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. Install the bearing bracket with the 3 bolts.

      Torque:
      64 N*m  { 650 kgf*cm, 47 ft.*lbf }

  2. INSTALL EXHAUST MANIFOLD WITH TURBOCHARGER SUB-ASSEMBLY


    1. A01INXCE02
      Text in Illustration
      *1 Collar
      *2 Groove

      Temporarily install a new gasket, and the exhaust manifold and 2 collars with 2 new 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 6 new 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. A01INKZE01

      Using an E8 "TORX" wrench, install a new stud bolt.

      Torque:
      8.0 N*m  { 82 kgf*cm, 71 in.*lbf }

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

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

    5. Connect the vacuum hose.

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

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

      Note

      Do not reuse the turbocharger stay.

    7. 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. 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. 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. 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

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


    1. 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. 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. 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. 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.

      A01IMXEE01
      Text in Illustration
      *1 Nut - -
      Standard Bolt
      Item Length
      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. Connect the vacuum hose.

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

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

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

  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.

      A01IO93E01
    2. A01IQ9Q

      Temporarily install the exhaust manifold converter with 3 new nuts.

    3. A01IUQ6

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

    4. A01IQ6M

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

    5. A01IUEH

      Temporarily install the manifold stay with the bolt and nut.

    6. A01IN6VE01

      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. A01IQ9Q

      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. A01IU0C

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

      Torque:
      56 N*m  { 571 kgf*cm, 41 ft.*lbf }
    9. A01IQA2

      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. A01INQC

      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. A01INQW

      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. A01IPQW

      Tighten the nut of the manifold stay.

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

    13. Connect the 2 connectors.

  15. INSTALL NO. 1 MANIFOLD CONVERTER INSULATOR


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

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

  16. INSTALL VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A01IQ2TE01
      Text in Illustration
      *a CORRECT
      *b INCORRECT
      A01INHX Paint Mark

      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.

  17. INSTALL VACUUM REGULATING VALVE ASSEMBLY


    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.

  18. 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.

  19. INSTALL NO. 1 TURBO OIL PIPE


    1. A01ITWME01

      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.

  20. INSTALL NO. 3 WATER BY-PASS PIPE


    1. Apply soapy water to a new O-ring and install it to the water by-pass pipe.

    2. Install the water by-pass pipe with the 2 bolts.

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

  21. INSTALL FUEL HOSE PROTECTOR


    1. Install the fuel hose protector to the cylinder head.

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

  22. INSTALL SUPPLY PUMP ASSEMBLY


    1. Install a new O-ring to the supply pump.

    2. Install the supply pump drive coupling.

      Tech Tips

      Align 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

      Align 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.

  23. INSTALL NO. 3 FUEL HOSE

  24. INSTALL FUEL INJECTOR SEAL


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

  25. 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 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.

      A01INO9E01
      Text in Illustration
      *1 Nozzle Holder Clamp

  26. INSTALL FUEL TUBE SUB-ASSEMBLY


    1. 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. A01IPE8

      Connect the fuel tube connector to the injector.

    5. A01IQ7XE01
      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. Connect the exhaust fuel addition injector connector.

  27. INSTALL FUEL HOSE PROTECTOR


    1. Install the fuel hose protector with the bolt.

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

  28. 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 }

  29. INSTALL NO. 4 WATER BY-PASS HOSE

  30. INSTALL NO. 8 WATER BY-PASS HOSE

  31. INSTALL NO. 6 WATER BY-PASS HOSE

  32. 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.

    A01IU9WE03
    Text in Illustration
    *1 Paint Mark
    *a Upper Side

  33. INSTALL NO. 1 CYLINDER BLOCK INSULATOR


    1. A01ITY5

      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.

  34. 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.

  35. INSTALL INTAKE MANIFOLD


    1. A01IRJAE01

      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. A01IOHHE02
      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 }
      Standard Bolt
      Item Length
      Bolt A 90 mm (3.54 in.)
      Bolt B 25 mm (0.984 in.)

  36. 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 }

  37. INSTALL ENGINE COVER BRACKET


    1. Install the engine cover bracket with the bolt.

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

  38. 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 }

  39. INSTALL NO. 1 GAS FILTER


    1. A01IOCKE01
      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.

  40. INSTALL DIESEL TURBO PRESSURE SENSOR


    1. A01IOD1E01
      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.

  41. INSTALL INTAKE MANIFOLD INSULATOR


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

  42. INSTALL COMMON RAIL ASSEMBLY


    1. Install the common rail with the 2 bolts.

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

  43. INSTALL NO. 4 FUEL HOSE

  44. INSTALL INJECTION PIPE


    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 }

  45. 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 }

  46. 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.

  47. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A01IN07E01
      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. A01IQP8

      Install the electric EGR control valve.

  48. INSTALL NO. 2 EGR PIPE SUB-ASSEMBLY


    1. Install 2 new gaskets to the No. 2 EGR pipe and electric EGR control valve.

    2. A01IPRKE06
      Text in Illustration
      *1 Nut

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

      Standard Bolt
      Item Length
      Bolt A 25 mm (0.984 in.)
      Bolt B 70 mm (2.76 in.)

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

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

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

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }
    5. A01IOQA

      Connect the electric EGR control valve connector.

  49. INSTALL EGR VALVE BRACKET


    1. Install the 2 brackets with the 3 bolts.

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

  50. CONNECT NO. 8 WATER BY-PASS HOSE

    A01INDM

  51. INSTALL NO. 7 WATER BY-PASS HOSE

  52. 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.

  53. 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.

  54. 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 bolt heads are not as thick as typical bolts, be careful not to damage them during installation.

  55. INSTALL ENGINE MOUNTING BRACKET


    1. A01IUBZE01

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

    4. Tighten the 2 bolts labeled B and 2 nuts.

      Torque:
      80 N*m  { 816 kgf*cm, 59 ft.*lbf }

    5. Install the stud bolt to the engine mounting bracket.

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

  56. 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 }

  57. 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 }

  58. INSTALL IDLER PULLEY COVER PLATE


    1. Install the idler pulley cover plate.

  59. 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 }

  60. INSTALL GENERATOR ASSEMBLY


    1. Install the generator with the 3 bolts.

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

  61. INSTALL COMPRESSOR STAY


    1. Install the compressor stay to the cylinder block.

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

  62. INSTALL COMPRESSOR WITH PULLEY ASSEMBLY


    1. Using an E8 "TORX" socket wrench, install the compressor with pulley with the 2 stud bolts.

      Torque:
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }

    2. Install the 2 bolts and 2 nuts.

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

    3. Connect the connector.

  63. INSTALL FAN AND GENERATOR V BELT


    1. Using a 22 mm wrench, rotate the tensioner pulley counterclockwise, and then install the fan and generator V belt.

      CAUTION:


      • Be careful as the wrench only fits loosely on the belt tensioner tool set point. The wrench may come off the set point and cause injuries.

      • Be careful that your hands do not become jammed between parts such as the belt, pulleys, etc.