CAMSHAFT(w/ DPF)

INSTALL CAMSHAFT

Text in Illustration
*1	Key
*2	Knock Pin
*a	BTDC 75°
*b	Bolt Hole of timing chain cover assembly
	Upper of Engine

Turn the crankshaft to set the key in the 75° BTDC (bolt hole of timing chain cover assembly) position.

Apply engine oil to the camshaft journal portion and cam portion.
Install the camshaft onto the cylinder head sub-assembly.
Note
- Align the camshaft knock pin towards the upper of the engine.
- Do not tilt the No. 1 valve rocker arm sub-assembly when installing the camshaft onto the cylinder head sub-assembly.

Text in Illustration
*1	No. 1 Camshaft Bearing Cap
*2	No. 2 Camshaft Bearing Cap
*3	No. 4 Camshaft Bearing Cap
*a	Front Mark
	Front of Engine

Examine the front marks and numbers and check that the sequence is as shown in the illustration. Then, temporarily tighten the camshaft with the No. 1 camshaft bearing cap, 3 No. 2 camshaft bearing cap, No. 4 camshaft bearing cap and 10 bolts.

Using several steps, temporarily tighten the 10 bolts in the order shown in the illustration, and then tighten the 10 bolts to the specified torque.

Torque:

19 N*m { 194 kgf*cm, 14 ft.*lbf }

INSTALL CHAIN SUB-ASSEMBLY

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INSTALL NO. 1 CHAIN VIBRATION DAMPER

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INSTALL CHAIN TENSIONER SLIPPER

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INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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INSTALL TIMING CHAIN COVER OIL SEAL

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INSTALL TIMING CHAIN COVER ASSEMBLY

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CONNECT WATER INLET HOSE LH

Connect the water inlet hose LH to the water inlet and slide the hose clip to secure it.

Tech Tips

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

INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY

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INSTALL CAMSHAFT POSITION SENSOR

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INSTALL NO. 2 TIMING CHAIN COVER

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INSTALL ENGINE MOUNTING BRACKET RH

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CHECK VALVE CLEARANCE

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ADJUST VALVE CLEARANCE

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INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

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INSTALL VACUUM PUMP ASSEMBLY

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INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY

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

Note

Apply water to all around of the water by-pass pipe O-ring inserting hole surface of the water inlet housing before installing the water by-pass pipe sub-assembly.
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.

Torque:

9.0 N*m { 92 kgf*cm, 80 in.*lbf }

Text in Illustration
*a	View A
*b	RH of Engine
*c	Front of Engine

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

Text in Illustration
*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.

Text in Illustration
*a	View A
*b	Front of Engine
*c	LH of Engine

Connect the No. 6 water by-pass hose to the water by-pass pipe sub-assembly and slide the hose clip to secure it.

INSTALL NO. 4 WATER BY-PASS HOSE

Text in Illustration
*a	View A
*b	Upper of Engine
*c	Front 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.
Engage the clamp to connect the No. 4 water by-pass hose to the common rail assembly.

INSTALL NO. 2 OIL COOLER HOSE

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INSTALL SUPPLY PUMP ASSEMBLY

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INSTALL FUEL PUMP PROTECTOR

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INSTALL NO. 2 NOZZLE LEAKAGE PIPE

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CONNECT NO. 2 FUEL HOSE