CYLINDER HEAD (II) ASSEMBLY [WITH DIESEL PARTICULATE FILTER]

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1. Assemble in the order indicated in the table.

1
Breather pipe
2
Camshaft
3
Rocker bridge
4
Rocker arm and rocker arm shaft
5
Side wall
6
Supply pump bracket
7
Intake manifold
8
Nozzle seal
9
Supply pump
10
Common rail
11
injection nozzle
12
Fuel injection pipe
13
Fuel injection pipe
14
injection nozzle bracket
15
No. 3 engine mount bracket
16
Water outlet
17
Bypass pipe
18
Cylinder head cover
19
Dipstick

Rocker Arm and Rocker Arm Shaft Assembly Note

1. Apply sealant as shown in the figure.

Thickness
2.0 mm {0.079 in} min.

2. Install the camshaft caps according to the cap number.

3. Install the rocker arm shaft plane side upward.

Caution
• Because there is little camshaft thrust clearance, the camshaft must be held horizontally while it is installed. Otherwise, excessive force will be applied to the thrust area, causing burr on the thrust receiving area of the cylinder head journal. To avoid this, the following procedure must be observed.

4. Tighten the bolts in two or three steps in the order shown.

5. Apply clean engine oil to the new oil seal.

6. Push the oil seal slightly in by hand.

7. Tap the oil seal into the cylinder head using the SST and a hammer.

Side Wall Assembly Note

1. Apply silicone sealant as shown in the figure.

Thickness
2.0 mm {0.079 in} min.

Supply Pump Bracket Assembly Note

1. Tighten the bolts in the order shown.

Intake Manifold Assembly Note

• Tighten from centre to outwards.

injection Nozzle Assembly Note

1. Temporarily tighten the fuel injector bracket.

Tightening torque
10-20 N·m {1.0-2.0 kgf·m, 8-l4 ft·lbf}

2. Temporarily tighten the common rail.

3. Temporarily tighten the injection pipes.

4. Fully tighten the fuel injector side injection pipes, then tighten the common rail side.

Tightening torque
40-50 N·m {4.1-5.0 kgf·m, 29.6-36.8 ft·lbf}

5. Fully tighten the supply pump side and common rail side injection pipes.

Tightening torque
40-50 N·m {4.1-5.0 kgf·m, 29.6-36.8 ft·lbf}

6. Fully tighten the fuel injector bracket.

Tightening torque
52-62 N·m {5.3-6.3 kgf·m, 38.4-45.7 ft·lbf}

7. Fully tighten the common rail.

Tightening torque
18.6-25.5 N·m {1.9-2.6 kgf·m, 13.8-18.8 ft·lbf}

Cylinder Head Cover Assembly Note

1. Press in the injector seal using the SST and a hammer.

Injector seal press-in amount
0-1.5 mm {0.020-0.059 in}

2. Wrap the fuel injector coupler with vinyl tape 2 times covering the coupler edge so as not to damage the injector seal.

3. Apply silicone sealant to the shaded areas.

Thickness
2 mm {0.079 in}

4. Remove the cylinder head cover so as not to damage the injector seal from the coupler edge.

5. Verify that the injector seal is not damaged, then remove the vinyl tape wrapped around the fuel injector coupler.

6. Tighten the bolts in the order shown.

Tightening torque
7.8-10.8 N·m {79.6-110 kgf·cm, 69.0-95.5 in·lbf}

Water Outlet Assembly Note

1. Tighten the bolts in the order shown.