CYLINDER HEAD > INSTALLATION

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1. INSTALL CYLINDER HEAD GASKET


A060285E01

  1. Find where the piston head protrudes most by slowly turning the crankshaft clockwise and counterclockwise.



    A058134E01

  1. Measure the piston protrusion of each cylinder at 2 points as shown in the illustration.

  1. For the piston protrusion value of each cylinder, use the average of the 2 measurements of each cylinder.

    Piston protrusion:
    0.005 to 0.254 mm (0.0002 to 0.0100 in.)

    HINT:
    When removing the piston and connecting rod assembly: If the protrusion is not as specified, remove the piston and connecting rod assembly and reinstall them.



    A060174E01

  1. Select a new cylinder head gasket.

    HINT:
    New cylinder head gaskets are available in 5 sizes, and are marked A, B, C, D or E.

    New installed cylinder head gasket thickness:
    Mark
    		Thickness
    A
    		0.80 to 0.90 mm (0.0315 to 0.0354 in.)
    B
    		0.85 to 0.95 mm (0.0335 to 0.0374 in.)
    C
    		0.90 to 1.00 mm (0.0354 to 0.0394 in.)
    D
    		0.95 to 1.05 mm (0.0374 to 0.0413 in.)
    E
    		1.00 to 1.10 mm (0.0394 to 0.0433 in.)


    1. Select the largest piston protrusion value from the measurements made. Then select a new appropriate gasket according to the table below.

      Use gasket size:
      Gasket Size
      		Piston Protrusion
      Use A
      		0.005 to 0.054 mm (0.0002 to 0.0021 in.)
      Use B
      		0.055 to 0.104 mm (0.0022 to 0.0041 in.)
      Use C
      		0.105 to 0.154 mm (0.0041 to 0.0061 in.)
      Use D
      		0.155 to 0.204 mm (0.0061 to 0.0080 in.)
      Use E
      		0.205 to 0.255 mm (0.0081 to 0.0100 in.)



    A060144E01

  1. Place the cylinder head on the cylinder block.

    1. Place the cylinder head gasket on the cylinder block.

      NOTICE:
      Be careful of the installation direction.

    2. Place the cylinder head on the cylinder head gasket.



2. INSTALL CYLINDER HEAD SUB-ASSEMBLY


A060284E01

HINT:
  1. The cylinder head bolts are tightened in 3 progressive steps.
  2. If any bolt is broken or deformed, replace it.

  1. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.

  1. Install and uniformly tighten the 18 cylinder head bolts, in several passes in the sequence shown in the illustration.

    Torque:
    85 N*m{ 867 kgf*cm , 63 ft.*lbf }

    Bolt length A:
    110 mm (4.33 in.)

    Bolt length B:
    167 mm (6.57 in.)

    If any of the cylinder head bolts does not meet the torque specification, replace it.



    A060141E02

  1. Mark the front of the cylinder head bolt with paint.

  1. Further tighten the cylinder head bolts by 90° in the sequence shown in the illustration above.

  1. Finally, tighten the cylinder head bolts by an additional 90°.

  1. Check that the painted mark is now facing rearward.



3. INSTALL CAMSHAFT


G036616E01

  1. Using the crankshaft pulley bolt, set the No. 1 cylinder to 90° BTDC/compression.

    HINT:
    Set the No. 1 cylinder to 90° BTDC/compression to avoid interference with the piston top and valve head.



    A060149E01

  1. Install the camshaft.

    1. Apply MP grease to the thrust portion of the camshaft.

    2. Place the camshaft on the cylinder head, facing the key groove upward.



      3. A060150E01

    3. Align the timing marks (1 dot mark) of the camshaft drive and driven main gears, and set the No. 2 camshaft in place.



    A060283E02

  1. Remove any old packing (FIPG) material from the camshaft bearing cap.



  1. Apply seal packing to the specified areas shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    Seal diameter:
    4 mm (0.16 in.)

    NOTICE:
    1. Do not allow FIPG to contact the oil passage of the bearing cap.
    2. After applying FIPG, install the camshaft bearing caps within 3 minutes and fasten the bolts within 15 minutes.
    3. Do not start the engine for at least 2 hours after the installation.




      A060146E01

    1. Install the 5 bearing caps in their proper locations.



      2. A060147E02

    2. Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.

    3. Install and uniformly tighten the 10 bearing cap bolts in several passes in the sequence shown in the illustration.

      Torque:
      19 N*m{ 194 kgf*cm , 14 ft.*lbf }

  1. Install the camshaft oil seal.



4. INSPECT VALVE CLEARANCE


A060176E02

  1. Check only the valves indicated.

    1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

      Valve clearance (Cold):
      Intake
      		Exhaust
      0.20 to 0.30 mm (0.008 to 0.012 in.)
      		0.35 to 0.45 mm (0.014 to 0.018 in.)

      Write down valve clearance measurements that are out of the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed.

  1. Turn the crankshaft 360° to set the No. 4 cylinder to TDC / compression.



    A060175E02

  1. Check only the valves indicated.

    1. Using a feeler gauge, measure the clearance between the valve lifter and camshaft.

      Valve clearance:
      Intake
      		Exhaust
      0.20 to 0.30 mm (0.008 to 0.012 in.)
      		0.35 to 0.45 mm (0.014 to 0.018 in.)

      Write down valve clearance measurements that are out of the specified range. These measurements will be used later to determine the size of the adjustment shim to be installed.



5. ADJUST VALVE CLEARANCE

  1. Drain coolant.

  1. Remove the fan shroud.

  1. Remove the No. 1 timing belt cover.

  1. Remove the timing belt.

  1. Remove the camshaft timing pulley.

  1. Remove the No. 1 timing belt idler.

  1. Remove the No. 2 timing belt cover.

  1. Remove the camshafts.



    A001082E01

  1. Remove the valve lifters.

  1. Using a micrometer, measure the thickness of the removed lifter.

  1. Calculate the thickness of a new lifter so that the valve clearance comes within the specified value.

    Valve clearance:
    A
    		B
    		C
    Thickness of new lifter
    		Thickness of used lifter
    		Measured valve clearance

    Valve clearance (Cold):
    Intake A = B + (C - 0.25 mm (0.0098 in.))

    Valve clearance (Cold):
    Exhaust A = B + (C - 0.40 mm (0.00158 in.))

  1. Select a new lifter with a thickness as close as possible to the calculated values.

    HINT:
    Valve lifters are available in 35 sizes in increments of 0.020 mm (0.0008 in.), from 5.060 mm (0.1992 in.) to 5.740 mm (0.2260 in.).



  1. Install the selected valve lifter.


    A111876E01



    A111877E01

    Intake valve clearance (Cold):
    0.20 to 0.30 mm (0.008 to 0.012 in.)

    EXAMPLE:
    The 5.250 mm (0.2067 in.) lifter is installed, and the measured clearance is 0.400 mm (0.0158 in.). Replace the 5.250 mm (0.2067 in.) shim with a No. 40 lifter.


    New Lifter Thickness mm (in.):

    Shim No.
    		Thickness
    		Shim No.
    		Thickness
    		Shim No.
    		Thickness
    06
    		5.060 (0.1992)
    		30
    		5.300 (0.2087)
    		54
    		5.540 (0.2181)
    08
    		5.080 (0.2000)
    		32
    		5.320 (0.2094)
    		56
    		5.560 (0.2189)
    10
    		5.100 (0.2008)
    		34
    		5.340 (0.2102)
    		58
    		5.580 (0.2197)
    12
    		5.120 (0.2016)
    		36
    		5.360 (0.2110)
    		60
    		5.600 (0.2205)
    14
    		5.140 (0.2024)
    		38
    		5.380 (0.2118)
    		62
    		5.620 (0.2213)
    16
    		5.160 (0.2031)
    		40
    		5.400 (0.2126)
    		64
    		5.640 (0.2220)
    18
    		5.180 (0.2039)
    		42
    		5.420 (0.2134)
    		66
    		5.660 (0.2228)
    20
    		5.200 (0.2047)
    		44
    		5.440 (0.2142)
    		68
    		5.680 (0.2236)
    22
    		5.220 (0.2055)
    		46
    		5.460 (0.2150)
    		70
    		5.700 (0.2244)
    24
    		5.240 (0.2063)
    		48
    		5.480 (0.2157)
    		72
    		5.720 (0.2252)
    26
    		5.260 (0.2071)
    		50
    		5.500 (0.2165)
    		74
    		5.740 (0.2260)
    28
    		5.280 (0.2079)
    		52
    		5.520 (0.2173)
    		-
    		-



    A111878E01



    A111879E01

    Exhaust valve clearance (Cold):
    0.35 to 0.45 mm (0.014 to 0.018 in.)

    EXAMPLE:
    The 5.340 mm (0.2102 in.) lifter is installed, and the measured clearance is 0.480 mm (0.0189 in.). Replace the 5.340 mm (0.2102 in.) shim with a No. 42 lifter.


    New Lifter Thickness mm (in.):

    Shim No.
    		Thickness
    		Shim No.
    		Thickness
    		Shim No.
    		Thickness
    06
    		5.060 (0.1992)
    		30
    		5.300 (0.2087)
    		54
    		5.540 (0.2181)
    08
    		5.080 (0.2000)
    		32
    		5.320 (0.2094)
    		56
    		5.560 (0.2189)
    10
    		5.100 (0.2008)
    		34
    		5.340 (0.2102)
    		58
    		5.580 (0.2197)
    12
    		5.120 (0.2016)
    		36
    		5.360 (0.2110)
    		60
    		5.600 (0.2205)
    14
    		5.140 (0.2024)
    		38
    		5.380 (0.2118)
    		62
    		5.620 (0.2213)
    16
    		5.160 (0.2031)
    		40
    		5.400 (0.2126)
    		64
    		5.640 (0.2220)
    18
    		5.180 (0.2039)
    		42
    		5.420 (0.2134)
    		66
    		5.660 (0.2228)
    20
    		5.200 (0.2047)
    		44
    		5.440 (0.2142)
    		68
    		5.680 (0.2236)
    22
    		5.220 (0.2055)
    		46
    		5.460 (0.2150)
    		70
    		5.700 (0.2244)
    24
    		5.240 (0.2063)
    		48
    		5.480 (0.2157)
    		72
    		5.720 (0.2252)
    26
    		5.260 (0.2071)
    		50
    		5.500 (0.2165)
    		74
    		5.740 (0.2260)
    28
    		5.280 (0.2079)
    		52
    		5.520 (0.2173)
    		-
    		-

  1. Install the camshaft.

  1. Install the No. 2 timing belt cover.

  1. Install the No. 1 timing belt idler.

  1. Install the camshaft timing pulley.

  1. Install the timing belt.

  1. Install the No. 1 timing belt cover.

  1. Install the fan shroud.

  1. Add engine coolant.



6. INSTALL INJECTOR ASSEMBLY


B008252E01

NOTICE:
Be sure to install the injector, holder clamp, washer and bolt in their original positions.

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

  1. Apply a light amount of clean engine oil to 4 new O-rings.



    G036760E02

  1. Install the O-ring to each injector as shown in the illustration.

  1. Insert the 4 injectors into the cylinder head.

    NOTICE:
    1. At this time, insert the injector until it touches the nozzle sheet surface.
    2. After installing the injector to the cylinder head, the O-ring may prevent the injector from fully seating. If so, pull out the injector and reinstall it.
    3. Always return an injector to the same place it was removed from.

  1. Register injector compensation code (when replacing with a new injector).



    A060177E02

  1. Temporarily install 4 new washers and the 4 nozzle clamps with the 4 clamp bolts.

    HINT:
    Apply a light amount of engine oil to the threads and under the heads of the clamp bolts.

    NOTICE:

    1. G037744E01
    2. The fork portion of the nozzle holder clamp must be set to the injector.
    3. Before tightening the bolts, check that the nozzle holder clamp is set properly.
    4. To fasten the clamp bolts, first tighten them by hand until they cannot be turned further. Then, tighten the bolts to the specified torque at following step.
    5. When tightening the bolts, pay attention not to tilt the bolt and the clamp.
    6. Do not reuse the washer.
    7. If the nozzle leakage pipe is accidentally tightened beyond the torque specification, it must be replaced.

  1. Temporarily install the 4 injection pipes with the union nuts.

    HINT:
    To position the injectors, loosely tighten the union nut.



    A062123E01

  1. Check the nozzle leakage pipe. Check that there are no scratches or dents on the 5 union seal surfaces.
    If scratches or dents are present, replace the nozzle leakage pipe.



    A070538E01

  1. Set the leakage pipe and 5 new gaskets in place.

  1. Apply a light amount of oil to the 4 hollow screws and union bolt.



    A060184E01

  1. Temporarily install the leakage pipe with the 4 hollow screws and union bolt.

  1. Tighten the 4 holder clamp bolts.

    Torque:
    22 N*m{ 224 kgf*cm , 16 ft.*lbf }



    A051297E01

  1. Tighten the 4 hollow screws in order from 1 to 4.

    Torque:
    16 N*m{ 163 kgf*cm , 12 ft.*lbf }

    NOTICE:
    If a hollow screw is accidentally tightened beyond the torque specification, it must be replaced.

  1. Tighten the union bolt.

    Torque:
    12.5 N*m{ 127 kgf*cm , 9 ft.*lbf }

    NOTICE:
    If the union bolt is accidentally tightened beyond the torque specification, it must be replaced.

  1. Remove the 4 injection pipes.



7. CHECK FOR FUEL LEAKS


G036759E01


  1. Check that there are no leaks from the nozzle leakage pipe connection.

    1. Install the gasket and No. 2 nozzle leakage pipe to the cylinder head with SST (check valve).

      Part No.:
      23762-27010 (No. 2 nozzle leakage pipe)

      SST
      09280-00010  

      Torque:
      21 N*m{ 214 kgf*cm , 16 ft.*lbf }

    2. Apply a light amount of soapy water (or other fluid for detecting fuel leakage) on the nozzle leakage pipe connection.



      3. A060186E02

    3. Install SST (turbocharger pressure gauge) to the fuel return side of the leakage pipe, and maintain 250 kPa (2.5 kgf/cm２, 35.5 psi) of pressure for 60 seconds to check that no bubbles form.

      SST
      09992-00242  

      NOTICE:
      Before checking the leakage, be sure to remove the ball and spring in the check valve.

    4. After checking for fuel leaks, wipe off the soapy water from the leakage pipe connection.

    5. Remove SST, No. 2 nozzle leakage pipe and gasket.

      SST
      09280-00010  
      09992-00242  

      HINT:
      Never reinstall the disassembled check valve on the engine.



8. INSTALL NO. 2 TIMING BELT COVER


A060279E01

  1. Apply seal packing (FIPG) to the specified areas shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    NOTICE:
    After applying FIPG, install the No. 2 timing belt cover within 3 minutes and tighten its bolts and nut within 15 minutes.

  1. Install the No. 2 timing belt cover with the 4 bolts and nut.

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



9. INSTALL CAMSHAFT TIMING PULLEY


A060182E01

  1. Install the camshaft timing pulley.

  1. Fasten the bolt of the camshaft timing pulley by holding the camshaft with a wrench.

    Torque:
    98 N*m{ 1,000 kgf*cm , 72 ft.*lbf }



10. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY


A060179E02

  1. Remove any old seal packing (FIPG) material from the cylinder head.

  1. Apply seal packing to the specific areas shown in the illustration.

    Seal packing:
    Part No. 08826-00080 or equivalent

    NOTICE:
    1. Remove any oil from the contact surface.
    2. Install the belt cover within 3 minutes after applying seal packing.
    3. Do not start the engine for at least 2 hours after installing the seal packing.



    G034877E01

  1. Install the gasket and cylinder head cover with the 10 bolts and 2 nuts.

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

  1. Install 4 new nozzle holder seals.



11. INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY


12. INSTALL TIMING BELT


A070691E02

  1. Check that the timing marks are aligned as shown in the illustration.

    HINT:
    If reusing the timing belt, align the points marked during removal, and install the belt with the arrow pointing in the direction of engine revolution.

    NOTICE:
    1. The engine should be cold.
    2. When turning the crankshaft, the valve heads will hit against the piston's top position. Do not turn it more than necessary.

  1. Using a 10 mm hexagon wrench, install the washer and timing belt idler pulley with the bolt.

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

  1. Check that the idler pulley moves smoothly.
    If it does not move smoothly, check the idler sub-assembly and washer.

  1. Install the timing belt to the pump drive shaft pulley, camshaft timing pulley and No. 1 timing belt idler in sequence.



    A070548E01

  1. Place the tensioner upright. Then set the press to the top of the tensioner.

    NOTICE:
    1. Do not scratch or deform the rod end.
    2. Press in the tensioner rod upward.
    3. Protect the tip of the push rod with a cloth in order to prevent damage.

  1. Using a press, slowly push in the push rod using 981 to 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) of force.

    NOTICE:
    Do not impose a load of over 9,807 N (100 to 1,000 kgf, 220 to 2,205 lbf) to the push rod.

  1. Align the holes of the push rod and housing. Then pass a 1.27 mm hexagon wrench through the holes to keep the setting position of the push rod.

  1. Install the timing belt tensioner with the 2 bolts while pushing the idler pulley toward the timing belt.

  1. Tighten the 2 bolts.

    Torque:
    13 N*m{ 133 kgf*cm , 10 ft.*lbf }

    NOTICE:
    Uniformly tighten the 2 bolts and install the tensioner.



    A059983E01

  1. Remove the 1.5 mm hexagon wrench from the tensioner.



    A070549E02

  1. Turn the crankshaft clockwise 720° and check that the timing marks are aligned as shown in the illustration.



13. INSTALL NO. 1 TIMING BELT COVER

  1. Install the timing belt cover with the 6 bolts.

    Torque:
    6.0 N*m{ 61 kgf*cm , 53 in.*lbf }

  1. Install the wire harness clamp.

  1. Install the water hose clamp with the bolt.

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



14. INSTALL EGR VALVE ASSEMBLY

  1. Install a new gasket and the EGR valve.



15. INSTALL NO. 2 NOZZLE LEAKAGE PIPE ASSEMBLY


A098898E01

  1. Temporarily install the leakage pipe with the 3 bolts.

  1. Temporarily install a new gasket with the check valve.

  1. Fully tighten the 3 bolts and check valve.

    Torque:
    21 N*m{ 214 kgf*cm , 16 ft.*lbf } for check valve
    13 N*m{ 133 kgf*cm , 10 ft.*lbf } for bolt

  1. Connect the 2 fuel hoses.



16. INSTALL INJECTION PIPE


G038585E02

NOTICE:
  1. When replacing the injector, also replace the injection pipe.
  2. Keep the joints of the injection pipe clean.

  1. Temporarily install the No. 1, No. 2 and No. 3 injection pipes with the union nuts.

  1. Install the No. 2 and No. 3 injection pipe clamps with the bolt and 2 nuts, as shown in the illustration.

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

    HINT:
    If the painted mark on the No. 1 injection pipe has disappeared, use the illustration as a reference to install the clamps.



    A098972E01

  1. Using SST, tighten the injection pipe union nuts on the common rail side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

    HINT:
    Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

  1. Using SST, tighten the injection pipe union nuts on the injector side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

    HINT:
    Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).



    A098893E01

  1. Temporarily install the No. 4 injection pipe with the union nuts.

  1. Install 2 new injection pipe clamps with the 2 bolts.

    Torque:
    13 N*m{ 133 kgf*cm , 10 ft.*lbf }

    NOTICE:
    1. Make sure that the inner-rubbers of the injection pipe fit inside the clamps.
    2. When installing the pipe, check that the inner-rubbers and the clamps are in their proper positions.



    A098973E01

  1. Using SST, tighten the injection pipe union nuts on the common rail side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

    HINT:
    Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).

  1. Using SST, tighten the injection pipe union nuts on the injector side.

    SST
    09023-12701  

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for use with SST
    35 N*m{ 357 kgf*cm , 26 ft.*lbf } for use without SST

    HINT:
    Use a torque wrench with a fulcrum length of 30 cm (11.81 in.).



17. CONNECT WIRE HARNESS


18. INSTALL MANIFOLD STAY


A099932E01

  1. Install the stay with the 2 bolts.

    Torque:
    19 N*m{ 194 kgf*cm , 14 ft.*lbf }

    HINT:
    The stay's indented area (labeled A) must face the manifold.



19. INSTALL EXHAUST MANIFOLD


A098946E01

  1. Install a new gasket, manifold, 4 new collars and 8 spacers to the cylinder head with 8 new nuts.

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

    NOTICE:
    1. Make sure that the side of the collar with the smaller diameter faces the exhaust manifold.
    2. Install the collars to the positions labeled A.



20. INSTALL NO. 1 COMPRESSOR MOUNTING BRACKET

  1. Install the bracket with the 4 bolts.

    Torque:
    47 N*m{ 479 kgf*cm , 35 ft.*lbf }



21. INSTALL COOLER COMPRESSOR ASSEMBLY

  1. Install the compressor with the 4 bolts.

    Torque:
    50 N*m{ 510 kgf*cm , 37 ft.*lbf }



22. INSTALL FAN PULLEY

  1. Install the fan pulley.



23. INSTALL FAN SHROUD

  1. Install the fan pulley to the water pump.

  1. Install the shroud together with the coupling fan between the radiator and engine component.

    NOTICE:
    Be careful not to damage the radiator core.

  1. Install the fluid coupling fan to the fan pulley with the 4 nuts.
    Tighten the nuts as much as possible by hand.



    A110385

  1. Attach the shroud's claws to the radiator.

  1. Install the shroud with the 2 bolts.

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

  1. Install the drive belt (Click here).

  1. Tighten the 4 nuts of the fluid coupling fan.

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



    A110386

  1. Install the radiator reservoir with the 2 bolts.

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

  1. Connect the No. 1 and No. 2 water by-pass hoses to the tank upper and lower.



    A110387

  1. Install the oil reservoir with the 3 bolts.

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



24. INSTALL VENTILATION PIPE


25. INSTALL AIR CLEANER ASSEMBLY

  1. Install the cleaner with the 2 bolts.

    Torque:
    14 N*m{ 143 kgf*cm , 10 ft.*lbf }

  1. Connect the connector to the MAF meter.

  1. Connect the hose clamp.



26. INSTALL CHARGE AIR COOLER ASSEMBLY WITH INTAKE AIR CONNECTOR


    A112150

  1. Install a new gasket and the intake air connector with the 4 bolts.

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



    A112149

  1. Using a 22 mm deep socket wrench, install a new gasket and the IAT sensor.

    Torque:
    29.4 N*m{ 300 kgf*cm , 22 ft.*lbf }



    A110367E01

  1. Install the CAC with the 4 bolts.

    Torque:
    32 N*m{ 326 kgf*cm , 24 ft.*lbf } for bolt A

    Torque:
    12 N*m{ 122 kgf*cm , 9 ft.*lbf } for bolt B

  1. Tighten the 4 hose clamps of the No. 1 and No. 2 air hose.

    Torque:
    6.5 N*m{ 66 kgf*cm , 58 in.*lbf }

  1. Connect the diesel turbo IAT sensor connector.



27. INSTALL NO. 1 ENGINE COVER SUB-ASSEMBLY


    A110362

  1. Install the cover with the 3 bolts and 2 nuts.

    Torque:
    7.0 N*m{ 71 kgf*cm , 62 in.*lbf }



28. INSTALL FRONT EXHAUST PIPE ASSEMBLY


    A111834

  1. Using a vernier caliper, measure the free length of the compression spring.

    Minimum length:
    40 mm (1.57 in.)
    If the free length is less than the minimum, replace the compression spring.

  1. Install the front pipe to the pipe support.



    A111803E01

  1. Install a new gasket to the outlet pipe.

    NOTICE:
    1. Be careful with the installation direction of the gasket.
    1. Do not reuse the gasket.
    1. To ensure a proper seal, do not use the front pipe to force the gasket onto the outlet pipe.

    HINT:
    1. Using a plastic-faced hammer, uniformly strike the gasket so that the gasket and outlet pipe are properly fit.

  1. Install the front pipe with the 2 compression springs and 2 bolts. Alternately tighten the bolts in several passes.

    Torque:
    43 N*m{ 438 kgf*cm , 32 ft.*lbf }

    CAUTION:
    Do not reuse the gasket.



29. ADD FUEL


30. TIGHTEN FUEL TANK CAP ASSEMBLY


31. ADD ENGINE OIL

  1. Wipe the oil pan and drain plug before installing the plug.

  1. Install a new gasket and the drain plug.

    Torque:
    34 N*m{ 347 kgf*cm , 25 ft.*lbf }

  1. Add new oil.

    Oil capacity:

    Item
    		Capacity
    Drain and refill with oil filter change
    		6.9 liters (7.3 US qts, 6.1 Imp. qts)
    Drain and refill without oil filter change
    		6.6 liters (7.0 US qts, 5.8 Imp. qts)
    Dry fill
    		7.4 liters (7.8 US qts, 6.5 Imp. qts)

  1. Install the oil filler cap.



32. BLEED AIR FROM FUEL SYSTEM


A098962E01

  1. Using the hand pump, bleed air from the fuel system until pumping becomes difficult.



33. CONNECT CABLE TO NEGATIVE BATTERY TERMINAL


34. PERFORM INITIALIZATION

  1. Perform initialization (Click here).

    NOTICE:
    Certain systems need to be initialized after disconnecting and reconnecting the cable from the negative (-) battery terminal.



35. CHECK FOR ENGINE OIL LEAKS


36. CHECK FOR FUEL LEAKS


37. CHECK OIL LEVEL