CAMSHAFT INSTALLATION

CAUTION / NOTICE / HINT

PROCEDURE

1. INSPECT VALVE LASH ADJUSTER ASSEMBLY

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2. INSTALL VALVE LASH ADJUSTER ASSEMBLY

   
   

   1. Install the 16 valve lash adjuster assemblies to the cylinder head sub-assembly.

      Note

      Install the valve lash adjuster assemblies to their original positions.

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

   
   

   1. Install the 16 No. 1 valve rocker arm sub-assemblies.

4. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

   
   

   1. Install 4 new gaskets.

   2. 

      Uniformly tighten the 14 bolts in several steps in the sequence shown in the illustration.

   3. Using an E10 "TORX" socket wrench, install the camshaft housing sub-assembly with the 14 bolts.

      Torque:

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

5. SET NO. 1 CYLINDER TO TDC / COMPRESSION

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6. INSTALL CAMSHAFT AND NO. 2 CAMSHAFT

   
   

   1. Apply clean engine oil to the cam lobe of each camshaft, journals of the camshaft housing sub-assembly and No. 1 valve rocker arm sub-assemblies.

   2. 

      *a	Mark (E) (Intake Side)
      *b	Mark (A) (Exhaust Side)

      Place the camshaft and No. 2 camshaft on the camshaft housing sub-assembly as shown in the illustration so that mark (E) and mark (A) face upward.

   3. 

      *a	Timing Mark

      Align the camshaft and No. 2 camshaft timing marks.

   4. 

      Set the 5 intake camshaft bearing caps and 5 exhaust camshaft bearing caps on the camshaft and No. 2 camshaft as shown in the illustration.

   5. Using an E8 "TORX" socket wrench, temporarily tighten the 20 bolts.

   6. 

      Uniformly tighten the 20 bolts in several steps in the sequence shown in the illustration.

      Torque:

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

   7. 

      *a	No clearance

      Using SST, hold the camshaft and No. 2 camshaft.

      SST
      PZ4TB-04961-12

      Note

      Make sure there is no clearance between SST and the camshaft housing sub-assembly.

   8. 

      Using an E10 "TORX" socket wrench, temporarily install the camshaft timing sprocket with No. 2 chain sub-assembly to the camshaft with the 3 bolts.

      
      

      1. Step 1:

         Tighten the 3 bolts.

         Torque:

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

      2. Step 2:

         Loosen the 3 bolts 90°.

   9. Using a T45 "TORX" socket wrench, install the No. 2 timing chain guide with the bolt.

      Torque:

      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

   10. Using a 24 mm socket wrench, install the No. 2 chain tensioner assembly.

       Torque:

       70 N*m  { 714 kgf*cm, 52 ft.*lbf }

   11. Using an E10 "TORX" socket wrench, install the camshaft timing sprocket with the 3 bolts.

       Torque:

       14 N*m  { 143 kgf*cm, 10 ft.*lbf }

   12. Remove SST from the camshaft.

7. INSTALL NO. 2 ENGINE HANGER

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8. INSTALL NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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9. INSTALL NO. 1 TURBO INSULATOR

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10. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    
    

    1. Install 5 new gaskets to the cylinder head cover sub-assembly.

    2. Install the cylinder head cover sub-assembly and tighten the 17 bolts.

       Tech Tips

       Refer to "SPECIFICATIONS - STANDARD BOLT" for the tightening torque.

11. INSTALL OIL FILLER CAP SUB-ASSEMBLY

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12. INSTALL VACUUM CONTROL VALVE BRACKET

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13. INSTALL INJECTOR ASSEMBLY

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14. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY

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15. INSTALL CAMSHAFT POSITION SENSOR

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16. INSTALL COMMON RAIL ASSEMBLY

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17. INSTALL INJECTION PIPE SUB-ASSEMBLY

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18. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

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19. INSTALL INTAKE MANIFOLD

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20. INSTALL NO. 1 VACUUM PIPE

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21. CONNECT NO. 2 VACUUM HOSE ASSEMBLY

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22. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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23. CONNECT ENGINE WIRE

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24. INSTALL AIR CLEANER CASE SUB-ASSEMBLY

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25. INSTALL AIR CLEANER CAP SUB-ASSEMBLY WITH AIR CLEANER HOSE ASSEMBLY

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26. INSTALL ENGINE COVER

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27. INSTALL DIESEL THROTTLE BODY ASSEMBLY

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28. INSTALL RADIATOR ASSEMBLY

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29. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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

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30. INSPECT FOR FUEL LEAK

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31. INSPECT FOR ENGINE OIL LEAK

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