CYLINDER HEAD (II) ASSEMBLY [WITHOUT DIESEL PARTICULATE FILTER]

1. Assemble in the order indicated in the table.

Rocker Arm and Rocker Arm Shaft Assembly Note

1. Apply sealant as shown in the figure.

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.

2.0 mm {0.079 in} min.

Injection Pump Bracket Assembly Note

1. Tighten the bolts in the order shown.

Intake Manifold Assembly Note

Injection Nozzle Assembly Note

1. Temporarily tighten the injection nozzle bracket.

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 injector side injection pipes, then tighten the common rail side.

50-60 N·m {5.0-6.0 kgf·m, 37-44 ft·lbf}

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

50-60 N·m {5.0-6.0 kgf·m, 37-44 ft·lbf}

6. Fully tighten the injection nozzle bracket.

52-61 N·m {5.3-6.3 kgf·m, 39-45 ft·lbf}

7. Fully tighten the common rail.

19-25 N·m {1.9-2.6 kgf·m, 14-18 ft·lbf}

Cylinder Head Cover Assembly Note

1. Apply silicone sealant to the shaded areas.

2.0 mm {0.079 in} min.

2. Tighten the bolts in the order shown.

Water Outlet Assembly Note

1. Tighten the bolts in the order shown.