ENGINE UNIT INSTALLATION

Note

When replacing the injectors (including shuffling the injectors between the cylinders), common rail, intake manifold or cylinder head, it is necessary to replace the injection pipes with new ones.
When replacing the fuel supply pump, common rail, intake manifold or cylinder head, it is necessary to replace the fuel inlet pipe with a new one.

INSTALL DRIVE SHAFT BEARING BRACKET
1. Install the bearing bracket with the 3 bolts.
  
  Torque:
  
  64 N*m { 653 kgf*cm, 47 ft.*lbf }
INSTALL EXHAUST MANIFOLD AND TURBOCHARGER SUB-ASSEMBLY (for CCo)

Click here
INSTALL EXHAUST MANIFOLD AND TURBOCHARGER SUB-ASSEMBLY (for DPF)

Click here

INSTALL EGR COOLER WITH PIPE ASSEMBLY

Install a new O-ring to the EGR cooler with pipe.
Install a new gasket to the EGR cooler and a new gasket to the No. 1 EGR pipe.

Temporarily install the EGR cooler with pipe with the 6 bolts and 2 nuts labeled A, B and C.

Text in Illustration
*1	Nut	-	-

Bolt Length

Item	Specified Condition
Bolt A	16 mm (0.630 in.)
Bolt B	16 mm (0.630 in.)
Bolt C	25 mm (0.984 in.)

Tighten the 2 bolts and 2 nuts labeled A shown in the illustration.

Torque:

10 N*m { 102 kgf*cm, 7 ft.*lbf }
Tighten the 2 bolts labeled B shown in the illustration.

Torque:

16 N*m { 163 kgf*cm, 12 ft.*lbf }
Tighten the 2 bolts labeled C shown in the illustration.

Torque:

24 N*m { 245 kgf*cm, 18 ft.*lbf }
Tighten the 2 bolts and 2 nuts labeled D shown in the illustration.

Torque:

21 N*m { 214 kgf*cm, 15 ft.*lbf }
Connect the vacuum hose.

INSTALL NO. 2 WATER BY-PASS HOSE
INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (for CCo)
1. Install a new gasket to the turbocharger.
  
  Tech Tips
  
  Make sure that the part labeled A is facing downwards as shown in the illustration.
2. Temporarily install the exhaust manifold converter with 3 new nuts.
3. Temporarily install the No. 2 exhaust manifold stay with the 2 bolts and nut.
4. Temporarily install the No. 2 manifold stay with the 3 bolts.
5. Temporarily install the manifold stay with the bolt and nut.
6. Tighten the 2 bolts of the No. 2 exhaust manifold stay in the order shown in the illustration.
  
  Torque:
  
  56 N*m { 571 kgf*cm, 41 ft.*lbf }
7. Tighten the 3 nuts of the exhaust manifold converter.
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
  
  Note
  
  Tighten the nuts while pressing the exhaust manifold converter against the engine.
8. Tighten the nut of the No. 2 exhaust manifold stay.
  
  Torque:
  
  56 N*m { 571 kgf*cm, 41 ft.*lbf }
9. Tighten the bolt of the No. 2 manifold stay shown in the illustration.
  
  Torque:
  
  56 N*m { 571 kgf*cm, 41 ft.*lbf }
  
  Note
  
  Tighten the bolt while pressing the No. 2 manifold stay against the exhaust manifold converter and cylinder block.
10. Tighten the 2 bolts of the No. 2 manifold stay shown in the illustration.
  
  Torque:
  
  56 N*m { 571 kgf*cm, 41 ft.*lbf }
11. Tighten the bolt of the manifold stay.
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
  
  Note
  
  Tighten the bolt while pressing the manifold stay against the exhaust manifold converter and cylinder block.
12. Tighten the nut of the manifold stay.
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (for DPF)
1. Install a new gasket to the turbocharger.
  
  Text in Illustration
  
  Top
  
  Tech Tips
  
  Make sure that the part labeled A is facing downwards as shown in the illustration.
2. Temporarily install the exhaust manifold converter with 3 new nuts.
3. Temporarily install the No. 2 exhaust manifold stay with the 2 bolts and nut.
4. Temporarily install the No. 2 manifold stay with the 3 bolts.
5. Temporarily install the manifold stay with the bolt and nut.
6. Tighten the 2 bolts of the No. 2 exhaust manifold stay in the order shown in the illustration.
  
  Torque:
  
  56 N*m { 571 kgf*cm, 41 ft.*lbf }
7. Tighten the 3 nuts of the exhaust manifold converter.
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
  
  Note
  
  Tighten the nuts while pressing the exhaust manifold converter against the engine.
8. Tighten the nut of the No. 2 exhaust manifold stay.
  
  Torque:
  
  56 N*m { 571 kgf*cm, 41 ft.*lbf }
9. Tighten the bolt of the No. 2 manifold stay shown in the illustration.
  
  Torque:
  
  56 N*m { 571 kgf*cm, 41 ft.*lbf }
  
  Note
  
  Tighten the bolt while pressing the No. 2 manifold stay against the exhaust manifold converter and cylinder block.
10. Tighten the 2 bolts of the No. 2 manifold stay shown in the illustration.
  
  Torque:
  
  56 N*m { 571 kgf*cm, 41 ft.*lbf }
11. Tighten the bolt of the manifold stay.
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
  
  Note
  
  Tighten the bolt while pressing the manifold stay against the exhaust manifold converter and cylinder block.
12. Tighten the nut of the manifold stay.
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
13. Connect the 2 connectors.
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 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 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 NO. 1 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 }

Text in Illustration
	Top

INSTALL VACUUM TRANSMITTING HOSE ASSEMBLY

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.

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. 1 TURBO OIL PIPE
1. Install the oil pipe and 2 new gaskets with the 2 union bolts.
  
  Torque:
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }
  
  Tech Tips
  
  Be sure to install union bolt A so that the gasket is positioned as shown in the illustration.
INSTALL NO. 3 WATER BY-PASS PIPE
1. Apply soapy water to a new O-ring and install it to the by-pass pipe.
2. Install the No. 3 water by-pass pipe with the 2 bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL FUEL HOSE PROTECTOR
1. Install the fuel hose protector to the cylinder head.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
INSTALL SUPPLY PUMP ASSEMBLY
1. Install a new O-ring to the supply pump.
2. Install the supply pump drive coupling.
  
  Tech Tips
  
  Line up the coupling with the groove in the camshaft end.
  
  Note
  
  When reusing the coupling, it must be installed in the same orientation (top/bottom, front/back) as when it was removed,
3. Install the supply pump with the 2 bolts.
  
  Torque:
  
  21 N*m { 209 kgf*cm, 15 ft.*lbf }
  
  Tech Tips
  
  Line up the end of the supply pump drive shaft with the supply pump drive coupling.
  
  Note
  
  Apply engine oil to the O-ring of the supply pump.
INSTALL NO. 3 FUEL HOSE
INSTALL FUEL INJECTOR SEAL (for DPF)
1. Install a new fuel injector seal to the exhaust fuel addition injector.
INSTALL EXHAUST FUEL ADDITION INJECTOR ASSEMBLY (for DPF)
Note

If there is foreign matter on the installation surface of the exhaust fuel addition injector, be sure to clean the injector before installation.
1. Install a new gasket, the exhaust fuel addition injector, the nozzle holder clamp, and the washer with the bolt.
  
  Torque:
  
  29 N*m { 296 kgf*cm, 21 ft.*lbf }
  
  Tech Tips
  
  Align the nozzle holder clamp with the cutouts of the injector as shown in the illustration.
  
  Text in Illustration
  
  *1 Nozzle Holder Clamp
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 }

Text in Illustration
*1	Nozzle Holder Clamp

INSTALL FUEL TUBE SUB-ASSEMBLY (for DPF)

Temporarily install the fuel tube and 2 new gaskets with the check valve and union bolt.
Tighten the check valve.

Torque:

32 N*m { 321 kgf*cm, 23 ft.*lbf }
Tighten the union bolt.

Torque:

23 N*m { 235 kgf*cm, 17 ft.*lbf }
Connect the fuel tube connector to the injector.

Text in Illustration
*1	Fuel Tube Connector
*2	Injector
*3	Retainer
*4	O-Ring

Turn the retainer in the direction indicated by the arrow until it makes a "click" sound.

Note

If the fuel tube connector is not inserted to the correct position on the injector, the retainer cannot be turned far enough in the direction of the arrow.

Connect the exhaust fuel addition injector connector.

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 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
INSTALL NO. 8 WATER BY-PASS HOSE
INSTALL NO. 6 WATER BY-PASS HOSE
INSTALL WATER BY-PASS HOSE

Tech Tips

Make sure the claws of hose clamp A are positioned above the paint mark as shown in the illustration.

Text in Illustration

*1 Paint Mark

*a Upper Side
INSTALL NO. 1 CYLINDER BLOCK INSULATOR
1. Install the No. 1 cylinder block insulator to the cylinder block.
  
  Note
  
  Be sure to install the oil cooler before installing the No. 1 cylinder block insulator.
INSTALL GLOW PLUG ASSEMBLY
1. Using a 10 mm deep socket wrench, install the 4 glow plugs.
  
  Torque:
  
  12 N*m { 125 kgf*cm, 9 ft.*lbf }
2. Install the glow plug connector with the 4 nuts.
  
  Torque:
  
  2.2 N*m { 22 kgf*cm, 19 in.*lbf }
3. Install the 4 grommets.

Text in Illustration
*1	Paint Mark
*a	Upper Side

INSTALL INTAKE MANIFOLD

Install a new gasket to the cylinder head.

Tech Tips

Install the gasket with the part labeled A facing the right side of the vehicle as shown in the illustration.

Text in Illustration
*1	Nut

Install the intake manifold with the 7 bolts and 2 nuts.

Torque:: 23 N*m { 235 kgf*cm, 17 ft.*lbf }

Bolt Length

Item	Length
Bolt A	90 mm (3.54 in.)
Bolt B	25 mm (0.984 in.)

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 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 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 with the 2 bolts.
  
  Torque:
  
  21 N*m { 209 kgf*cm, 15 ft.*lbf }
INSTALL NO. 4 FUEL HOSE
INSTALL INJECTION PIPE SUB-ASSEMBLY
1. Using a 14 mm union nut wrench, tighten the 4 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 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 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 with the 2 clamps and nut.
2. Using a 14 mm union nut wrench, first tighten the nut at the common rail end of the fuel inlet pipe.
  
  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 supply pump end of the fuel inlet pipe.
  
  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. Connect the connector and attach the wire harness clamp to the engine oil level dipstick guide.
4. Install the engine oil level dipstick.
INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY
1. Text in Illustration
  
  *1 Protrusion
  
  Install a new gasket.
  
  Note
  
  Make sure the protrusion of the gasket is facing upward as shown in the illustration.
2. Install the electric EGR control valve.

Text in Illustration
*1	Protrusion
*2	Groove

Text in Illustration
*1	Protrusion

Text in Illustration
*1	Protrusion

INSTALL NO. 2 EGR PIPE SUB-ASSEMBLY

Install a new gasket to the electric EGR control valve.

Text in Illustration
*1	Nut

Temporarily install the No. 2 EGR pipe with the 3 bolts and 2 nuts.

Bolt Length

Item	Specified Condition
Bolt A	25 mm (0.984 in.)
Bolt B	70 mm (2.76 in.)

Tighten the 2 bolts labeled A shown in the illustration.

Torque:

24 N*m { 245 kgf*cm, 18 ft.*lbf }
Tighten the bolt and 2 nuts labeled B shown in the illustration.

Torque:

24 N*m { 245 kgf*cm, 18 ft.*lbf }
Connect the electric EGR control valve connector.

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
INSTALL NO. 7 WATER BY-PASS HOSE
INSTALL DIESEL THROTTLE BODY ASSEMBLY
1. Install a new gasket and the diesel throttle body with the 2 bolts and 2 nuts.
  
  Torque:
  
  11 N*m { 112 kgf*cm, 8 ft.*lbf }
2. Connect the No. 6 and No. 7 water by-pass hoses.
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.
3. Install the vacuum pump with 3 new bolts.
  
  Torque:
  
  21 N*m { 214 kgf*cm, 15 ft.*lbf }
4. Connect the vacuum hose.
INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
1. Install the belt tensioner with the 3 bolts.
  
  Torque:
  
  20 N*m { 204 kgf*cm, 15 ft.*lbf }
  
  Note
  
  As the bolts' heads are not as thick as typical bolts, be careful not to damage them during installation.
INSTALL ENGINE MOUNTING BRACKET
1. Set the mounting bracket on the engine.
2. Temporarily install the 2 bolts labeled B and 2 nuts.
3. Install the 2 bolts labeled A.
  
  Torque:
  
  for bolt A
  
  28 N*m { 286 kgf*cm, 21 ft.*lbf }
4. Tighten the 2 bolts labeled B and 2 nuts.
  
  Torque:
  
  for bolt B, nut
  
  80 N*m { 816 kgf*cm, 59 ft.*lbf }
INSTALL NO. 4 WATER BY-PASS PIPE
1. Install a new O-ring to the No. 4 water by-pass pipe.
2. Install the No. 4 water by-pass pipe with the bolt.
  
  Torque:
  
  11 N*m { 112 kgf*cm, 8 ft.*lbf }
INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY
1. Install the idler pulley with the bolt.
  
  Torque:
  
  40 N*m { 408 kgf*cm, 30 ft.*lbf }
INSTALL IDLER PULLEY COVER PLATE
1. Install the idler pulley cover plate.
INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
1. Install the idler pulley and plate with the bolt.
  
  Torque:
  
  40 N*m { 408 kgf*cm, 30 ft.*lbf }
INSTALL GENERATOR ASSEMBLY
1. Install the generator with the 3 bolts.
  
  Torque:
  
  25 N*m { 255 kgf*cm, 18 ft.*lbf }
INSTALL COMPRESSOR STAY
1. Install the compressor stay to the cylinder block.
  
  Torque:
  
  35 N*m { 357 kgf*cm, 26 ft.*lbf }