ENGINE UNIT INSTALLATION
CAUTION / NOTICE / HINT
When replacing the injectors (including shuffling the injectors between the cylinders), common rail assembly, intake manifold or cylinder head sub-assembly, it is necessary to replace the injection pipes with new ones.
When replacing the fuel supply pump assembly, common rail assembly, intake manifold or cylinder head sub-assembly, it is necessary to replace the fuel inlet pipe sub-assembly with a new one.
PROCEDURE
INSTALL DRIVE SHAFT BEARING BRACKET
Install the drive shaft bearing bracket with the 3 bolts.
63.7 N*m
650 kgf*cm
47 ft.*lbf
INSTALL EXHAUST MANIFOLD AND TURBOCHARGER SUB-ASSEMBLY
INSTALL NO. 2 TURBO OIL PIPE
INSTALL NO. 5 WATER BY-PASS PIPE
CONNECT NO. 3 WATER BY-PASS HOSE
INSTALL NO. 1 TURBO INSULATOR
INSTALL TURBO OIL OUTLET PIPE
INSTALL EGR COOLER WITH PIPE ASSEMBLY
INSTALL NO. 2 WATER BY-PASS HOSE
INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
for CCo:
for DPF:
INSTALL NO. 1 MANIFOLD CONVERTER INSULATOR
for CCo:
for DPF:
INSTALL VACUUM TRANSMITTING HOSE ASSEMBLY
INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY
INSTALL VACUUM REGULATING VALVE ASSEMBLY
INSTALL NO. 1 TURBO OIL PIPE
INSTALL NO. 3 WATER BY-PASS PIPE
INSTALL FUEL SUPPLY PUMP ASSEMBLY
Apply a light coat of engine oil to a new O-ring.
Install a new O-ring to the fuel supply pump assembly.
Install the No. 1 supply pump drive coupling.
Note:When reusing the No. 1 supply pump drive coupling, it must be installed in the same orientation (top/bottom, front/back) as when it was removed.
Tip:Line up the No. 1 supply pump drive coupling with the groove in the No. 2 camshaft end.
Install the fuel supply pump assembly with the 2 bolts.
21 N*m
209 kgf*cm
15 ft.*lbf
Tip:Line up the end of the supply pump drive shaft with the No. 1 supply pump drive coupling.
INSTALL NO. 3 FUEL HOSE
INSTALL FUEL INJECTOR SEAL (for DPF)
INSTALL EXHAUST FUEL ADDITION INJECTOR ASSEMBLY (for DPF)
INSTALL FUEL TUBE SUB-ASSEMBLY (for DPF)
INSTALL FUEL HOSE PROTECTOR (for DPF)
INSTALL NO. 2 FUEL PIPE (for CCo)
INSTALL NO. 2 WATER BY-PASS PIPE
INSTALL NO. 4 WATER BY-PASS HOSE
INSTALL NO. 8 WATER BY-PASS HOSE
INSTALL NO. 6 WATER BY-PASS HOSE
INSTALL WATER BY-PASS HOSE
INSTALL NO. 1 CYLINDER BLOCK INSULATOR
INSTALL GLOW PLUG ASSEMBLY
Using a 10 mm deep socket wrench, install the 4 glow plug assemblies.
12 N*m
125 kgf*cm
9 ft.*lbf
Install the No. 1 glow plug connector with the 4 nuts.
2.2 N*m
22 kgf*cm
19 in.*lbf
Install the 4 glow plug screw grommets.
INSTALL INTAKE MANIFOLD
INSTALL NO. 2 INTAKE MANIFOLD
INSTALL ENGINE COVER BRACKET
INSTALL GAS FILTER BRACKET
INSTALL NO. 1 GAS FILTER
INSTALL DIESEL TURBO PRESSURE SENSOR
INSTALL INTAKE MANIFOLD INSULATOR
INSTALL COMMON RAIL ASSEMBLY
INSTALL NO. 4 FUEL HOSE
INSTALL INJECTION PIPE SUB-ASSEMBLY
INSTALL FUEL INLET PIPE SUB-ASSEMBLY
INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY
INSTALL NO. 2 EGR PIPE SUB-ASSEMBLY
INSTALL EGR VALVE BRACKET
CONNECT NO. 8 WATER BY-PASS HOSE
INSTALL NO. 7 WATER BY-PASS HOSE
INSTALL DIESEL THROTTLE BODY ASSEMBLY
INSTALL VACUUM PUMP ASSEMBLY
INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
INSTALL ENGINE MOUNTING BRACKET
INSTALL NO. 4 WATER BY-PASS PIPE
INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY
INSTALL IDLER PULLEY COVER PLATE
INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
INSTALL GENERATOR ASSEMBLY
INSTALL COMPRESSOR STAY
Install the compressor stay to the cylinder block sub-assembly.
35 N*m
357 kgf*cm
26 ft.*lbf
INSTALL COOLER COMPRESSOR ASSEMBLY WITH PULLEY
INSTALL FAN AND GENERATOR V-BELT
CONNECT ENGINE WIRE