ENGINE UNIT INSTALLATION

CAUTION / NOTICE / HINT

Note:

Always be sure to check the tightening torque.
If the pressure lines are leaking after installation, they must be replaced.
Do not overtighten the pressure lines.
All pressure lines may only be reused 3 times. After the 3rd time, they must be replaced.

PROCEDURE

INSTALL DRIVE SHAFT BEARING BRACKET
1. Using a T50 "TORX" socket wrench, install the drive shaft bearing bracket with the 3 bolts.
  
  64 N*m
  
  650 kgf*cm
  
  47 ft.*lbf
INSTALL VACUUM CONTROL VALVE BRACKET

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INSTALL EGR BYPASS VALVE SWITCHING VALVE ASSEMBLY

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INSTALL GLOW PLUG ASSEMBLY

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INSTALL COMMON RAIL ASSEMBLY

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INSTALL INJECTION PIPE SUB-ASSEMBLY

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INSTALL NO. 3 INJECTION PIPE SUB-ASSEMBLY

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INSTALL NO. 1 ENGINE HANGER
1. Install the No. 1 engine hanger to the cylinder head sub-assembly with the bolt.
  
  Tip:
  Refer to "SPECIFICATIONS - STANDARD BOLT" for the tightening torque.
INSTALL NO. 2 ENGINE HANGER
1. Install the No. 2 engine hanger to the cylinder head sub-assembly with the 2 bolts.
  
  Tip:
  Refer to "SPECIFICATIONS - STANDARD BOLT" for the tightening torque.
INSTALL EGR VALVE BRACKET
1. Install the EGR valve bracket to the cylinder head sub-assembly with the 2 bolts.
  
  Tip:
  Refer to "SPECIFICATIONS - STANDARD BOLT" for the tightening torque.
INSTALL TURBOCHARGER STAY
1. Install the turbocharger stay with the 2 bolts.
  
  Tip:
  Refer to "SPECIFICATIONS - STANDARD BOLT" for the tightening torque.
INSTALL NO. 2 TURBO INSULATOR
1. Install the No. 2 turbo insulator with the 3 bolts.
  
  Tip:
  Refer to "SPECIFICATIONS - STANDARD BOLT" for the tightening torque.
INSTALL NO. 1 TURBO OIL PIPE
1. Install the No. 1 turbo oil pipe, 2 nuts and 2 new gaskets with the union bolt.
  
  for union bolt
  
  35 N*m
  
  357 kgf*cm
  
  26 ft.*lbf
  
  Tip:
  Refer to "SPECIFICATIONS - STANDARD BOLT" for the tightening torque.
INSTALL EXHAUST MANIFOLD

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INSTALL EGR COOLER ASSEMBLY WITH EGR VALVE ASSEMBLY

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INSTALL TURBOCHARGER SUB-ASSEMBLY

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CONNECT NO. 1 TURBO OIL PIPE

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INSTALL TURBO OIL OUTLET PIPE

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INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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INSTALL FUEL FEED PIPE SUB-ASSEMBLY
1. Install the fuel feed pipe sub-assembly with the 2 bolts.
  
  Tip:
  Refer to "SPECIFICATIONS - STANDARD BOLT" for the tightening torque.
2. Connect the 2 fuel hoses to the fuel supply pump assembly, and tighten the 2 clamps to secure the 2 hoses.
3. Connect the fuel return tube to the common rail assembly.
  (Click here)
4. Attach the fuel hose clamp.
5. Connect the nozzle leakage pipe assembly to the fuel feed pipe sub-assembly.
INSTALL INTAKE MANIFOLD

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INSTALL NO. 1 VACUUM PIPE

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INSTALL NO. 2 VACUUM HOSE ASSEMBLY
1. Install the No. 2 vacuum hose assembly to the No. 2 engine hanger with the bolt and nut.
  
  8.5 N*m
  
  87 kgf*cm
  
  75 in.*lbf
CONNECT NO. 2 VACUUM HOSE ASSEMBLY

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INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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INSTALL DIESEL THROTTLE BODY ASSEMBLY

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INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
1. Install the V-ribbed belt tensioner assembly with the 2 bolts.
  
  20 N*m
  
  204 kgf*cm
  
  15 ft.*lbf
INSTALL ENGINE MOUNTING BRACKET
1. Install the stud bolt to the engine mounting bracket.
  
  13 N*m
  
  127 kgf*cm
  
  9 ft.*lbf
2. Using an E12 "TORX" socket wrench, install the engine mounting bracket with the 3 bolts.
  
  59 N*m
  
  602 kgf*cm
  
  44 ft.*lbf
INSTALL IDLER PULLEY ASSEMBLY
1. Using a T50 "TORX" socket wrench, tighten the bolt to install the idler pulley assembly.
  
  40 N*m
  
  408 kgf*cm
  
  30 ft.*lbf
INSTALL GENERATOR ASSEMBLY

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INSTALL COMPRESSOR ASSEMBLY WITH PULLEY (w/ Air Conditioning System)

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INSTALL FAN AND GENERATOR V BELT

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CONNECT ENGINE WIRE
INSTALL ENGINE COVER