ENGINE UNIT(w/ Glow Plug Controller) INSTALLATION

PROCEDURE

  1. INSTALL NO. 2 OIL PAN COVER SILENCER

    1. Install the No. 2 oil pan cover silencer to the oil pan sub-assembly with the 2 bolts and 2 plate washers.

      7.0 N*m

      71 kgf*cm

      62 in.*lbf

  2. INSTALL OIL PAN COVER

    1. Install the oil pan cover to the oil pan sub-assembly with the 2 bolts and 2 plate washers.

      7.0 N*m

      71 kgf*cm

      62 in.*lbf

  3. INSTALL NO. 2 TURBOCHARGER STAY

    1. Install the No. 2 turbocharger stay to the cylinder head sub-assembly with the 2 bolts.

      37 N*m

      377 kgf*cm

      27 ft.*lbf

  4. INSTALL HARNESS BRACKET

    1. Install the harness bracket to the timing chain cover sub-assembly with the bolt.

      8.4 N*m

      86 kgf*cm

      74 in.*lbf

  5. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

    1. A348760N01

      Install the V-ribbed belt tensioner assembly to the timing chain cover sub-assembly with the 2 bolts.

      24 N*m

      245 kgf*cm

      18 ft.*lbf

      Bolt Length

      Bolt

      Length

      (A)

      20 mm (0.787 in.)

      (B)

      50 mm (1.97 in.)

  6. INSTALL VACUUM PUMP ASSEMBLY

    1. A353979

      Install 2 new O-rings to the vacuum pump assembly.

      Note:

      Do not twist the O-ring.

    2. C165378N02

      Install the vacuum pump assembly so that the coupling teeth (A) on the side of the vacuum pump assembly engages with the tip groove of camshaft (B).

    3. Install the vacuum pump assembly to the cylinder head sub-assembly with 2 new bolts.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

      Note:

      Make sure that the O-ring is not damaged or does not jump out of position during installation.

  7. INSTALL WATER INLET PIPE

    1. Install the water inlet pipe to the cylinder block sub-assembly with the 2 bolts.

      9.0 N*m

      92 kgf*cm

      80 in.*lbf

  8. INSTALL WATER INLET HOSE LH

    1. A349655C01

      *a

      View (A)

      *b

      Upper of Engine

      *c

      LH of Engine

      Install the water inlet hose LH to the water inlet pipe and water inlet housing, and slide the 2 hose clips to secure it.

      Note:

      Perform the installation with the hose clip at the correct angle.

      Tip:

      The hose clip at the water inlet housing can be installed in any orientation, as long as it does not contact any of the surrounding parts.

  9. INSTALL WATER INLET HOSE RH

    1. A349656C01

      *a

      View (A)

      *b

      View (B)

      *c

      Upper of Engine

      *d

      RH of Engine

      *e

      Rear of Engine

      Install the water inlet hose RH to the water outlet sub-assembly and water inlet pipe, and slide the 2 hose clips to secure it.

      Note:

      Perform the installation with the hose clips at the correct angle.

  10. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY

    1. Install a new O-ring to the water by-pass pipe sub-assembly.

      Note:

      • Apply coolant around the O-ring groove of the water inlet housing before installing the water by-pass pipe sub-assembly.

      • Do not twist the O-ring.

    2. A349708C01

      *a

      View (A)

      *b

      Upper of Engine

      *c

      RH of Engine

      Install the water by-pass hose to the water by-pass pipe sub-assembly and slide the hose clip to secure it.

      Note:

      Perform the installation with the hose clip at the correct angle.

    3. Install the water by-pass pipe sub-assembly to the No. 2 turbocharger stay, cylinder head sub-assembly, cylinder block sub-assembly and water inlet housing with the 3 bolts.

      9.0 N*m

      92 kgf*cm

      80 in.*lbf

      Note:

      Make sure that the O-ring is not damaged or does not jump out of position during installation.

    4. Install the 3 clamps to the water by-pass pipe sub-assembly.

  11. CONNECT WATER BY-PASS HOSE

    1. A349657C01

      *a

      View (A)

      *b

      Upper of Engine

      *c

      Front of Engine

      Connect the water by-pass hose to the tube connector and slide the hose clip to secure it.

      Note:

      Perform the installation with the hose clip at the correct angle.

  12. INSTALL NO. 6 WATER BY-PASS HOSE

    1. A349658C01

      *a

      View (A)

      *b

      View (B)

      *c

      Upper of Engine

      *d

      Front of Engine

      *e

      RH of Engine

      Install the No. 6 water by-pass hose to the water by-pass pipe sub-assembly and water outlet sub-assembly, and slide the 2 hose clips to secure it.

      Note:

      Perform the installation with the hose clips at the correct angle.

  13. INSTALL NO. 2 TURBO WATER HOSE

    1. A349659C01

      *a

      View (A)

      *b

      Upper of Engine

      *c

      LH of Engine

      Install the No. 2 turbo water hose to the water by-pass pipe sub-assembly and slide the hose clip to secure it.

      Note:

      Perform the installation with the hose clip at the correct angle.

  14. INSTALL NO. 1 TURBO WATER HOSE

    1. A349660C01

      *a

      View (A)

      *b

      Upper of Engine

      *c

      LH of Engine

      Install the No. 1 turbo water hose to the water by-pass pipe sub-assembly and slide the hose clip to secure it.

      Note:

      Perform the installation with the hose clip at the correct angle.

  15. INSTALL NO. 2 WATER BY-PASS HOSE

    1. A349661C01

      *a

      View (A)

      *b

      Upper of Engine

      *c

      RH of Engine

      Install the No. 2 water by-pass hose to the water by-pass pipe sub-assembly and slide the hose clip to secure it.

      Note:

      Perform the installation with the hose clip at the correct angle.

  16. INSTALL NO. 3 WATER BY-PASS HOSE

    1. A349662C01

      *a

      View (A)

      *b

      Upper of Engine

      *c

      Rear of Engine

      Install the No. 3 water by-pass hose to the water by-pass pipe sub-assembly and slide the hose clip to secure it.

      Note:

      Perform the installation with the hose clip at the correct angle.

  17. INSTALL NO. 2 OIL COOLER HOSE

    1. A349663C01

      *a

      View (A)

      *b

      RH of Engine

      *c

      Front of Engine

      Install the No. 2 oil cooler hose to the oil filter bracket sub-assembly and slide the hose clip to secure it.

      Note:

      Perform the installation with the hose clip at the correct angle.

    2. Engage the 4 clamps to connect the No. 2 oil cooler hose to the 2 clamps and water by-pass pipe sub-assembly.

      Note:

      Align the No. 2 oil cooler hose paint mark with the clamp center.

  18. INSTALL OIL COOLER HOSE

    1. A349664C01

      *a

      View (A)

      *b

      RH of Engine

      *c

      Front of Engine

      Install the oil cooler hose to the water by-pass pipe sub-assembly and oil cooler assembly, and slide the 2 hose clips to secure it.

      Note:

      Perform the installation with the hose clip at the correct angle.

  19. INSTALL INJECTION NOZZLE SEAT

    Click here

  20. INSTALL INJECTOR ASSEMBLY

    Click here

  21. INSTALL NOZZLE HOLDER CLAMP SEAT

    Click here

  22. INSTALL NO. 1 NOZZLE HOLDER CLAMP

    Click here

  23. INSTALL COMMON RAIL ASSEMBLY

    1. Install the common rail assembly to the cylinder head sub-assembly with the 2 bolts.

      21 N*m

      214 kgf*cm

      15 ft.*lbf

    2. A349665C01

      *a

      View (A)

      *b

      Upper of Engine

      *c

      Rear of Engine

      Install the No. 4 water by-pass hose to the water inlet pipe and slide the hose clip to secure it.

      Note:

      Perform the installation with the hose clip at the correct angle.

    3. Engage the hose clamp to connect the No. 4 water by-pass hose to the common rail assembly.

  24. INSTALL GLOW PLUG ASSEMBLY

    1. Clean the glow plug assembly installation holes in the cylinder head sub-assembly.

    2. Using a 10 mm deep socket wrench, install the 4 glow plug assemblies to the cylinder head sub-assembly.

      13 N*m

      133 kgf*cm

      10 ft.*lbf

  25. INSTALL NO. 1 GLOW PLUG CONNECTOR

    1. Install the No. 1 glow plug connector to each glow plug assembly with the 4 nuts.

      2.2 N*m

      22 kgf*cm

      19 in.*lbf

    2. Install the 4 glow plug screw grommets.

      Tip:

      Push the glow plug screw grommet into the threaded portion of the glow plug assembly by hand, and then turn it clockwise.

  26. INSTALL SUPPLY PUMP ASSEMBLY

    Click here

  27. INSTALL FUEL PUMP PROTECTOR

    Click here

  28. INSTALL NO. 2 NOZZLE LEAKAGE PIPE

    1. A358307N01

      Install the No. 2 nozzle leakage pipe to the fuel pump protector and cylinder head cover sub-assembly with the 2 bolts.

      Bolt (A)

      21 N*m

      214 kgf*cm

      15 ft.*lbf

      Bolt (B)

      9.0 N*m

      92 kgf*cm

      80 in.*lbf

  29. INSTALL NO. 1 FUEL HOSE

    1. A349666C01

      *a

      View (A)

      *b

      Upper of Engine

      *c

      Rear of Engine

      Install a new gasket and No. 1 fuel hose to the supply pump assembly with the union bolt.

      20 N*m

      204 kgf*cm

      15 ft.*lbf

      Note:

      Make sure the linking portion of the gasket is towards the bottom of the vehicle.

    2. Connect the No. 1 fuel hose to the No. 2 nozzle leakage pipe and slide the hose clip to secure it.

      Note:

      Perform the installation with the hose clip at the correct angle.

  30. INSTALL NO. 2 FUEL HOSE

    1. A349721C01

      *a

      View (A)

      *b

      View (B)

      *c

      Upper of Engine

      *d

      Rear of Engine

      *e

      LH of Engine

      Install the No. 2 fuel hose to the No. 2 nozzle leakage pipe and common rail assembly, and slide the 2 hose clips to secure it.

      Note:

      Perform the installation with the hose clips at the correct angle.

  31. INSTALL NO. 4 INJECTION PIPE SUB-ASSEMBLY

    Click here

  32. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

    1. To prevent contamination by foreign matter, do not remove the plastic bags that were protecting the connector portions of the supply pump assembly and common rail assembly until immediately before installing the fuel inlet pipe sub-assembly.

    2. A125732C07

      *a

      Correct

      *b

      Incorrect

      Temporarily install a new fuel inlet pipe sub-assembly to the supply pump assembly and common rail assembly.

      Note:

      • When installing, the sealing surface of the fuel inlet pipe sub-assembly should be fitted tightly against the supply pump assembly and common rail assembly.

      • When installing, do not tilt or angle the sealing surface of the fuel inlet pipe sub-assembly.

      • When temporarily installing, tighten the union nut of the fuel inlet pipe sub-assembly by hand until it cannot be turned any further.

    3. Tighten the bolt of the No. 1 nozzle holder clamp.

      19 N*m

      194 kgf*cm

      14 ft.*lbf

    4. A349718N01

      Using a 17 mm union nut wrench, fully tighten the 2 union nuts in the order shown in the illustration.

      Specified Tightening Torque

      28 N*m

      286 kgf*cm

      21 ft.*lbf

      Note:

      When fully tightening the union nuts, make sure to tighten the common rail assembly side first.

      Tip:

      • Calculate the torque wrench reading when changing the fulcrum length of the torque wrench.

        Click hereClick here

      • When a 17 mm union nut wrench (fulcrum length of 30 mm (1.18 in.)) + torque wrench (fulcrum length of 180 mm (7.09 in.)): 24 N*m (245 kgf*cm, 18 ft.*lbf).

    5. Install the No. 2 injection pipe clamp to the fuel inlet pipe sub-assembly and No. 4 injection pipe sub-assembly with the bolt.

      5.0 N*m

      51 kgf*cm

      44 in.*lbf

  33. INSTALL NO. 3 INJECTION PIPE SUB-ASSEMBLY

    Click here

  34. INSTALL NO. 2 INJECTION PIPE SUB-ASSEMBLY

    Click here

  35. INSTALL NO. 1 INJECTION PIPE SUB-ASSEMBLY

    Click here

  36. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  37. INSTALL INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY

    1. Install a new intake air connector gasket to the cylinder head sub-assembly.

    2. Install the intake air connector with diesel throttle body to the cylinder head sub-assembly with the 2 bolts and 2 nuts.

      23 N*m

      235 kgf*cm

      17 ft.*lbf

    3. A349670C01

      *a

      View (A)

      *b

      Upper of Engine

      *c

      LH of Engine

      Connect the No. 3 water by-pass hose to the intake air connector with diesel throttle body and slide the hose clip to secure it.

      Note:

      Perform the installation with the hose clip at the correct angle.

    4. Engage the clamp to connect the vacuum transmitting hose assembly to the No. 2 oil cooler hose.

  38. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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

    2. Install the O-ring to the engine oil level dipstick guide.

      Note:

      Do not twist the O-ring.

    3. Install the engine oil level dipstick guide to the intake air connector and oil pan sub-assembly with the bolt.

      9.0 N*m

      92 kgf*cm

      80 in.*lbf

      Note:

      Make sure that the O-ring is not damaged or does not jump out of position during installation.

  39. INSTALL ENGINE OIL LEVEL DIPSTICK

    1. Install the engine oil level dipstick to the engine oil level dipstick guide.

  40. INSTALL EGR VALVE (ELECTRIC EGR CONTROL VALVE ASSEMBLY)

    Click hereClick here

  41. INSTALL HARNESS BRACKET (for LHD)

    1. Install the 2 harness brackets to the cylinder head cover sub-assembly with the 2 bolts.

      8.4 N*m

      86 kgf*cm

      74 in.*lbf

    2. Connect the vacuum hose to the vacuum pump assembly.

  42. INSTALL HARNESS BRACKET (for RHD)

    1. Install the harness bracket to the cylinder head cover sub-assembly with the bolt.

      8.4 N*m

      86 kgf*cm

      74 in.*lbf

    2. Connect the vacuum hose to the vacuum pump assembly.

  43. INSTALL NO. 1 EGR COOLER BRACKET

    1. Install the No. 1 EGR cooler bracket to the cylinder head sub-assembly with the 2 bolts.

      23 N*m

      235 kgf*cm

      17 ft.*lbf

  44. INSTALL EGR WITH COOLER PIPE ASSEMBLY

    1. Install a new EGR inlet gasket to the EGR valve (electric EGR control valve assembly).

    2. Install a new EGR pipe gasket to the EGR with cooler pipe assembly.

    3. A349673C01

      *a

      View (A)

      *b

      RH of Engine

      *c

      Rear of Engine

      Install the EGR with cooler pipe assembly to the EGR valve (electric EGR control valve assembly), No. 1 EGR cooler bracket and cylinder head sub-assembly with the 5 bolts and nut.

      23 N*m

      235 kgf*cm

      17 ft.*lbf

    4. Connect the No. 2 water by-pass hose to the EGR with cooler pipe assembly and slide the hose clip to secure it.

      Note:

      Perform the installation with the hose clip at the correct angle.

    5. Connect the No. 2 oil cooler hose to the EGR with cooler pipe assembly and slide the hose clip to secure it.

      Note:

      Perform the installation with the hose clip at the correct angle.

    6. Connect the vacuum hose to the EGR with cooler pipe assembly.

    7. Connect the 3 vacuum transmitting hoses to the EGR with cooler pipe assembly.

    8. Engage the clamp to connect the connector to the EGR with cooler pipe assembly.

  45. INSTALL GENERATOR BRACKET

    1. Install the generator bracket to the cylinder block sub-assembly with the 2 bolts.

      40 N*m

      408 kgf*cm

      30 ft.*lbf

  46. INSTALL GENERATOR ASSEMBLY

    1. A348732N01

      Install the generator assembly to the engine mounting bracket RH and generator bracket with the 2 bolts.

      54 N*m

      551 kgf*cm

      40 ft.*lbf

      Bolt Length

      Bolt

      Length

      (A)

      50 mm (1.97 in.)

      (B)

      80 mm (3.15 in.) or 90 mm (3.54 in.)

  47. INSTALL ENGINE COVER BRACKET

    1. Install the engine cover bracket to the engine mounting bracket RH with the bolt.

      21 N*m

      214 kgf*cm

      15 ft.*lbf