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

  1. INSTALL DRIVE SHAFT BEARING BRACKET

    1. A347058N01

      Using a T50 "TORX" socket wrench, install the drive shaft bearing bracket with the 3 bolts.

      63.7 N*m

      650 kgf*cm

      47 ft.*lbf

      Note:

      • Temporarily tighten the bolt (A), and then fully tighten the 3 bolts in the order of (B), (A) and (C).

      • Make sure that the bolts and bolt holes are free of oil. Clean them if necessary.

  2. INSTALL VACUUM CONTROL VALVE BRACKET

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  3. INSTALL EGR BYPASS VALVE SWITCHING VALVE

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  4. INSTALL GLOW PLUG ASSEMBLY

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  5. INSTALL COMMON RAIL ASSEMBLY

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  6. INSTALL INJECTION PIPE SUB-ASSEMBLY

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  7. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

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  8. 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.

  9. 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.

  10. 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.

  11. INSTALL TURBOCHARGER STAY

    1. Install the turbocharger stay with the 2 bolts.

      Tip:

      Refer to "SPECIFICATIONS - STANDARD BOLT" for the tightening torque.

  12. 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.

  13. INSTALL NO. 1 TURBO OIL PIPE

    1. Install the No. 1 turbo oil pipe, 2 nuts and 2 new gaskets with the union bolt.

      Union Bolt

      35 N*m

      357 kgf*cm

      26 ft.*lbf

      Tip:

      Refer to "SPECIFICATIONS - STANDARD BOLT" for the tightening torque.

  14. INSTALL EXHAUST MANIFOLD

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  15. INSTALL EGR COOLER ASSEMBLY WITH EGR VALVE ASSEMBLY

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  16. INSTALL TURBOCHARGER SUB-ASSEMBLY

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  17. CONNECT NO. 1 TURBO OIL PIPE

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  18. INSTALL TURBO OIL OUTLET PIPE

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  19. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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  20. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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  21. 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.

    4. Attach the fuel hose clamp.

    5. Connect the nozzle leakage pipe assembly to the fuel feed pipe sub-assembly.

  22. INSTALL INTAKE MANIFOLD

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  23. INSTALL NO. 1 VACUUM PIPE

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  24. 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

  25. CONNECT NO. 2 VACUUM HOSE ASSEMBLY

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  26. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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  27. INSTALL DIESEL THROTTLE BODY ASSEMBLY

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  28. 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

  29. INSTALL ENGINE MOUNTING BRACKET

    1. Install the 2 stud bolts to the engine mounting bracket.

      10 N*m

      102 kgf*cm

      7 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

  30. 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

  31. INSTALL GENERATOR ASSEMBLY

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

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  33. INSTALL V-RIBBED BELT

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  34. INSTALL ENGINE WIRE

    1. Install the engine wire to the engine assembly.

  35. INSTALL ENGINE COVER

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