CAMSHAFT INSTALLATION

CAUTION / NOTICE / HINT

Note


  • When replacing the injectors (including shuffling the injectors between the cylinders), common rail, intake manifold or cylinder head, it is necessary to replace the injection pipes with new ones.

  • When replacing the fuel supply pump, common rail, intake manifold or cylinder head, it is necessary to replace the fuel inlet pipe with a new one.

PROCEDURE


  1. INSPECT VALVE LASH ADJUSTER ASSEMBLY

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  2. INSTALL VALVE LASH ADJUSTER ASSEMBLY


    1. Install the 16 valve lash adjusters to the cylinder head.

      Note

      Install the valve lash adjusters to their original positions.

  3. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY


    1. Install the 16 No. 1 valve rocker arms to the lash adjusters.

  4. INSTALL CAMSHAFT


    1. Install the No. 2 camshaft bearing cap.

    2. A004OSME08
      Text in Illustration
      *a Apply Engine Oil

      Apply clean engine oil to the cam of each camshaft, journals of the cylinder head and No. 1 valve rocker arms.

    3. A004QMKE01
      Text in Illustration
      *1 No. 3 Cylinder Cam Lobe
      *2 No. 1 Cylinder Cam Lobe

      Place the No. 2 camshaft on the cylinder head as shown in the illustration so that the No. 1 and No. 3 cylinder cam lobes face upward.

      Note

      A004PRBE08

      Before and after setting the camshaft and No. 2 camshaft on the cylinder head, check that the No. 1 valve rocker arm is firmly set to the valve lash adjuster.

    4. A004OKGE04
      Text in Illustration
      *1 No. 1 Valve Rocker Arm
      *2 Valve Stem
      *3 Valve Lash Adjuster
      *a CORRECT
      *b INCORRECT

      Align the camshaft and No. 2 camshaft timing mark (1 dot mark each).

    5. Place the camshaft on the cylinder head.

    6. A004R62
      Text in Illustration
      *1 Dot Mark

      Set the 8 No. 3 camshaft bearing caps and No. 1 camshaft bearing cap on the camshafts as shown in the illustration.

      Tech Tips

      Make sure of the marks and numbers on the camshaft bearing caps and place them in the proper position and direction.

    7. Partially tighten the 20 bolts.

    8. A004NSOE01
      Text in Illustration
      *1 Oil Pipe Seat

      Uniformly tighten the bolts in several steps, in the sequence shown in the illustration.

      Torque:
      for 1 to 16
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      for 17 to 20
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    9. Install the 2 oil pipe seats.

      Torque:
      17 N*m  { 173 kgf*cm, 13 ft.*lbf }

  5. INSTALL CAMSHAFT TIMING SPROCKET

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  6. INSTALL OIL PUMP DRIVE GEAR

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  7. INSTALL NO. 1 CHAIN VIBRATION DAMPER

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  8. INSTALL CHAIN TENSIONER SLIPPER

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  9. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY

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  10. INSTALL SUPPLY PUMP ASSEMBLY

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  11. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

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  12. INSTALL CRANKSHAFT PULLEY

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  13. INSTALL WATER PUMP ASSEMBLY

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  14. CONNECT CRANKSHAFT POSITION SENSOR WIRE HARNESS

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  15. INSTALL CAMSHAFT POSITION SENSOR

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  16. INSTALL OIL STRAINER SUB-ASSEMBLY

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  17. INSTALL OIL FILTER BRACKET

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  18. INSTALL OIL FILTER ELEMENT

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  19. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

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  20. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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  21. INSTALL NOZZLE HOLDER CLAMP SEAT

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  22. INSTALL OIL FILLER CAP SUB-ASSEMBLY

  23. INSTALL VENTILATION HOSE

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  24. INSTALL VACUUM TRANSMITTING HOSE ASSEMBLY

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  25. INSTALL VACUUM REGULATING VALVE ASSEMBLY

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  26. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

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  27. INSTALL INJECTOR ASSEMBLY

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  28. INSTALL NO. 1 NOZZLE LEAKAGE PIPE

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  29. INSTALL NO. 2 NOZZLE LEAKAGE PIPE

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  30. INSTALL NO. 3 FUEL HOSE

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  31. INSTALL FUEL TUBE SUB-ASSEMBLY

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  32. INSTALL FUEL HOSE PROTECTOR

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  33. INSTALL WATER INLET HOUSING

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  34. INSTALL NO. 4 WATER BY-PASS HOSE

  35. INSTALL NO. 2 WATER BY-PASS PIPE

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  36. INSTALL NO. 1 OIL COOLER BRACKET

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  37. INSTALL NO. 1 TURBO OIL PIPE

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  38. INSTALL NO. 3 WATER BY-PASS PIPE

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  39. INSTALL NO. 8 WATER BY-PASS HOSE

  40. INSTALL NO. 6 WATER BY-PASS HOSE

  41. INSTALL OIL COOLER ASSEMBLY

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  42. INSTALL WATER BY-PASS HOSE

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  43. INSTALL NO. 1 CYLINDER BLOCK INSULATOR

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  44. INSTALL INTAKE MANIFOLD

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  45. INSTALL NO. 2 INTAKE MANIFOLD

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  46. INSTALL ENGINE COVER BRACKET

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  47. INSTALL GAS FILTER BRACKET

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  48. INSTALL NO. 1 GAS FILTER

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  49. INSTALL DIESEL TURBO PRESSURE SENSOR

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  50. INSTALL INTAKE MANIFOLD INSULATOR

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  51. INSTALL COMMON RAIL ASSEMBLY

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  52. INSTALL NO. 4 FUEL HOSE

  53. INSTALL INJECTION PIPE SUB-ASSEMBLY

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  54. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

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  55. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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  56. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY

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  57. INSTALL NO. 2 EGR PIPE SUB-ASSEMBLY

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  58. INSTALL EGR VALVE BRACKET

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  59. CONNECT NO. 8 WATER BY-PASS HOSE

  60. INSTALL NO. 7 WATER BY-PASS HOSE

  61. INSTALL DIESEL THROTTLE BODY ASSEMBLY

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  62. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

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  63. INSTALL ENGINE MOUNTING BRACKET

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  64. INSTALL NO. 4 WATER BY-PASS PIPE

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  65. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

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  66. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY

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  67. INSTALL IDLER PULLEY COVER PLATE

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  68. INSTALL VACUUM PUMP ASSEMBLY

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  69. INSTALL GENERATOR ASSEMBLY

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  70. CONNECT ENGINE WIRE

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  71. INSTALL ENGINE ASSEMBLY

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  72. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.