CAMSHAFT(w/o DPF) INSTALLATION

PROCEDURE

1. INSTALL CAMSHAFT

   

   
   

   1. Turn the crankshaft to set the key in the 75° BTDC position.

      Text in Illustration

      *1	TDC Mark
      *2	Key
      *a	BTDC 75°

   2. Apply engine oil to the camshaft journal portion and cam portion.

   3. 

      Examine the front marks and numbers and check that the sequence is as shown in the illustration. Then, temporarily tighten the camshaft with the camshaft bearing caps and bolts.

      Text in Illustration

      Engine Front Side

      Note

      Do not tilt the valve rocker arm when installing the camshaft onto the cylinder head.

   4. 

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

      Torque:

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

2. INSTALL CHAIN SUB-ASSEMBLY

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3. INSTALL NO. 1 CHAIN VIBRATION DAMPER

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4. INSTALL CHAIN TENSIONER SLIPPER

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5. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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6. INSTALL TIMING CHAIN COVER OIL SEAL

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7. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

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8. CONNECT WATER INLET HOSE LH

   
   

   1. Connect the water inlet hose LH.

      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.

9. INSTALL CRANKSHAFT DAMPER SUB-ASSEMBLY

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10. INSTALL NO. 3 TIMING CHAIN COVER

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11. INSTALL NO. 2 TIMING CHAIN COVER

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12. INSTALL ENGINE MOUNTING BRACKET RH

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13. CHECK VALVE CLEARANCE

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14. ADJUST VALVE CLEARANCE

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15. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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16. INSTALL HARNESS BRACKET

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17. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

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18. INSTALL VACUUM PUMP ASSEMBLY

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19. INSTALL CAMSHAFT POSITION SENSOR

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20. INSTALL NO. 2 CYLINDER HEAD COVER

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21. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY

    
    

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

       Note

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

    2. 

       Install the water by-pass pipe with the 2 bolts, in the order shown in the illustration.

       Torque:

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

    3. 

       Text in Illustration

       *a	View A
       *b	Front
       *c	LH

       Connect the oil cooler hose.

    4. 

       Text in Illustration

       *a	View A
       *b	Upper

       Connect the No. 1 water by-pass hose.

22. INSTALL NO. 4 WATER BY-PASS HOSE

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23. INSTALL NO. 2 OIL COOLER HOSE

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24. INSTALL NO. 1 SUPPLY PUMP DRIVE COUPLING

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25. TEMPORARILY TIGHTEN SUPPLY PUMP ASSEMBLY

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26. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

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27. CONNECT NO. 2 FUEL HOSE

    
    

    1. Connect the No. 2 fuel hose.

28. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY

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29. INSTALL NOZZLE LEAKAGE PIPE SET CLAMP

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30. INSTALL NO. 1 FUEL PIPE

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31. INSTALL INTAKE AIR CONNECTOR WITH DIESEL THROTTLE BODY ASSEMBLY

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32. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE SUB-ASSEMBLY

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33. INSTALL ENGINE OIL LEVEL DIPSTICK SUB-ASSEMBLY

34. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY

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35. INSTALL HARNESS BRACKET

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36. INSTALL NO. 1 EGR COOLER BRACKET

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37. INSTALL EGR WITH COOLER PIPE ASSEMBLY

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38. INSTALL GENERATOR BRACKET

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39. INSTALL GENERATOR ASSEMBLY

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40. INSTALL ENGINE COVER BRACKET

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41. INSTALL ENGINE ASSEMBLY

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