FUEL TEMPERATURE SENSOR INSTALLATION


  1. INSTALL FUEL TEMPERATURE SENSOR


    1. B007PKBE01

      Apply a light coat of light oil to a new O-ring.

    2. Install the O-ring to the fuel temperature sensor.

    3. Using the SST, install the fuel temperature sensor.

      SST
      09922-10010
      Torque:
      22 N*m  { 220 kgf*cm, 16 ft.*lbf }

  2. INSTALL INJECTION OR SUPPLY PUMP ASSEMBLY


    1. B007QUH

      Confirm that the supply pump gear in the timing gear case moves back and forth smoothly.

    2. Install a new O-ring and the pulley key to the supply pump.

    3. Aligning the projecting edge of the supply pump head to the key-slot of the supply pump gear, install the pump to the timing gear case.

    4. While holding the supply pump by hand, push the supply pump gear rearward to engage the pump gear and drive shaft.

    5. Temporarily install the supply pump with the 2 nuts.

    6. B007RG9

      Using SST, hold the crankshaft.

      SST
      09213-58013
      09330-00021

    7. Install the supply pump gear set nut.

      Tech Tips

      Set a new O-ring before tightening the supply pump gear set nut.

      Torque:
      64 N*m  { 653 kgf*cm, 47 ft.*lbf }
    8. B007UMO

      Temporarily install the supply pump stay with the 2 bolts on the engine block side.

    9. Tighten the 2 nuts for the injection pump.

      Torque:
      21 N*m  { 214 kgf*cm, 16 ft.*lbf }
    10. B007P1X

      Install the camshaft timing pulley flange No.2 and pump drive shaft pulley with the 4 bolts.

      Torque:
      31 N*m  { 316 kgf*cm, 23 ft.*lbf }

  3. CHECK PUMP DRIVE SHAFT THRUST CLEARANCE


    1. B007QNK

      Push the pump drive shaft pulley back and forth to check a thrust clearance of the injection pump drive shaft.

      Thrust clearance
      0.15 to 0.55 mm (0.0059 to 0.0217 in.)

      Note

      Make sure that the crankshaft pulley's notch is at 30 degree in the counterclockwise direction form the TDC position.

      Tech Tips

      If there is not thrust clearance, disassemble and reassemble the injection pump and pump drive shaft pulley.

  4. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    Note


    • When replacing the fuel supply pump, common rail, cylinder block, cylinder head, cylinder head gasket, or timing gear case with a new one, replace the fuel inlet pipe.

    • Be careful not to adhere dusts, dirt or any other materials onto the joint area of the fuel inlet pipe.


    1. Temporarily install the fuel inlet pipe.

    2. Using SST, tighten the injection pipe on the common rail side.

      SST
      09023-12701
      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf, for use with SST }

    3. Using SST, tighten the injection pipe on the supply pump side.

      SST
      09023-12701
      Torque:
      32 N*m  { 326 kgf*cm, 24 ft.*lbf, for use with SST }

  5. INSTALL INJECTION PIPE

    SST
    09023-12701

    Note


    • When replacing the fuel injector, common rail, or cylinder head with a new one, replace injection pipes No. 1, No. 2, No. 3, and No. 4.

    • Keep clean the joint of the injection pipe.


    1. Install the injection pipes.


      1. B007QK6

        Temporarily install the 4 injection pipes.

      2. B007SS6

        Install the injection pipe clamp No.3 in 2 nuts.

        Torque:
        5.0 N*m  { 51 kgf*cm, 44 in.*lbf }
      3. B007QK6E01

        Fasten the union sequentially, from the injection pipe common rail to the injector, using SST.

        SST
        09023-12701
        Torque:
        Use union nut wrench and torque wrench
        32 N*m  { 326 kgf*cm, 24 ft.*lbf }

  6. INSTALL OIL LEVEL GAGE GUIDE


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

    2. Apply a light coat of engine oil to the O-ring.

    3. Install the oil level gauge guide with the bolt.

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

    4. Install the oil level gauge.

  7. CONNECT INTAKE AIR CONNECTOR (w/o EGR Valve)


    1. B007OQ4E01

      Temporarily install 2 new gaskets and intake air connector No.2 to the intake air connector.

    2. B007OKQ

      Temporarily tighten the intake air connector assembly with the bolt and 2 nuts.

    3. Tighten the manifold stay with the bolt.

    4. Tighten the intake air connector with the bolt and 2 nuts.

    5. Install the vacuum hose to the intake air connector.

  8. TEMPORARILY TIGHTEN ELECTRIC EGR CONTROL VALVE ASSEMBLY (w/ EGR Valve)


    1. Temporarily tighten the EGR valve assembly with the sensor.


      1. B007UFUE01

        Install 2 new gaskets and the EGR valve to the intake air connector as shown in the illustration.

      2. B007QH9

        Temporarily tighten the intake air connector with EGR valve assembly to the intake manifold with the bolt and the 2 nuts.

      3. Install the vacuum hose to the intake air connector.

      4. Temporarily tighten the manifold stay with the bolt.

      5. B007Q7Z

        Connect the EGR valve position sensor connector.

      6. Connect the intake air temperature sensor connector.

    2. Install the vacuum regulating valve.


      1. B007SOX

        Install the vacuum regulating valve with the 2 bolts.

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

      2. Connect the 2 vacuum hoses and the regulating valve connector.

  9. INSTALL EGR PIPE SUB-ASSEMBLY NO.1 (w/ EGR Valve)


    1. B007W39

      Install the 2 gaskets to the cylinder head and EGR pipe sub-assembly as shown in the illustration.

    2. B007S6J

      Install the EGR pipe sub-assembly with the 2 bolts and 2 nuts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

    3. Tighten the intake air connector with the bolt and the 2 nuts.

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

    4. Tighten the manifold stay.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  10. REMOVE EGR PIPE SUB-ASSEMBLY NO.1 (w/ EGR Valve)


    1. Remove the 3 bolts, the 2 nuts, and the EGR pipe sub-assembly.

    2. Remove the 2 gaskets.

  11. INSTALL DIESEL THROTTLE BODY ASSEMBLY

    Note

    After removing and installing, or replacing the throttle body, be sure to perform the operation check.


    1. Install a new gasket to intake air connector.

    2. B007PX5

      Install the throttle body with the 2 bolts and the 2 nuts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }
    3. B007RAM

      Connect the 2 throttle body connectors.

  12. INSTALL AIR HOSE NO.4


    1. B007S1N

      Install the air hose No.4 with the 2 clamps.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

  13. INSTALL EGR PIPE SUB-ASSEMBLY (w/ EGR Valve)


    1. B007W39

      Install 2 new gaskets to the cylinder head and the EGR pipe sub-assembly No.1 as shown in the illustration.

    2. B007S6J

      Install the EGR pipe with the 2 bolts and the 2 nuts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }
    3. B007QY1

      Connect the fuel pressure sensor connector.

  14. INSTALL OIL RETURN HOSE


    1. B007T4F

      Connect the oil return hose with the clip.

  15. INSTALL VANE PUMP OIL RESERVOIR ASSEMBLY


    1. B007TSM

      Install the vane pump oil reservoir assembly with the 2 bolts.

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

  16. INSTALL TIMING BELT


    1. B007PVSE01

      Check that the timing marks are aligned as shown in the illustration.

    2. Install the timing belt to pump drive shaft pulley, camshaft timing pulley and timing belt idler No.1 in sequence.

    3. B007W58

      Set the tensioner to the press upright.

      Note


      • Do not allow the rod end to scratch and deform.

      • Press the tensioner rod in upward.

      • Protect a tip of the push rod with a rag in order to prevent damage.

    4. Using a press, slowly apply 981 to 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) of force to the push rod.

      Note

      Do not apply loads 981 to 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) or more on the push rod.

    5. Align the holes of push rod and housing, pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.

    6. Temporarily install the timing belt tensioner with the 2 bolts while pushing the idler pulley toward the timing belt.

    7. Tighten the 2 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

      Note

      Uniformly tighten the 2 bolts and install the tensioner

    8. Remove the 1.5 mm hexagon wrench from the tensioner.

    9. B007P0XE01

      Turn the crankshaft in the clockwise direction twice, check that the timing marks are aligned as shown in the illustration.

  17. INSTALL TIMING BELT COVER NO.1


    1. B007R8N

      Install the timing belt No.1 cover with the 6 bolts.

      Torque:
      6.0 N*m  { 61 kgf*cm, 53 in.*lbf }

    2. Install the wire harness clamp.

  18. INSTALL FAN & GENERATOR V BELT


    1. Rotate the V-ribbed belt tensioner pulley clockwise, and then install the fan and generator V belt.

      Note

      Make sure that the fan and generator V belt is set properly on each pulley.

    2. Check that the indicator mark of the V-ribbed belt tensioner Click here.

  19. INSTALL ENGINE SERVICE HOLE SUB COVER SUB-ASSEMBLY


    1. Install the engine service hole sub cover with the 5 bolts.

      Torque:
      13 N*m  { 133 kgf*cm, 10 ft.*lbf }

  20. INSTALL FRONT SEAT ASSEMBLY RH (for Hi-back Seat Type)


    1. B007T2L

      Connect the front seat inner belt assembly connector and install the front seat assembly.

    2. Align the front seat assembly adjuster pin with the holes in the body.

    3. Move the front seat assembly to the rearmost position.

      Note

      Make sure that the front seat assembly is securely locked.

    4. Temporarily tighten the 2 bolts on the front side of the front seat assembly.

    5. Move the front seat assembly fully forward.

      Note

      Make sure that the front seat assembly is securely locked.

    6. Temporarily tighten the 2 bolts on the rear side of the front seat assembly.

    7. Move the front seat assembly to the rearmost position.

      Note

      Make sure that the front seat assembly is securely locked.

    8. Fully tighten the 2 bolts on the front side of the front seat assembly in the order of outer and inner side.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

    9. Move the front seat assembly fully forward.

      Note

      Make sure that the front seat assembly is securely locked.

    10. Fully tighten the 2 bolts on the rear side of the front seat assembly in the order of outer and inner side.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

  21. INSTALL FRONT SEAT ASSEMBLY RH (for Low-back Seat Type)


    1. B007OW8

      Connect the front seat inner belt assembly connector and install the front seat assembly.

    2. Align the front seat assembly adjuster pin with the holes in the body.

    3. Move the front seat assembly to the rearmost position.

      Note

      Make sure that the front seat assembly is securely locked.

    4. Temporarily tighten the 2 bolts on the front side of the front seat assembly.

    5. Move the front seat assembly fully forward.

      Note

      Make sure that the front seat assembly is securely locked.

    6. Temporarily tighten the 2 bolts on the rear side of the front seat assembly.

    7. Move the front seat assembly to the rearmost position.

      Note

      Make sure that the front seat assembly is securely locked.

    8. Fully tighten the 2 bolts on the front side of the front seat assembly in the order of outer and inner side.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

    9. Move the front seat assembly fully forward.

      Note

      Make sure that the front seat assembly is securely locked.

    10. Fully tighten the 2 bolts on the rear side of the front seat assembly in the order of outer and inner side.

      Torque:
      39 N*m  { 398 kgf*cm, 29 ft.*lbf }

  22. INSTALL FRONT DOOR SCUFF PLATE RH

  23. CONNECT BATTERY NEGATIVE CABLE

  24. BLEED FUEL LINE


    1. B007W8BE01

      Using the hand pump, bleed air from the fuel system until pumping becomes difficult.

  25. CHECK FOR FUEL LEAKAGE


    1. PERFORM ACTIVE TEST


      1. Connect the GTS to the DLC3.

      2. Turn the ignition switch on.

      3. Turn the GTS on.

      4. Enter the following menus: Powertrain / Engine and ECT / Active Test.

      5. Perform the Active Test.

        Tester Display Test Details Control Range Diagnostic Notes
        Test the Fuel Leak Pressurizes common rail internal fuel pressure, and checks for fuel leaks Stop/Start

        • Fuel pressure inside common rail pressurized to specified value and engine speed increased to 2,000 rpm when ON is selected

        • Above conditions preserved while test is ON