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CYLINDER HEAD (II) ASSEMBLY [WITHOUT 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 (See Rocker Arm and Rocker Arm Shaft Assembly Note)
5 | Side wall
6 | Injection pump bracket (See Injection Pump Bracket Assembly Note)
7 | Intake manifold (See Intake Manifold Assembly Note)
8 | Nozzle seal
9 | Injection pump
10 | EGR water cooler
11 | Common rail
12 | Injection nozzle (See Injection Nozzle Assembly Note)
13 | Fuel injection pipe
14 | Fuel injection pipe
15 | Injection nozzle bracket
16 | No. 3 engine mount bracket
17 | Water outlet (See Water Outlet Assembly Note)
18 | Bypass pipe
19 | Cylinder head cover (See Cylinder Head Cover Assembly Note)
20 | 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.

## Injection 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 injection nozzle 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 injector side injection pipes, then tighten the common rail side.

Tightening torque

  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.

Tightening torque

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

6. Fully tighten the injection nozzle bracket.

Tightening torque

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

7. Fully tighten the common rail.

Tightening torque

  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.

Thickness

  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.