CAUTION / NOTICE / HINT
When replacing the injector sub-assemblies (including exchanging the injector sub-assemblies between the cylinders), common rail assembly, intake manifold or cylinder head sub-assembly, it is necessary to replace the injection pipe sub-assemblies with new ones.
When replacing the fuel tube sub-assembly, 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.
INSTALL TURBOCHARGER SUB-ASSEMBLY
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INSTALL EGR PIPE WITH COOLER SUB-ASSEMBLY
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INSTALL NO. 2 WATER BY-PASS HOSE
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INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
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INSTALL MANIFOLD CONVERTER INSULATOR SUB-ASSEMBLY
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INSTALL NO. 4 MANIFOLD CONVERTER INSULATOR
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INSTALL NO. 1 WIRE HARNESS CLAMP BRACKET
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INSTALL VACUUM TRANSMITTING HOSE ASSEMBLY
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INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY
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INSTALL NO. 1 TURBO OIL PIPE
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INSTALL NO. 3 WATER BY-PASS PIPE
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INSTALL SUPPLY PUMP ASSEMBLY
Install a new O-ring to the supply pump assembly.
Install the No. 1 supply pump drive coupling.
Line up the No. 1 supply pump drive coupling with the groove in the camshaft end.
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,
Install the supply pump assembly with the 2 bolts.
Line up the end of the supply pump assembly drive shaft with the No. 1 supply pump drive coupling.
Apply engine oil to the O-ring of the supply pump assembly.
INSTALL NO. 3 FUEL HOSE
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INSTALL FUEL INJECTOR SEAL
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INSTALL EXHAUST FUEL ADDITION INJECTOR ASSEMBLY
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INSTALL FUEL TUBE SUB-ASSEMBLY
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INSTALL FUEL HOSE PROTECTOR
Install the fuel hose protector to the cylinder head sub-assembly with the bolt.
INSTALL NO. 4 WATER BY-PASS HOSE
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INSTALL NO. 2 WATER BY-PASS PIPE
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INSTALL NO. 8 WATER BY-PASS HOSE
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INSTALL NO. 6 WATER BY-PASS HOSE
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INSTALL WATER BY-PASS HOSE
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INSTALL NO. 1 CYLINDER BLOCK INSULATOR
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INSTALL GLOW PLUG ASSEMBLY
Using a 10 mm deep socket wrench, install the 4 glow plug assemblies.
Install the No. 1 glow plug connector with the 4 nuts.
Install the 4 glow plug screw grommets.
INSTALL INTAKE MANIFOLD
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CONNECT NO. 2 INTAKE MANIFOLD
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INSTALL ENGINE COVER BRACKET
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INSTALL GAS FILTER BRACKET
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INSTALL NO. 1 GAS FILTER
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INSTALL DIESEL TURBO PRESSURE SENSOR
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INSTALL INTAKE MANIFOLD INSULATOR
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INSTALL COMMON RAIL ASSEMBLY
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INSTALL NO. 4 FUEL HOSE
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INSTALL INJECTION PIPE SUB-ASSEMBLY
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INSTALL FUEL INLET PIPE SUB-ASSEMBLY
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INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE
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INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY
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INSTALL NO. 2 EGR PIPE SUB-ASSEMBLY
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INSTALL EGR VALVE BRACKET
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CONNECT NO. 8 WATER BY-PASS HOSE
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CONNECT NO. 7 WATER BY-PASS HOSE
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INSTALL DIESEL THROTTLE BODY ASSEMBLY
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INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
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INSTALL ENGINE MOUNTING BRACKET
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INSTALL STUD BOLT
Perform this procedure only when replacement of the stud bolt is necessary.
Using an 8 mm socket wrench, install the stud bolt to the engine mounting bracket.
INSTALL NO. 4 WATER BY-PASS PIPE
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INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY
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INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY
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INSTALL IDLER PULLEY COVER PLATE
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INSTALL VACUUM PUMP ASSEMBLY
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INSTALL GENERATOR ASSEMBLY
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INSTALL COMPRESSOR STAY
Install the compressor stay to the cylinder block.