasket and the No. 2 intake manifold with the bolt and 2 nuts.

   Torque:

   24 N*m  { 245 kgf*cm, 18 ft.*lbf }

INSTALL ENGINE COVER BRACKET

1. Install the engine cover bracket with the bolt.

   Torque:

   20 N*m  { 204 kgf*cm, 15 ft.*lbf }

INSTALL GAS FILTER BRACKET

1. Install the gas filter bracket with the 2 bolts.

   Torque:

   8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

INSTALL NO. 1 GAS FILTER

1. 

   Text in Illustration

   *1	Protrusion
   *2	Groove

   Install the No. 1 gas filter to the gas filter bracket.

   Note

   Make sure the protrusion of the No. 1 gas filter is aligned with the groove of the gas filter bracket.

2. Connect the vacuum hose.

INSTALL DIESEL TURBO PRESSURE SENSOR

1. 

   Text in Illustration

   *1	Protrusion

   Install the diesel turbo pressure sensor with the bolt.

   Torque:

   8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

   Note

   Make sure the protrusion of the gas filter bracket is inserted into the hole of the diesel turbo pressure sensor.

2. Connect the vacuum hose.

INSTALL INTAKE MANIFOLD INSULATOR

1. Install the intake manifold insulator to the intake manifold.

INSTALL COMMON RAIL ASSEMBLY

1. Install the common rail assembly with the 2 bolts.

   Torque:

   21 N*m  { 209 kgf*cm, 15 ft.*lbf }

INSTALL NO. 4 FUEL HOSE

1. Install the No. 4 fuel hose to the No. 2 nozzle leakage pipe and common rail assembly, and slide the 2 clamps to secure it.

INSTALL INJECTION PIPE

1. Using a 14 mm union nut wrench, tighten the 4 union nuts at the common rail end of the injection pipes.

   Torque:

   30 N*m  { 306 kgf*cm, 22 ft.*lbf }

   Note

   Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

2. Using a 14 mm union nut wrench, tighten the 4 union nuts at the injector end of the injection pipes.

   Torque:

   30 N*m  { 306 kgf*cm, 22 ft.*lbf }

   Note

   Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

3. Install the 4 No. 2 injection pipe clamps with the 2 bolts.

   Torque:

   5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

INSTALL FUEL INLET PIPE SUB-ASSEMBLY

1. Temporarily install the fuel inlet pipe sub-assembly with the 2 No. 2 injection pipe clamps and nut.

2. Using a 14 mm union nut wrench, first tighten the nut at the common rail assembly end of the fuel inlet pipe sub-assembly.

   Torque:

   30 N*m  { 306 kgf*cm, 22 ft.*lbf }

   Note

   Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

3. Using a 14 mm union nut wrench, tighten the nut at the fuel supply pump assembly end of the fuel inlet pipe sub-assembly.

   Torque:

   30 N*m  { 306 kgf*cm, 22 ft.*lbf }

   Note

   Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

4. Tighten the No. 2 injection pipe clamp nut.

   Torque:

   5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

1. Install a new O-ring to the engine oil level dipstick guide.

2. Install the engine oil level dipstick guide with the 2 bolts.

   Torque:

   24 N*m  { 245 kgf*cm, 18 ft.*lbf }

3. Install the engine oil level dipstick.

INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY

1. 

   Обозначения на рисунке

   *1

   Выступ

   Установите новую прокладку.

   Tech Tips

   Убедитесь, что выступ прокладки обращен вверх, как показано на рисунке.

2. Установите электрический клапан управления РОГ в сборе.

INSTALL NO. 2 EGR PIPE SUB-ASSEMBLY

1. Установите 2 новые прокладки на трубу РОГ № 2 и электрический клапан РОГ.

2. 

   Обозначения на рисунке

   *1

   Гайка

   Временно закрепите трубу РОГ № 2 в сборе 3 болтами и 2 гайками.

   Стандартный болт
   Параметр / Устройство Длина Болт A 25 мм (0,984 дюйма) Болт B 70 мм (2,76 дюйма)

3. Затяните 2 болта, обозначенные А, как показано на рисунке.

   Torque:

   24 Н*м  { 245 кгс*см, 18 фунт-сила-футов }

4. Затяните болт B и 2 гайки, показанные на рисунке.

   Torque:

   24 Н*м  { 245 кгс*см, 18 фунт-сила-футов }

5. Подсоедините разъем электрического клапана управления РОГ.

INSTALL EGR VALVE BRACKET

1. Install the 2 EGR valve brackets with the 3 bolts.

   Torque:

   24 N*m  { 245 kgf*cm, 18 ft.*lbf }

CONNECT NO. 8 WATER BY-PASS HOSE

1. Подсоедините перепускной шланг охлаждающей жидкости № 8 к электрическому клапану РОГ и надвиньте хомут, чтобы закрепить его.

INSTALL NO. 7 WATER BY-PASS HOSE

1. Подсоедините перепускной шланг охлаждающей жидкости № 7 к электрическому клапану РОГ и надвиньте хомут, чтобы закрепить его.

INSTALL DIESEL THROTTLE BODY ASSEMBLY

1. Install a new gasket and the diesel throttle body assembly with the 2 bolts and 2 nuts.

   Torque:

   11 N*m  { 112 kgf*cm, 8 ft.*lbf }

2. Connect the No. 6 water by-pass hose and No. 7 water by-pass hose to the diesel throttle body assembly, and slide the 2 clamps to secure it.

INSTALL VACUUM PUMP ASSEMBLY

1. Apply a light coat of engine oil to 2 new O-rings.

2. Install the 2 O-rings to the vacuum pump assembly.

3. Install the vacuum pump assembly with 3 new bolts.

   Torque:

   21 N*m  { 214 kgf*cm, 15 ft.*lbf }

4. Connect the vacuum hose.

INSTALL FAN AND GENERATOR V BELT