CYLINDER HEAD GASKET(w/o DPF) INSTALLATION
CAUTION / NOTICE / HINT
Note
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Before performing these installation procedures, sufficiently clean and remove any foreign matter from the cylinder block sub-assembly, cylinder head, camshaft and other parts.
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When replacing an injector assembly (including interchanging injector assemblies between cylinders), common rail assembly, cylinder head, or intake manifold, replace the corresponding injection pipes with a new one.
PROCEDURE
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CHECK INJECTOR COMPENSATION CODE
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SELECT CYLINDER HEAD GASKET
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Set the 2 crankshaft pulley set bolts to the crankshaft.
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Clean the cylinder block sub-assembly with solvent.
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Inspect the protrusion for each cylinder.
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Set the piston of the cylinder to be measured to slightly before TDC.
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Place a dial indicator on the cylinder block sub-assembly, and set the measuring tip as shown in the illustration.
Note
Make sure that the dial indicator is at a right angle to the cylinder block sub-assembly top surface.
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Set the dial indicator at 0 mm (0 in.).
Tech Tips
Make sure that the measuring tip is flat against the cylinder block sub-assembly surface and piston head when taking the measurements.
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Find where the piston head protrudes most by slowly turning the crankshaft clockwise and counterclockwise.
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Measure the piston protrusion value of each cylinder at 2 places as shown in the illustration below, making a total of 8 measurements.
Standard piston protrusion 0.520 to 0.780 mm (0.0205 to 0.0307 in.) If the protrusion is not as specified, remove and reinstall the piston and connecting rod.
Text in Illustration *A for Bank 1 *B for Bank 2 *a Measuring *b Front
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Select a new cylinder head gasket.
Text in Illustration *A for Bank 1 *B for Bank 2 *a Front - - Tech Tips
Cylinder head gaskets are marked A, B, C, D or E accordingly.
New Installed Cylinder Head Gasket Thickness Item Cutout Specified Condition* A 1 1.20 to 1.30 mm (0.0472 to 0.0512 in.) B 2 1.25 to 1.35 mm (0.0492 to 0.0394 in.) C 3 1.30 to 1.40 mm (0.0512 to 0.0551 in.) D 4 1.35 to 1.45 mm (0.0531 to 0.0571 in.) E 5 1.40 to 1.50 mm (0.0551 to 0.0591 in.) Tech Tips
*: The specified condition indicates the thickness of the cylinder head gasket after tightening the cylinder head.
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Select the largest piston protrusion value from the measurements and then select a new appropriate cylinder head gasket according to the table below.
Standard Piston Protrusion Item Specified Condition A 0.520 to 0.575 mm (0.0205 to 0.0226 in.) B 0.575 to 0.625 mm (0.0226 to 0.0246 in.) C 0.625 to 0.675 mm (0.0246 to 0.0266 in.) D 0.675 to 0.725 mm (0.0266 to 0.0285 in.) E 0.725 to 0.780 mm (0.0285 to 0.0307 in.)
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INSTALL NO. 2 CYLINDER HEAD GASKET
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Text in Illustration *a Front *b Exhaust Side Remove any oil from the contact surface.
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Place the No. 2 cylinder head gasket on the cylinder block sub-assembly surface with the front face of the indicated mark "L" upward and facing the exhaust side.
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INSTALL CYLINDER HEAD GASKET
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Text in Illustration *a Front *b Exhaust Side Remove any oil from the contact surface.
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Place the cylinder head gasket on the cylinder block sub-assembly surface with the front face of the indicated mark "R" upward and facing the exhaust side.
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INSTALL CYLINDER HEAD LH
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INSTALL CYLINDER HEAD SUB-ASSEMBLY
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SET NO. 1 CYLINDER TO 45° BEFORE TDC
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INSTALL NO. 2 VALVE LASH ADJUSTER ASSEMBLY
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INSTALL NO. 1 VALVE LASH ADJUSTER ASSEMBLY
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INSTALL NO. 2 VALVE ROCKER ARM SUB-ASSEMBLY
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INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
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INSTALL NO. 5 CAMSHAFT BEARING CAP
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INSTALL NO. 2 CAMSHAFT BEARING CAP
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INSTALL NO. 3 CAMSHAFT AND NO. 4 CAMSHAFT
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INSTALL NO. 1 CAMSHAFT AND NO. 2 CAMSHAFT
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INSTALL TIMING GEAR CASE SUB-ASSEMBLY
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INSTALL V-BANK SILENCER
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INSTALL FUEL SUPPLY PUMP ASSEMBLY
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INSTALL FUEL PUMP MOTOR WIRE
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INSPECT RADIAL BALL BEARING
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TEMPORARILY INSTALL FUEL SUPPLY PUMP DRIVE GEAR
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SET NO. 1 CAMSHAFT AND NO. 2 CAMSHAFT TO TDC
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INSTALL NO. 1 IDLE GEAR SHAFT
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INSTALL IDLE GEAR ASSEMBLY
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TIGHTEN FUEL SUPPLY PUMP DRIVE GEAR NUT
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CHECK NO. 1 CYLINDER TO TDC/COMPRESSION
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INSTALL NO. 2 CAMSHAFT TIMING SPROCKET AND NO. 2 TIMING CHAIN
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INSTALL NO. 1 CAMSHAFT TIMING SPROCKET AND NO. 1 TIMING CHAIN
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INSTALL PUMP DRIVE SHAFT GEAR
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INSTALL NO. 2 CHAIN VIBRATION DAMPER
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INSTALL NO. 2 CHAIN TENSIONER SLIPPER
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INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY
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INSTALL NO. 1 CHAIN VIBRATION DAMPER
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INSTALL NO. 1 CHAIN TENSIONER SLIPPER
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INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
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INSTALL NO. 1 CRANKSHAFT POSITION SENSOR PLATE
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CHECK NO. 1 CYLINDER TO TDC/COMPRESSION
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INSTALL FRONT CRANKSHAFT OIL SEAL
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INSTALL TIMING CHAIN COVER SUB-ASSEMBLY
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TEMPORARILY INSTALL INTAKE MANIFOLD
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TEMPORARILY INSTALL COMMON RAIL ASSEMBLY RH
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TEMPORARILY INSTALL COMMON RAIL ASSEMBLY LH
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INSTALL FUEL INJECTOR RH
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INSTALL FUEL INJECTOR LH
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REMOVE COMMON RAIL ASSEMBLY RH
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REMOVE COMMON RAIL ASSEMBLY LH
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REMOVE INTAKE MANIFOLD
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INSTALL NOZZLE HOLDER GASKET LH
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INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
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INSTALL NOZZLE HOLDER SEAL LH
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INSTALL OIL SEPARATOR ASSEMBLY
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INSTALL NOZZLE HOLDER GASKET RH
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INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
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INSTALL NOZZLE HOLDER SEAL RH
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INSTALL CYLINDER HEAD COVER SILENCER LH
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INSTALL CYLINDER HEAD COVER SILENCER RH
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INSTALL VACUUM PUMP ASSEMBLY
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INSTALL NO. 1 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY
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INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY
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INSTALL GLOW PLUG ASSEMBLY
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INSTALL NO. 1 GLOW PLUG CONNECTOR
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INSTALL WATER OUTLET PIPE
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INSTALL WATER OUTLET
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INSTALL NO. 2 INTERCOOLER SUPPORT BRACKET
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INSTALL STARTER HOSE BRACKET
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Install the starter hose bracket with the 2 bolts.
- Torque:
- 10 N*m { 102 kgf*cm, 7 ft.*lbf }
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INSTALL STARTER ASSEMBLY
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INSTALL ENGINE WATER PUMP ASSEMBLY
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CONNECT INLET WATER HOSE
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INSTALL NO. 2 IDLER PULLEY BRACKET (w/ Viscous Heater)
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INSTALL NO. 2 IDLER PULLEY (w/ Viscous Heater)
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INSTALL FAN BRACKET SUB-ASSEMBLY
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INSTALL TIMING GEAR COVER INSULATOR
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INSTALL THERMOSTAT
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INSTALL WATER INLET
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INSTALL NO. 1 IDLER PULLEY BRACKET (w/ Viscous Heater)
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INSTALL VISCOUS WITH MAGNET CLUTCH HEATER ASSEMBLY (w/ Viscous Heater)
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INSTALL CRANKSHAFT POSITION SENSOR
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INSTALL CAMSHAFT POSITION SENSOR
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INSTALL NO. 1 OIL PAN SUB-ASSEMBLY
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INSTALL OIL STRAINER SUB-ASSEMBLY
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INSTALL NO. 2 OIL PAN SUB-ASSEMBLY
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INSTALL ENGINE OIL LEVEL SENSOR
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INSTALL OIL FILTER BRACKET SUB-ASSEMBLY
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INSTALL OIL FILTER ELEMENT
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INSTALL TIMING GEAR COVER SPACER
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INSTALL CRANKSHAFT PULLEY
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CONNECT NO. 2 OIL COOLER HOSE
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CONNECT NO. 1 OIL COOLER HOSE
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INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
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INSTALL STIFFENER INSULATOR RH
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INSTALL COMPRESSOR BRACKET
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INSTALL NO. 2 CYLINDER BLOCK INSULATOR
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INSTALL ENGINE MOUNTING BRACKET LH
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INSTALL NO. 2 WATER BY-PASS PIPE SUB-ASSEMBLY
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INSTALL NO. 3 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY
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INSTALL TURBOCHARGER WIRE
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INSTALL NO. 2 INTAKE AIR CONNECTOR BRACKET
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INSTALL NO. 1 CYLINDER BLOCK INSULATOR
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INSTALL ENGINE MOUNTING BRACKET RH
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INSTALL NO. 4 VACUUM TRANSMITTING PIPE SUB-ASSEMBLY
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INSTALL NO. 1 WATER BY-PASS PIPE SUB-ASSEMBLY
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INSTALL AIR TUBE SUPPORT
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INSTALL NO. 1 INTAKE AIR CONNECTOR BRACKET
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INSTALL GENERATOR ASSEMBLY
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INSTALL TURBOCHARGER SUB-ASSEMBLY WITH EXHAUST MANIFOLD AND NO. 2 TURBOCHARGER SUB-ASSEMBLY WITH NO. 2 EXHAUST MANIFOLD
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CONNECT CABLE TO NEGATIVE BATTERY TERMINAL
Note
When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.
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Connect the cables to the negative (-) main battery and sub-battery terminals.
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