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.


  1. INSTALL DRIVE SHAFT BEARING BRACKET


    1. A00OSSS

      Install the bearing bracket with the 3 bolts.

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }

  2. INSTALL EXHAUST MANIFOLD WITH TURBOCHARGER SUB-ASSEMBLY


    1. A006V7HE02
      Text in Illustration
      *1 Collar
      *2 Groove

      Temporarily install a new gasket, and the exhaust manifold and 2 collars with the 2 nuts labeled A. Tighten the nuts until the mating surface of the exhaust manifold contacts the cylinder head.

    2. Temporarily install the 6 collars with the 6 nuts.

      Tech Tips


      • When installing the collars, pay attention to the mounting orientation. The ring groove of the collar should be on the outside. Refer to the illustration.

      • Do not fully tighten the nuts as doing so may result in misalignment of the exhaust manifold.

    3. Install a new gasket and the turbocharger with 3 new nuts.

      Torque:
      60 N*m  { 612 kgf*cm, 44 ft.*lbf }
      A006WMSE02

    4. Connect the vacuum hose.

    5. A006VIIE01
      Text in Illustration
      *1 New Turbocharger Stay
      *2 Collar

      Install the 2 collars and a new turbocharger stay with the 2 nuts.

      Torque:
      36 N*m  { 367 kgf*cm, 27 ft.*lbf }

      Note

      Do not reuse the turbocharger stay.

    6. Tighten the 8 nuts of the exhaust manifold.

      Torque:
      47 N*m  { 479 kgf*cm, 35 ft.*lbf }

  3. INSTALL NO. 2 TURBO OIL PIPE


    1. A006WNME01

      Install the No. 2 turbo oil pipe and 2 new gaskets with the 2 union bolts.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

    2. Connect the vacuum hose.

  4. INSTALL NO. 5 WATER BY-PASS PIPE (for Automatic Transaxle)


    1. A006T8K

      Install the No. 5 water by-pass pipe with the 2 bolts.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

  5. INSTALL NO. 2 TURBO WATER PIPE SUB-ASSEMBLY (for Manual Transaxle)


    1. A006SNWE01
      Text in Illustration
      *1 Union Bolt

      Install the No. 2 turbo water pipe and a new gasket with the union bolt and bolt.

      Torque:
      for bolt
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }
      for union bolt
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

  6. CONNECT NO. 3 WATER BY-PASS HOSE

    A006SRM

  7. INSTALL NO. 1 TURBO WATER PIPE SUB-ASSEMBLY (for Manual Transaxle)


    1. A006WBA

      Install the No. 1 turbo water pipe and a new gasket with the union bolt.

      Torque:
      38 N*m  { 387 kgf*cm, 28 ft.*lbf }

      Note

      Make sure there is no coolant on the union bolt.

  8. INSTALL NO. 1 TURBO INSULATOR


    1. A006U13

      Install the No. 1 turbo insulator with the 2 bolts.

      Torque:
      21 N*m  { 209 kgf*cm, 15 ft.*lbf }

  9. INSTALL TURBO OIL OUTLET PIPE


    1. Install 2 new gaskets to the turbo oil outlet pipe.

    2. A006TR3E01
      Text in Illustration
      *1 Nut

      Install the turbo oil outlet pipe with the 2 bolts and 2 nuts.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  10. INSTALL EGR COOLER WITH PIPE ASSEMBLY


    1. A006WQ4E01

      Install a new O-ring to the EGR cooler with pipe.

    2. Install a new gasket to the EGR cooler and a new gasket to the No. 1 EGR pipe.

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

      A006U5SE01
      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.)

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

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

    5. Tighten the 2 bolts labeled B shown in the illustration.

      Torque:
      16 N*m  { 163 kgf*cm, 12 ft.*lbf }

    6. Tighten the 2 bolts labeled C shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

    7. Tighten the 2 bolts and 2 nuts labeled D shown in the illustration.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }
    8. A006SF6

      Connect the vacuum hose.

  11. INSTALL NO. 2 WATER BY-PASS HOSE (for Automatic Transaxle)

    A006TXG

  12. INSTALL NO. 5 WATER BY-PASS HOSE (for Manual Transaxle)

    A006WB1

  13. INSTALL NO. 1 TURBO WATER HOSE (for Manual Transaxle)

    A006V3D

  14. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    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.

      A003DM6E01
    2. A003AVD

      Temporarily install the exhaust manifold converter with the 3 nuts.

    3. A003DF4

      Temporarily install the No. 2 exhaust manifold stay with the 2 bolts and nut.

    4. A003AZX

      Temporarily install the No. 2 manifold stay with the 3 bolts.

    5. A003D1P

      Temporarily install the manifold stay with the bolt and nut.

    6. A003CFEE01

      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. A003AVD

      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. A003CTP

      Tighten the nut of the No. 2 exhaust manifold stay.

      Torque:
      56 N*m  { 571 kgf*cm, 41 ft.*lbf }
    9. A003ARW

      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. A003CFO

      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. A003DU8

      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. A003CGT

      Tighten the nut of the manifold stay.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
    13. A003DW1

      Connect the 2 connectors.

  15. INSTALL NO. 1 MANIFOLD CONVERTER INSULATOR


    1. A003CP1

      Install the No. 1 manifold converter insulator with the 5 bolts.

      Torque:
      29 N*m  { 291 kgf*cm, 21 ft.*lbf }

  16. INSTALL VACUUM SWITCHING VALVE BRACKET


    1. A00ORBC

      Install the vacuum switching valve bracket with the 5 bolts.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    2. Connect the 2 vacuum hoses.

  17. INSTALL NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY


    1. A00ORKZ

      Install the No. 1 vacuum transmitting pipe with the bolt.

      Torque:
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

    2. Connect the 2 vacuum hoses.

  18. INSTALL NO. 1 TURBO OIL PIPE


    1. A00OUMZE01

      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.

  19. 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. A00OUN0

      Install the by-pass pipe with the 2 bolts.

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

  20. INSTALL FUEL HOSE PROTECTOR


    1. A00OT11

      Install the fuel hose protector to the cylinder head.

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

  21. INSTALL SUPPLY PUMP ASSEMBLY

    A00OVCA

    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.

  22. INSTALL NO. 3 FUEL HOSE

    A00ORMT

  23. INSTALL FUEL INJECTOR SEAL


    1. A003ELAE01
      Text in Illustration
      *1 Fuel Injector Seal

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

  24. INSTALL EXHAUST FUEL ADDITION INJECTOR ASSEMBLY

    Note

    If there is foreign matter on the installation surface of the exhaust fuel addition injector, be sure to clean it before installation.


    1. A003E5DE01

      Install a new gasket, the exhaust fuel addition injector, nozzle holder clamp and washer with the bolt.

      Torque:
      29 N*m  { 296 kgf*cm, 21 ft.*lbf }
      Text in Illustration
      *1 Washer
      *2 Nozzle Holder Clamp

      Tech Tips

      Align the nozzle holder clamp with the cutouts of the injector as shown in the illustration.

      A003D76E01
      Text in Illustration
      *1 Nozzle Holder Clamp

  25. INSTALL FUEL TUBE SUB-ASSEMBLY


    1. A003D04E01
      Text in Illustration
      *1 Check Valve

      Temporarily install the fuel tube 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 }
    4. A003C5C

      Connect the fuel tube connector to the injector.

    5. A003DXDE01
      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.

    6. A003CV6

      Connect the exhaust fuel addition injector connector.

  26. INSTALL FUEL HOSE PROTECTOR


    1. A003BGR

      Install the fuel hose protector with the bolt.

      Torque:
      21 N*m  { 209 kgf*cm, 15 ft.*lbf }

  27. INSTALL NO. 2 WATER BY-PASS PIPE


    1. A00OUK0

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

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  28. INSTALL NO. 4 WATER BY-PASS HOSE

    A00ORW3

  29. INSTALL NO. 8 WATER BY-PASS HOSE

    A00OR5P

  30. INSTALL NO. 6 WATER BY-PASS HOSE

    A00OUJ2

  31. 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.

    A003DA0E01

  32. INSTALL NO. 1 CYLINDER BLOCK INSULATOR


    1. A00OV0J

      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.

  33. INSTALL GLOW PLUG ASSEMBLY


    1. A00OUIO

      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.

  34. INSTALL INTAKE MANIFOLD


    1. A003EHNE01

      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.

    2. A003DELE02
      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 Specified Condition
      Bolt A 90 mm (3.54 in.)
      Bolt B 25 mm (0.984 in.)

  35. INSTALL NO. 2 INTAKE MANIFOLD


    1. A003DE3

      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 }

  36. INSTALL ENGINE COVER BRACKET


    1. A003EJ9

      Install the engine cover bracket with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  37. INSTALL GAS FILTER BRACKET


    1. A003AWW

      Install the gas filter bracket with the 2 bolts.

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

  38. INSTALL NO. 1 GAS FILTER


    1. A003BCNE01
      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.

  39. INSTALL DIESEL TURBO PRESSURE SENSOR


    1. A00OU7HE01
      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.

  40. INSTALL INTAKE MANIFOLD INSULATOR


    1. A003CC9

      Install the intake manifold insulator to the intake manifold.

  41. INSTALL COMMON RAIL ASSEMBLY


    1. A00OS2W

      Install the common rail with the 2 bolts.

      Torque:
      21 N*m  { 209 kgf*cm, 15 ft.*lbf }

  42. INSTALL NO. 4 FUEL HOSE

    A00OSTV

  43. INSTALL INJECTION PIPE


    1. A003C13

      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 }

  44. INSTALL FUEL INLET PIPE SUB-ASSEMBLY


    1. A003B35

      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 }

  45. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


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

    2. A00OQW3

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

      Torque:
      33 N*m  { 337 kgf*cm, 24 ft.*lbf }

    3. Install the engine oil level dipstick.

  46. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A006TUJE01
      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. A006UZM

      Install the electric EGR control valve.

  47. INSTALL NO. 2 EGR PIPE SUB-ASSEMBLY


    1. Install a new gasket to the electric EGR control valve.

    2. Install a new gasket to the No. 2 EGR pipe.

    3. A006VT0E06
      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.)

    4. Tighten the 2 bolts labeled A shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

    5. Tighten the bolt labeled B and 2 nuts shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }
    6. A006VQF

      Connect the electric EGR control valve connector.

  48. INSTALL EGR VALVE BRACKET


    1. A00ORPA

      Install the 2 EGR valve brackets with the 3 bolts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  49. CONNECT NO. 8 WATER BY-PASS HOSE

    A00OR5P

  50. INSTALL NO. 7 WATER BY-PASS HOSE

    A003C0A

  51. INSTALL DIESEL THROTTLE BODY ASSEMBLY


    1. A00OSP8

      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. A00OQTYE01
      Text in Illustration
      *1 No. 6 Water By-pass Hose
      *2 No. 7 Water By-pass Hose

      Connect the No. 6 and No. 7 water by-pass hoses.

  52. 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. A00ORBQ

      Install the vacuum pump with new 3 bolts.

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

    4. Connect the vacuum hose.

  53. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. A00OTYB

      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.

  54. INSTALL ENGINE MOUNTING BRACKET


    1. A00OTLAE01

      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 }

  55. INSTALL NO. 4 WATER BY-PASS PIPE


    1. A00ORNB

      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 }

  56. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. A00OTEK

      Install the idler pulley with the bolt.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  57. INSTALL IDLER PULLEY COVER PLATE


    1. Install the idler pulley cover plate.

  58. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. A00OSTA

      Install the idler pulley and plate with the bolt.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  59. INSTALL GENERATOR ASSEMBLY


    1. A00OV15

      Install the generator with the 3 bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

  60. INSTALL COMPRESSOR STAY


    1. A00OSDQ

      Install the compressor stay to the cylinder block.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }