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 to the valve lash adjuster assemblies.

4. INSTALL CAMSHAFT

   
   

   1. Install the No. 2 camshaft bearing cap.

   2. 

      *a	Apply Engine Oil

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

   3. 

      *1	No. 3 Cylinder Cam Lobe
      *2	No. 1 Cylinder Cam Lobe

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

   4. 

      *1

      Dot Mark

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

   5. Place the camshaft on the cylinder head sub-assembly.

   6. 

      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. 

      *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 GEAR OR 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 FRONT CRANKSHAFT OIL SEAL

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12. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY

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13. INSTALL CRANKSHAFT PULLEY

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14. INSTALL ENGINE WATER PUMP ASSEMBLY

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15. CONNECT CRANK POSITION SENSOR

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16. INSTALL CRANK POSITION SENSOR

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17. INSTALL OIL STRAINER SUB-ASSEMBLY

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18. INSTALL OIL FILTER BRACKET

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19. INSTALL OIL FILTER ELEMENT

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20. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

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21. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

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22. INSTALL NOZZLE HOLDER CLAMP SEAT

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23. INSTALL OIL FILLER CAP SUB-ASSEMBLY

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24. INSTALL PCV HOSE

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25. INSTALL VACUUM TRANSMITTING HOSE ASSEMBLY

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26. INSTALL VACUUM REGULATING VALVE ASSEMBLY

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27. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY

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28. INSTALL INJECTOR ASSEMBLY

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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 (for DPF)

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32. INSTALL FUEL HOSE PROTECTOR (for DPF)

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33. INSTALL NO. 2 FUEL PIPE (for CCo)

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34. INSTALL WATER INLET HOUSING

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35. INSTALL NO. 4 WATER BY-PASS HOSE

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36. INSTALL NO. 2 WATER BY-PASS PIPE

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37. INSTALL NO. 1 OIL COOLER BRACKET

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38. INSTALL NO. 1 TURBO OIL PIPE

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39. INSTALL NO. 3 WATER BY-PASS PIPE

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40. INSTALL NO. 8 WATER BY-PASS HOSE

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41. INSTALL NO. 6 WATER BY-PASS HOSE

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42. INSTALL OIL COOLER ASSEMBLY

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43. INSTALL WATER BY-PASS HOSE

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44. INSTALL NO. 1 CYLINDER BLOCK INSULATOR

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45. INSTALL INTAKE MANIFOLD

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46. INSTALL NO. 2 INTAKE MANIFOLD

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47. INSTALL ENGINE COVER BRACKET

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48. INSTALL GAS FILTER BRACKET

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49. INSTALL NO. 1 GAS FILTER

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50. INSTALL DIESEL TURBO PRESSURE SENSOR

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51. INSTALL INTAKE MANIFOLD INSULATOR

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52. INSTALL COMMON RAIL ASSEMBLY

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53. INSTALL NO. 4 FUEL HOSE

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54. INSTALL INJECTION PIPE SUB-ASSEMBLY

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55. INSTALL FUEL INLET PIPE SUB-ASSEMBLY

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56. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

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57. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY

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58. INSTALL NO. 2 EGR PIPE SUB-ASSEMBLY

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59. INSTALL EGR VALVE BRACKET

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60. CONNECT NO. 8 WATER BY-PASS HOSE

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61. INSTALL NO. 7 WATER BY-PASS HOSE

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62. INSTALL DIESEL THROTTLE BODY ASSEMBLY

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63. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY

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64. INSTALL ENGINE MOUNTING BRACKET

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65. INSTALL NO. 4 WATER BY-PASS PIPE

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66. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY

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67. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY

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68. INSTALL IDLER PULLEY COVER PLATE

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69. INSTALL VACUUM PUMP ASSEMBLY

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70. INSTALL GENERATOR ASSEMBLY

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71. CONNECT ENGINE WIRE

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72. INSTALL ENGINE ASSEMBLY

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73. 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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