Fuel Cooler (For Engine Room Side) Installation

Connect the water by-pass hose to the fuel cooler.

HINT:

1. Align the alignment marks and connect the hose.
   
2. Align the pinching portion of the clamp with the hose alignment mark and connect the hose.
   

Install the fuel cooler with the 2 bolts.

Torque:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Connect the fuel hose to the fuel cooler.

HINT:

1. Align the alignment marks and connect the hose.
   
2. Align the pinching portion of the clamp with the hose alignment mark and connect the hose.
   

Temporarily install a new gasket and the No. 4 nozzle leakage pipe with the union bolt and bolt.

Tighten the union bolt and bolt in the order shown in the illustration.

Torque:

for union bolt:

21 N*m{214 kgf*cm, 15 ft.*lbf}

for bolt:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Connect the No. 2 fuel hose to the fuel cooler.

Temporarily install a new gasket and the No. 3 nozzle leakage pipe with the union bolt and bolt.

Tighten the union bolt and bolt in the order shown in the illustration.

Torque:

for union bolt:

21 N*m{214 kgf*cm, 15 ft.*lbf}

for bolt:

10 N*m{102 kgf*cm, 7 ft.*lbf}

Connect the No. 1 fuel hose to the fuel cooler.

Connect the No. 5 water by-pass hose to the water by-pass outlet.

Install 2 new gaskets and the EGR valve with EGR cooler with the 6 bolts labeled A and 4 bolts labeled B shown in the illustration.

Torque:

for bolt A:

21 N*m{214 kgf*cm, 15 ft.*lbf}

for bolt B:

29 N*m{296 kgf*cm, 21 ft.*lbf}

HINT:

The gasket claws should face toward the No. 1 and No. 2 EGR pipes.

Install the EGR pipe insulator with the 2 bolts.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

NOTICE:

If the No. 1 and No. 2 EGR pipe insulator installation stay is deformed, or the bolt holes of the EGR pipe insulator do not align, replace the No. 1 and No. 2 EGR pipes as a set.

Install 2 new gaskets to the No. 1 and No. 2 intake manifolds.

Install the No. 3 intake manifold with the 16 bolts.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

Connect the No. 2 engine wire with the 3 bolts.

Torque:

for bolt A:

13 N*m{133 kgf*cm, 10 ft.*lbf}

for bolt B:

32 N*m{326 kgf*cm, 24 ft.*lbf}

Attach the 2 wire harness clamps.

w/ EGR System:
Install 2 new gaskets and the intake pipe with the 6 bolts and 2 nuts.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}

w/o EGR System:
Install a new gasket and the intake pipe with the 4 bolts and 2 nuts.

Torque:

21 N*m{214 kgf*cm, 15 ft.*lbf}