CAMSHAFT INSTALLATION

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.


  1. INSPECT VALVE LASH ADJUSTER ASSEMBLY

    Note


    • Keep the valve lash adjuster free from dirt and foreign objects.

    • Use only clean engine oil.


    1. Place the valve lash adjuster assembly into a container full of new engine oil.

    2. Insert SST tip into the valve lash adjuster plunger and use the tip to press down on the check ball inside the plunger.

      SST
      09276-75010
      A01ITY2E01
      Text in Illustration
      *1 Taper Port *2 Plunger
      *3 Lower Pressure Chamber *4 Check Ball
      *5 High Pressure Chamber - -
      *a CORRECT *b INCORRECT

    3. Squeeze SST and the valve lash adjuster together to move the plunger up and down 5 to 6 times.

    4. Check the movement of the plunger and bleed air.

      OK
      Plunger moves up and down.

      Note

      When bleeding high-pressure air from the compression chamber, make sure that the tip of SST is actually pressing the check ball as shown in the illustration. If the check ball is not pressed, air will not bleed.

    5. After bleeding air, remove SST. Then quickly and firmly press the plunger repeatedly with your fingers.

      OK
      Plunger can be pressed 3 times.

      If the plunger can still be compressed after pressing it 3 times, replace the valve lash adjuster assembly with a new one.

  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. A01INVVE08
      Text in Illustration
      *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. A01IRBQE07
      Text in Illustration
      *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.

      Note

      A01IT84E05

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

    4. A01IQRUE02
      Text in Illustration
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Stem
      *3 Valve Lash Adjuster Assembly
      *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 sub-assembly.

    6. A01IOMC
      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. A01ITINE02
      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


    1. A01IOQBE01
      Text in Illustration
      *A CCo
      *B DPF
      *1 Straight Pin
      *2 Timing Mark
      *3 Yellow Paint Mark
      *4 Pink Paint Mark

      Install the crankshaft timing sprocket and camshaft timing sprocket to the chain sub-assembly so that the timing marks of the sprockets and paint marks of the chain sub-assembly are aligned.

    2. Install the camshaft timing sprocket to the No. 2 camshaft by fitting the straight pin of the No. 2 camshaft into the hole on the camshaft timing sprocket.

    3. Install the crankshaft timing sprocket to the crankshaft.

    4. While holding the hexagon portion of the No. 2 camshaft, install and uniformly tighten the 4 bolts of the No. 2 camshaft.

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

  6. INSTALL OIL PUMP DRIVE GEAR


    1. Install the oil pump drive gear to the crankshaft.

  7. INSTALL NO. 1 CHAIN VIBRATION DAMPER


    1. Install the No. 1 chain vibration damper with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  8. INSTALL CHAIN TENSIONER SLIPPER


    1. Install the chain tensioner slipper.

  9. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01ITESE05
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate

      Move the stopper plate upward to release the lock, and push the plunger deep into the No. 1 chain tensioner assembly.

    2. Move the stopper plate downward to set the lock, and insert SST into the stopper plate hole.

      SST
      09240-00020   ( 09242-00200 )

    3. Install the No. 1 chain tensioner assembly with the 2 bolts.

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

    4. Remove SST.

  10. INSTALL SUPPLY PUMP ASSEMBLY


    1. Install a new O-ring to the supply pump assembly.

    2. Install the No. 1 supply pump drive coupling.

      Tech Tips

      Align the No. 1 supply pump drive coupling with the groove in the camshaft end.

      Note

      When reusing the No. 1 supply pump drive coupling, it must be installed in the same orientation (top/bottom, front/back) as when it was removed.

    3. Install the supply pump assembly with the 2 bolts.

      Torque:
      21 N*m  { 209 kgf*cm, 15 ft.*lbf }

      Tech Tips

      Align the end of the supply pump drive shaft with the No. 1 supply pump drive coupling.

      Note

      Apply engine oil to the O-ring of the supply pump assembly.

  11. INSTALL TIMING CHAIN COVER SUB-ASSEMBLY


    1. Install a new gasket and O-ring to the timing chain cover sub-assembly.

    2. Remove any old seal packing material.

    3. Apply seal packing in a continuous line to the timing chain cover sub-assembly as shown in the following illustration.

      A01IP1EE01
      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Apply Seal Packing as Follows
      Area Seal Packing Diameter (Round) Seal Packing Dimension (Flat) Seal Packing Application Length
      A - A 2.0 to 4.0 mm (0.0787 to 0.157 in.) - -
      B - B 8.0 to 10 mm (0.315 to 0.394 in.) - 30 mm (1.18 in.)
      C - C - 13 mm (0.512 in.) or more wide and 6.0 mm (0.236 in.) or more thick 15 mm (0.591 in.)

      Note


      • Be sure to clean and degrease the contact surfaces, especially the 4 areas indicated by the arrows in the illustration.

      • When the contact surfaces are wet, wipe them off with an oil-free cloth before applying seal packing.

      • When applying seal packing to area C - C, apply it in the direction of the white arrows in the illustration.

      • Install the timing chain cover sub-assembly within 3 minutes and tighten the bolts within 15 minutes after applying seal packing.

      • Do not start the engine for at least 4 hours after installation.

    4. for CCo:

      Apply adhesive to the 4 bolts labeled B.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
      A01ITU1E01
      Text in Illustration
      *A for CCo *B for DPF
      *1 Adhesive - -
      A01ISER Bolt and New Seal Washer - -

    5. for DPF:

      Apply adhesive to the 3 bolts labeled B and bolt labeled D.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent

    6. Temporarily install the timing chain cover sub-assembly and a new seal washer with the 13 bolts.

      Bolt Length
      Item Specified Condition
      Bolt A 60 mm (2.36 in.)
      Bolt B 30 mm (1.18 in.)
      Bolt C 30 mm (1.18 in.)
      Bolt D 45 mm (1.77 in.)

      Tech Tips

      Bolt B and C are identical.

    7. for CCo:

      Tighten the 12 bolts labeled B and C.

      Torque:
      23 N*m  { 229 kgf*cm, 17 ft.*lbf }

    8. for DPF:

      Tighten the 12 bolts labeled B, C and D.

      Torque:
      23 N*m  { 229 kgf*cm, 17 ft.*lbf }

    9. Tighten the bolt labeled A.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  12. INSTALL CRANKSHAFT PULLEY


    1. Align the keyway of the crankshaft pulley with the key located on the crankshaft, and then slide the crankshaft pulley into place to install it.

    2. A01IPB5E01

      Using SST, install a new pulley bolt.

      SST
      09213-58014   ( 91551-80840 )
      09330-00021
      Torque:
      300 N*m  { 3059 kgf*cm, 221 ft.*lbf }

  13. INSTALL WATER PUMP ASSEMBLY


    1. Remove the adhesive from the threads of the bolt and the bolt hole of the timing chain cover sub-assembly.

    2. A01IS5B

      Install a new gasket to the timing chain cover sub-assembly so that the protrusions indicated by the arrows in the illustration are aligned.

    3. A01IPDRE01

      Apply adhesive to 2 or 3 threads of the bolt labeled A.

      Adhesive
      Toyota Genuine Adhesive 1324, Three Bond 1324 or equivalent
      Standard Bolt Length
      Item Specified Condition
      Bolt A and C 45 mm (1.77 in.)
      Bolt B 30 mm (1.18 in.)
    4. A01IOSK

      Install the engine water pump assembly with the 2 bolts indicated by the arrows in the illustration.

      Torque:
      23 N*m  { 229 kgf*cm, 17 ft.*lbf }
    5. A01IO7L

      Install the 5 bolts.

      Torque:
      23 N*m  { 229 kgf*cm, 17 ft.*lbf }

  14. CONNECT CRANKSHAFT POSITION SENSOR WIRE HARNESS


    1. Install the sensor wire harness with the bolt and clip.

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }
      A01IS3NE01
      Text in Illustration
      *A for CCo *B for DPF
      *1 Protrusion - -

      Note

      Make sure the sensor wire harness is installed in the position shown in the illustration.

  15. INSTALL CAMSHAFT POSITION SENSOR


    1. Apply a light coat of engine oil to the O-ring of the camshaft position sensor.

    2. Install the camshaft position sensor with the bolt.

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

    3. Connect the camshaft position sensor connector.

    4. for DPF:

      Attach the wire harness clamp.

  16. INSTALL OIL STRAINER SUB-ASSEMBLY


    1. Install a new O-ring to the oil strainer sub-assembly.

    2. Apply a light coat of engine oil to the O-ring.

    3. A01IPZEE02

      Install the oil strainer sub-assembly with the 3 bolts.

      Torque:
      for bolt A
      42 N*m  { 428 kgf*cm, 31 ft.*lbf }
      for bolt B
      9.0 N*m  { 92 kgf*cm, 80 in.*lbf }

  17. INSTALL OIL FILTER BRACKET


    1. Install a new gasket to the oil filter bracket.

    2. Install the oil filter bracket with the 4 bolts.

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

  18. INSTALL OIL FILTER ELEMENT


    1. Clean the inside of the oil filter cap, its threads and its O-ring groove.

    2. A01IN35E01
      Text in Illustration
      *1 O-Ring
      *a CORRECT
      *b INCORRECT

      Apply a small amount of engine oil to a new O-ring and install it to the oil filter cap.

      Note


      • Be sure to install the O-ring in the proper location, otherwise oil may leak.

      • Do not twist the O-ring.

    3. Set a new oil filter element in the oil filter cap.

    4. Remove any dirt or foreign matter from the installation surface of the engine.

    5. Apply a small amount of engine oil to the O-ring again and temporarily install the oil filter cap.

    6. Using SST, tighten the oil filter cap.

      SST
      09228-06501
      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }
      A01ITSEE01
      *A for CCo *B for DPF
      *1 Oil Filter Cap *2 O-Ring
      *3 Oil Filter Bracket - -
      *a No Gap - -

      Note

      After tightening the oil filter cap, make sure that there is no gap and that the O-ring is not protruding.

  19. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY


    1. Remove any old seal packing material.

    2. A01INH3E01
      Text in Illustration
      *A for CCo
      *B for DPF
      *a 4.0 to 7.0 mm

      Apply seal packing in a continuous line as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard Seal Packing Dimension
      Area Seal Packing Diameter Acceptable Seal Packing Application Range
      A - A 4.0 to 7.0 mm (0.157 to 0.276 in.) 12 mm (0.472 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the No. 2 oil pan sub-assembly within 3 minutes and tighten the bolts within 10 minutes after applying seal packing.

      • Do not start the engine for at least 4 hours after installation.

    3. Install the No. 2 oil pan sub-assembly with the 18 bolts and 2 nuts.

      Torque:
      11 N*m  { 107 kgf*cm, 8 ft.*lbf }

  20. INSTALL OIL PRESSURE SWITCHING VALVE ASSEMBLY (for DPF)


    1. A01IQJGE01
      Text in Illustration
      *1 O-Ring

      Apply a light coat of engine oil to the O-ring of the oil pressure switching valve assembly.

      Note

      When reusing the oil pressure switching valve assembly, inspect the O-ring.

    2. Install the oil pressure switching valve assembly with the bolt.

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

      Note

      Make sure that the O-ring is not cracked or jammed when installing the oil pressure switching valve assembly.

    3. Connect the oil pressure switching valve connector and attach the wire harness clamp.

  21. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


    1. Remove any old seal packing material.

    2. A01IOYBE01

      Apply seal packing to the cylinder head as shown in the illustration.

      Seal packing
      Toyota Genuine Seal Packing Black, Three Bond 1207B or equivalent
      Standard Seal Packing Dimension
      Area Seal Packing Diameter Seal Packing Application Length
      A 6.0 mm (0.236 in.) 8.0 mm (0.315 in.)
      B 6.0 mm (0.236 in.) 10 mm (0.394 in.)

    3. Install a new cylinder head cover gasket to the cylinder head cover sub-assembly.


      1. Install the cylinder head cover gasket so that the triangle tabs of the cylinder head cover gasket are aligned with the protrusions of the cylinder head cover sub-assembly as shown in the parts of the illustration labeled A and B.

      2. Install the cylinder head cover gasket to the groove of the cylinder head cover sub-assembly moving from C and D in the direction of the black arrows shown in the illustration.

      3. Install the cylinder head cover gasket to the groove of the cylinder head cover sub-assembly moving from C and D towards E as shown by the white arrows in the illustration.

      4. Install the cylinder head gasket to the groove of the cylinder head cover sub-assembly moving from D towards F as shown by the striped arrow in the illustration.

      5. Install the cylinder head cover gasket to the cylinder head cover sub-assembly pins and cutouts as shown in the parts of the illustration labeled G and H.

        A01IOK1E01
        Text in Illustration
        *1 Triangle Tab of Cylinder Head Cover Gasket *2 Protrusion of Cylinder Head Cover Sub-assembly
        *3 Cylinder Head Cover Sub-assembly Pin *4 Cutout of Cylinder Head Cover Sub-assembly

        Note

        Make sure that the rib of the cylinder head cover gasket is securely inserted into the groove of the cylinder head cover sub-assembly.

        A01INFME01
        Text in Illustration
        *a CORRECT
        *b INCORRECT
        A01IOJV Rib of Cylinder Head Cover Gasket
    4. A01IN1EE01

      Install the cylinder head cover sub-assembly with the 14 bolts and nut, and tighten the bolts and nut in the order shown in the illustration.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }
      Text in Illustration
      A01ISER Nut

      Tech Tips

      Partially tighten the bolt indicated by the number 6 in the illustration until the cylinder head cover sub-assembly contacts the cylinder head, and then tighten the bolts and nut in the order shown in the illustration.

  22. INSTALL NOZZLE HOLDER CLAMP SEAT


    1. A01IOCF

      Install the 4 nozzle holder clamp seats.

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

  23. INSTALL OIL FILLER CAP SUB-ASSEMBLY

  24. INSTALL VENTILATION HOSE


    1. A01ISGHE01
      Text in Illustration
      *1 Paint Mark
      *a Upper Side
      *b Front Side of Vehicle

      Install the ventilation hose to the cylinder head cover sub-assembly, and slide the clamp to secure it.

      Tech Tips

      The direction of the hose clamp is indicated in the illustration.

  25. INSTALL NO. 1 WIRING HARNESS CLAMP BRACKET (for DPF)


    1. Install the No. 1 wiring harness clamp bracket with the bolt.

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

  26. INSTALL VACUUM TRANSMITTING HOSE ASSEMBLY


    1. A01IQ2TE01
      Text in Illustration
      *a CORRECT
      *b INCORRECT
      A01INHX Paint Mark

      for CCo:

      Attach the 10 clamps to install the 2 vacuum transmitting hoses.

      Tech Tips


      • Make sure that the paint marks of the vacuum transmitting hoses at the locations labeled A in the illustration are aligned as shown in the illustration. Any of the "CORRECT" alignments are acceptable for each location.

      • Make sure that the paint marks of the vacuum transmitting hoses at the locations labeled B in the illustration are aligned as shown in the illustration. Any of the "CORRECT" alignments are acceptable for each location.

    2. A01IPSDE01
      Text in Illustration
      *a CORRECT
      *b INCORRECT
      A01INHX Paint Mark

      for DPF:

      Attach the 8 clamps to install the 2 vacuum transmitting hoses.

      Tech Tips


      • Make sure that the paint marks of the vacuum transmitting hoses at the locations labeled A in the illustration are aligned as shown in the illustration. Any of the "CORRECT" alignments are acceptable for each location.

      • Make sure that the paint marks of the vacuum transmitting hoses at the locations labeled B in the illustration are aligned as shown in the illustration. Any of the "CORRECT" alignments are acceptable for each location.

  27. INSTALL NO. 1 VACUUM SWITCHING VALVE ASSEMBLY


    1. Using a 4 mm hexagon socket wrench, install the VSV with the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

    2. Connect the 2 vacuum hoses.

    3. Connect the VSV connector.

  28. INSTALL VACUUM REGULATING VALVE ASSEMBLY (for CCo)


    1. Install the vacuum regulating valve with the 2 bolts.

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

    2. Connect the 2 vacuum hoses.

    3. Connect the vacuum regulating valve connector.

  29. INSTALL INJECTOR ASSEMBLY

    Note

    Before installing the injector, check for carbon, foreign matter, etc. on the seal surfaces of the cylinder head and injector. If there is foreign matter, remove it before installing the injector.


    1. Install 4 new injection nozzle seats to the cylinder head.

    2. A01IT2HE01
      Text in Illustration
      *1 New O-Ring

      Install a new O-ring to each injector assembly.

    3. Apply a light coat of engine oil to the O-ring on each injector assembly.

    4. Install the 4 injectors to the cylinder head.

      Note

      Fit the injectors to the injection nozzle seats.

    5. A01IOSXE01
      Text in Illustration
      *1 Washer

      Install the 4 No. 1 nozzle holder clamps and 4 washers as shown in the illustration.

      Note

      Pay attention to the mounting orientation (beveled edge) of the washer.

    6. Temporarily install the nozzle holder clamp bolts.

      Note

      When temporarily installing the nozzle holder clamp bolt to the No. 1 nozzle holder clamp, make sure that the nozzle holder clamp bolt and No. 1 nozzle holder clamp are not at an angle.

      Tech Tips

      Apply a light coat of engine oil to the threads of the nozzle holder clamp bolts.

    7. Temporarily install the 4 injection pipes.

    8. Temporarily install the No. 1 leakage pipe and 4 new gaskets with the 4 union bolts and bolt.

    9. Tighten the 4 nozzle holder clamp bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

    10. Connect the 4 injector connectors.

  30. INSTALL NO. 1 NOZZLE LEAKAGE PIPE


    1. Tighten the 4 union bolts.

      Torque:
      18 N*m  { 184 kgf*cm, 13 ft.*lbf }

    2. Tighten the bolt.

      Torque:
      21 N*m  { 209 kgf*cm, 15 ft.*lbf }

  31. INSTALL NO. 2 NOZZLE LEAKAGE PIPE


    1. Temporarily install the No. 2 nozzle leakage pipe and a new gasket with the check valve and bolt.

    2. Tighten the check valve.

      Torque:
      32 N*m  { 321 kgf*cm, 23 ft.*lbf }

    3. Tighten the bolt.

      Torque:
      32 N*m  { 321 kgf*cm, 23 ft.*lbf }

  32. INSTALL NO. 3 FUEL HOSE


    1. A01IP1SE01
      Text in Illustration
      *a 2 to 3 mm (0.0787 to 0.118 in.)
      *b 2 to 6 mm (0.0787 to 0.236 in.)

      Using pliers, grip the claws of the 2 clips and slide the 2 clips to install the No. 3 fuel hose to the fuel supply pump assembly and No. 2 nozzle leakage pipe.

      Tech Tips


      • Push on the No. 3 fuel hose so that the clearance is 2 to 3 mm (0.0787 to 0.118 in.).

      • Position the clamp so that the distance from the end of the No. 3 hose is 2 to 6 mm (0.0787 to 0.236 in.).

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


    1. Temporarily install the No. 2 fuel pipe and 2 new gaskets with the check valve and union bolt.

    2. Tighten the check valve.

      Torque:
      32 N*m  { 321 kgf*cm, 23 ft.*lbf }

    3. Tighten the union bolt.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }

  34. INSTALL FUEL TUBE SUB-ASSEMBLY (for DPF)


    1. Temporarily install the fuel tube sub-assembly and 2 new gaskets with the check valve and union bolt.

    2. Tighten the check valve.

      Torque:
      32 N*m  { 321 kgf*cm, 23 ft.*lbf }

    3. Tighten the union bolt.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
    4. A01IPE8

      Connect the fuel tube connector to the exhaust fuel addition injector assembly.

    5. A01IQ7XE01
      Text in Illustration
      *1 Fuel Tube Connector
      *2 Exhaust Fuel Addition Injector Assembly
      *3 Retainer
      *4 O-Ring

      Turn the retainer in the direction indicated by the arrow until it makes a "click" sound.

      Note

      If the fuel tube connector is not inserted to the correct position on the exhaust fuel addition injector assembly, the retainer cannot be turned far enough in the direction of the arrow.

    6. Connect the exhaust fuel addition injector connector.

  35. INSTALL FUEL HOSE PROTECTOR (for DPF)


    1. Install the fuel hose protector with the bolt.

      Torque:
      21 N*m  { 209 kgf*cm, 15 ft.*lbf }

  36. INSTALL WATER INLET HOUSING


    1. Install a new gasket and the water inlet housing with the 3 nuts.

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

  37. INSTALL NO. 4 WATER BY-PASS HOSE


    1. Install the No. 4 water by-pass hose to the water inlet housing and cylinder head sub-assembly, and slide the 2 clamps to secure it.

  38. INSTALL NO. 2 WATER BY-PASS PIPE


    1. Install a new O-ring to the No. 2 water by-pass pipe.

    2. Install the No. 2 water by-pass pipe with the 2 bolts.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  39. INSTALL NO. 1 OIL COOLER BRACKET


    1. for CCo:


      1. A01INIOE02

        Apply engine oil to the 2 new O-rings labeled B in the illustration.

        Note

        Do not apply engine oil to the new O-ring labeled A in the illustration.

      2. Install 3 new O-rings to the No. 1 oil cooler bracket.

    2. for DPF:


      1. A01IRZME01

        Apply engine oil to the 2 new gaskets labeled B in the illustration.

        Note

        Do not apply engine oil to the new gasket labeled A in the illustration.

      2. Install 3 new gaskets to the No. 1 oil cooler bracket.

    3. Install the No. 1 oil cooler bracket with the 6 bolts and nut.

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

  40. INSTALL NO. 1 TURBO OIL PIPE


    1. A01IT4EE01
      Text in Illustration
      *1 Gasket

      Install the No. 1 turbo oil pipe and 2 new gaskets with the 2 union bolts.

      Torque:
      35 N*m  { 357 kgf*cm, 26 ft.*lbf }

      Note

      Make sure the gasket of union bolt A contacts the No. 1 turbo oil pipe as shown in the illustration when tightening the union bolt.

  41. INSTALL NO. 3 WATER BY-PASS PIPE


    1. Install a new O-ring to the No. 3 water by-pass pipe.

    2. Install the No. 3 water by-pass pipe with the 2 bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

  42. INSTALL NO. 8 WATER BY-PASS HOSE


    1. Install the No. 8 water by-pass hose to the No. 3 water by-pass pipe, and slide the clamp to secure it.

  43. INSTALL NO. 6 WATER BY-PASS HOSE


    1. Install the No. 6 water by-pass hose to the water outlet, and slide the clamp to secure it.

  44. INSTALL OIL COOLER ASSEMBLY


    1. for CCo:


      1. A01IT2UE01

        Apply engine oil to the 2 new O-rings labeled B in the illustration.

        Note

        Do not apply engine oil to the new O-ring labeled A in the illustration.

      2. Install 3 new O-rings to the No. 1 oil cooler bracket.

    2. for DPF:


      1. A01IOY3E01

        Apply engine oil to the 2 new gaskets labeled B in the illustration.

        Note

        Do not apply engine oil to the new gasket labeled A in the illustration.

      2. Install 3 new gaskets to the No. 1 oil cooler bracket.

    3. Install the oil cooler assembly with the 5 bolts.

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

  45. INSTALL WATER BY-PASS HOSE


    1. Install the water by-pass hose to the water outlet and oil cooler assembly, and slide the 2 clamps to secure it.

      Tech Tips

      Make sure the claws of hose clamp A are positioned above the paint mark as shown in the illustration.

      A01IU9WE03
      Text in Illustration
      *1 Paint Mark
      *a Upper Side

  46. INSTALL NO. 1 CYLINDER BLOCK INSULATOR


    1. A01ITY5

      Install the No. 1 cylinder block insulator to the cylinder block.

      Note

      Be sure to install the oil cooler assembly before installing the No. 1 cylinder block insulator.

  47. INSTALL INTAKE MANIFOLD


    1. A01IRJAE01

      Install a new gasket to the cylinder head.

      Tech Tips

      Install the gasket with the part labeled A facing the right side of the vehicle as shown in the illustration.

    2. A01IOHHE02
      Text in Illustration
      *1 Nut

      Install the intake manifold with the 7 bolts and 2 nuts.

      Torque:
      23 N*m  { 235 kgf*cm, 17 ft.*lbf }
      Bolt Length
      Item Length
      Bolt A 90 mm (3.54 in.)
      Bolt B 25 mm (0.984 in.)

  48. INSTALL NO. 2 INTAKE MANIFOLD


    1. Install a new gasket and the No. 2 intake manifold with the bolt and 2 nuts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  49. INSTALL ENGINE COVER BRACKET


    1. Install the engine cover bracket with the bolt.

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

  50. INSTALL GAS FILTER BRACKET


    1. Install the gas filter bracket with the 2 bolts.

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

  51. INSTALL NO. 1 GAS FILTER


    1. A01IOCKE01
      Text in Illustration
      *1 Protrusion
      *2 Groove

      Install the No. 1 gas filter to the gas filter bracket.

      Note

      Make sure the protrusion of the No. 1 gas filter is aligned with the groove of the gas filter bracket.

    2. Connect the vacuum hose.

  52. INSTALL DIESEL TURBO PRESSURE SENSOR


    1. A01IOD1E01
      Text in Illustration
      *1 Protrusion

      Install the diesel turbo pressure sensor with the bolt.

      Torque:
      8.8 N*m  { 90 kgf*cm, 78 in.*lbf }

      Note

      Make sure the protrusion of the gas filter bracket is inserted into the hole of the diesel turbo pressure sensor.

    2. Connect the vacuum hose.

  53. INSTALL INTAKE MANIFOLD INSULATOR


    1. Install the intake manifold insulator to the intake manifold.

  54. INSTALL COMMON RAIL ASSEMBLY


    1. Install the common rail assembly with the 2 bolts.

      Torque:
      21 N*m  { 209 kgf*cm, 15 ft.*lbf }

  55. INSTALL NO. 4 FUEL HOSE


    1. Install the No. 4 fuel hose to the No. 2 nozzle leakage pipe and common rail assembly, and slide the 2 clamps to secure it.

  56. INSTALL INJECTION PIPE SUB-ASSEMBLY


    1. Using a 14 mm union nut wrench, tighten the 4 union nuts at the common rail end of the injection pipes.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

    2. Using a 14 mm union nut wrench, tighten the 4 union nuts at the injector end of the injection pipes.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

    3. Install the 4 No. 2 injection pipe clamps with the 2 bolts.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  57. INSTALL FUEL INLET PIPE SUB-ASSEMBLY


    1. Temporarily install the fuel inlet pipe sub-assembly with the 2 No. 2 injection pipe clamps and nut.

    2. Using a 14 mm union nut wrench, first tighten the nut at the common rail assembly end of the fuel inlet pipe sub-assembly.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

    3. Using a 14 mm union nut wrench, tighten the nut at the fuel supply pump assembly end of the fuel inlet pipe sub-assembly.

      Torque:
      30 N*m  { 306 kgf*cm, 22 ft.*lbf }

      Note

      Use the formula to calculate special torque values for situations where a union nut wrench is combined with a torque wrench Click here.

    4. Tighten the No. 2 injection pipe clamp nut.

      Torque:
      5.0 N*m  { 51 kgf*cm, 44 in.*lbf }

  58. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE


    1. Install a new O-ring to the engine oil level dipstick guide.

    2. Install the engine oil level dipstick guide with the 2 bolts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

    3. Connect the connector and attach the wire harness clamp to the engine oil level dipstick guide.

    4. Install the engine oil level dipstick.

  59. INSTALL ELECTRIC EGR CONTROL VALVE ASSEMBLY


    1. A01IN07E01
      Text in Illustration
      *1 Protrusion

      Install a new gasket.

      Tech Tips

      Make sure the protrusion of the gasket is facing upward as shown in the illustration.

    2. Install the electric EGR control valve assembly.

  60. INSTALL NO. 2 EGR PIPE SUB-ASSEMBLY


    1. Install 2 new gaskets to the No. 2 EGR pipe sub-assembly and electric EGR control valve assembly.

    2. A01IPRKE06
      Text in Illustration
      *1 Nut

      Temporarily install the No. 2 EGR pipe sub-assembly with the 3 bolts and 2 nuts.

      Standard Bolt
      Item Length
      Bolt A 25 mm (0.984 in.)
      Bolt B 70 mm (2.76 in.)

    3. Tighten the 2 bolts labeled A shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

    4. Tighten the bolt labeled B and 2 nuts shown in the illustration.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

    5. Connect the electric EGR control valve connector.

  61. INSTALL EGR VALVE BRACKET


    1. Install the 2 EGR valve brackets with the 3 bolts.

      Torque:
      24 N*m  { 245 kgf*cm, 18 ft.*lbf }

  62. CONNECT NO. 8 WATER BY-PASS HOSE


    1. Connect the No. 8 water by-pass hose to the electric EGR control valve assembly, and slide the clamp to secure it.

  63. INSTALL NO. 7 WATER BY-PASS HOSE


    1. Install the No. 7 water by-pass hose to the electric EGR control valve assembly, and slide the clamp to secure it.

  64. INSTALL DIESEL THROTTLE BODY ASSEMBLY


    1. Install a new gasket and the diesel throttle body assembly with the 2 bolts and 2 nuts.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

    2. Connect the No. 6 water by-pass hose and No. 7 water by-pass hose to the diesel throttle body assembly, and slide the 2 clamps to secure it.

  65. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY


    1. Install the V-ribbed belt tensioner assembly with the 3 bolts.

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

      Note

      As the heads of the bolts are not as thick as those of typical bolts, be careful not to damage them during installation.

  66. INSTALL ENGINE MOUNTING BRACKET


    1. Temporarily install the engine mounting bracket with the 2 bolts labeled A.

    2. A01IQJUE01

      Temporarily install the 2 bolts and 2 nuts labeled B in the illustration.

    3. Tighten the 2 bolts labeled A in the illustration.

      Torque:
      28 N*m  { 286 kgf*cm, 21 ft.*lbf }

    4. Tighten the 2 bolts and 2 nuts labeled B in the illustration.

      Torque:
      80 N*m  { 816 kgf*cm, 59 ft.*lbf }

  67. INSTALL NO. 4 WATER BY-PASS PIPE


    1. Install a new O-ring to the No. 4 water by-pass pipe.

    2. Install the No. 4 water by-pass pipe with the bolt.

      Torque:
      11 N*m  { 112 kgf*cm, 8 ft.*lbf }

  68. INSTALL NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. A01IQMTE01
      Text in Illustration
      *1 No. 2 Idler Pulley Cover Plate
      *2 No. 2 Idler Pulley Sub-assembly

      Install the No. 2 idler pulley sub-assembly and No. 2 idler pulley cover plate with the bolt.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

      Note

      Make sure the No. 2 idler pulley cover plate is facing the direction shown in the illustration.

  69. INSTALL NO. 1 IDLER PULLEY SUB-ASSEMBLY


    1. Install the No. 1 idler pulley sub-assembly with the bolt.

      Torque:
      40 N*m  { 408 kgf*cm, 30 ft.*lbf }

  70. INSTALL IDLER PULLEY COVER PLATE


    1. Install the idler pulley cover plate to the No. 1 idler pulley sub-assembly.

  71. INSTALL VACUUM PUMP ASSEMBLY


    1. Apply a light coat of engine oil to 2 new O-rings.

    2. Install the 2 O-rings to the vacuum pump assembly.

    3. Install the vacuum pump assembly with 3 new bolts.

      Torque:
      21 N*m  { 214 kgf*cm, 15 ft.*lbf }

    4. Connect the vacuum hose.

  72. INSTALL GENERATOR ASSEMBLY


    1. A01ISLO

      Install the generator assembly with the 3 bolts.

      Torque:
      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

      Note

      Make sure that the wire harness of the crankshaft position sensor does not get caught between the cylinder block and generator when installing the generator.

    2. Attach the wire clamp.

    3. A01IN5D

      Connect the generator wire with the nut and bolt.

      Torque:
      for nut
      9.8 N*m  { 100 kgf*cm, 87 in.*lbf }
      for bolt
      8.4 N*m  { 85 kgf*cm, 74 in.*lbf }

    4. Connect the generator connector and attach the clamp.

    5. Install the terminal cap.

  73. CONNECT ENGINE WIRE


    1. Connect the connectors and attach the clamps, and then connect the engine wire to the engine with the bracket bolts.

  74. INSTALL ENGINE ASSEMBLY

    Click here

  75. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL

    Note

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