FUEL COOLER (for Engine Room Side) INSTALLATION


  1. CONNECT NO. 7 WATER BY-PASS HOSE


    1. A0156K4E03

      Connect the water by-pass hose to the fuel cooler.

      Tech Tips


      • Align the alignment marks and connect the hose.

      • Align the pinching portion of the clamp with the hose alignment mark and connect the hose.

  2. INSTALL FUEL COOLER ASSEMBLY


    1. A0159DJ

      Install the fuel cooler with the 2 bolts.

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

  3. CONNECT NO. 3 FUEL HOSE


    1. A015DF0

      Connect the fuel hose to the fuel cooler.

      Tech Tips


      • Align the alignment marks and connect the hose.

      • Align the pinching portion of the clamp with the hose alignment mark and connect the hose.

  4. CONNECT NO. 6 WATER BY-PASS HOSE

  5. INSTALL NO. 4 NOZZLE LEAKAGE PIPE


    1. A015AQIE01

      Temporarily install a new gasket and the No. 4 nozzle leakage pipe with the union bolt and bolt.

    2. Tighten the union bolt and bolt in the order shown in the illustration.

      Torque:
      for union bolt
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for bolt
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    3. Connect the No. 2 fuel hose to the fuel cooler.

  6. INSTALL NO. 3 NOZZLE LEAKAGE PIPE


    1. A015AB8E01

      Temporarily install a new gasket and the No. 3 nozzle leakage pipe with the union bolt and bolt.

    2. Tighten the union bolt and bolt in the order shown in the illustration.

      Torque:
      for union bolt
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for bolt
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    3. Connect the No. 1 fuel hose to the fuel cooler.

  7. INSTALL EGR COOLER INSULATOR (w/ EGR System)

  8. INSTALL EGR VALVE ASSEMBLY WITH EGR COOLER (w/ EGR System)


    1. Connect the No. 5 water by-pass hose to the water by-pass outlet.

    2. A01584ZE01

      Install 2 new gaskets and the EGR valve with EGR cooler with the 6 bolts labeled A and 4 bolts labeled B shown in the illustration.

      Torque:
      for bolt A
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      for bolt B
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }

      Tech Tips

      The gasket claws should face toward the No. 1 and No. 2 EGR pipes.

  9. INSTALL EGR PIPE INSULATOR (w/ EGR System)


    1. Install the EGR pipe insulator with the 2 bolts.

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

      Note

      If the No. 1 and No. 2 EGR pipe insulator installation stay is deformed, or the bolt holes of the EGR pipe insulator do not align, replace the No. 1 and No. 2 EGR pipes as a set.

  10. INSTALL INTAKE MANIFOLD INSULATOR (w/ EGR System)

  11. INSTALL NO. 3 INTAKE MANIFOLD

    A015DAAE01

    1. Install 2 new gaskets to the No. 1 and No. 2 intake manifolds.

    2. Install the No. 3 intake manifold with the 16 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
      Bolt Length
      Item Length
      Bolt A 25 mm (0.984 in.)
      Bolt B 70 mm (2.76 in.)

  12. CONNECT NO. 2 ENGINE WIRE


    1. A0156MME01

      Connect the No. 2 engine wire with the 3 bolts.

      Torque:
      for bolt A
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
      for bolt B
      32 N*m  { 326 kgf*cm, 24 ft.*lbf }

    2. Attach the 2 wire harness clamps.

  13. INSTALL INTAKE PIPE


    1. w/ EGR System:

      Install 2 new gaskets and the intake pipe with the 6 bolts and 2 nuts.

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

    2. w/o EGR System:

      Install a new gasket and the intake pipe with the 4 bolts and 2 nuts.

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

  14. INSTALL NO. 2 INTAKE MANIFOLD INSULATOR (w/ Intercooler)

  15. INSTALL NO. 1 INTAKE MANIFOLD INSULATOR (w/ Intercooler)

  16. INSTALL COMMON RAIL ASSEMBLY LH AND RH

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