Clean the cylinder head and the cylinder block surfaces contacting with their gaskets.

Select the cylinder head gasket.

(1)

Measure the piston protrusion from the upper cylinder block face on the twelve places (A ~ F for each bank) at TDC (top dead center).

(2)

Select the gasket in the table below using the average value of the six piston protrusions. If an average value of a piston is over than the each rank limit, use one rank thicker gasket than the specified one in the table below.

Grade(A)		A	B	C
Average of piston protrusion		0.310 ~ 0.410mm	0.410 ~ 0.510mm	0.510 ~ 0.610mm
Limit of each rank extant		0.460mm	0.560mm	-
Gasket thickness(compressed)		1.1 ± 0.04mm	1.2 ± 0.04mm	1.3 ± 0.04mm
Part No.	Left bank	22311 - 3A010	22311 - 3A000	22311 - 3A020
	Right bank	22312 - 3A010	22312 - 3A000	22312 - 3A020

Install the cylinder head gasket (A) on the cylinder block.

Place the cylinder head quietly in order not to damage the gasket with the bottom part of the end.

ce the cylinder head quietly in order not to damage the gasket with the bottom part of the end.

(1)

Tighten the eight cylinder head bolts on each bank, in several passes, in the sequence shown.

Tightening torque

1st step : 56.9 ~ 60.8 N.m (5.8 ~ 6.2 kgf.m, 42.0 ~ 44.8 lbf-ft)

2nd step : 88 ~ 92˚

3rd step : 118 ~ 122˚

note

Do not reuse the cylinder head bolts.

Install the timing chain case bracket (A). Tighten the vertical-direction bolts slightly first and then the horizontal-direction ones and the vertical-direction ones with the specified torque below.

Use the SST (09367-3C100), install the glow plugs (A).

Install the water pipe and hose assembly (A).

Install the camshafts and measure the end play.

After measuring the end play, remove the camshafts.

After applying oil, install the HLA (hydraulic lash adjuster) (A) and the cam follower assembly (B).

(2)

HLA should be inserted carefully to the cylinder head not to spill engine oil.

If engine oil has spilled out of the lash adjuster, HLA bleeding should be performed according to the below procedure.

HLA bleeding procedure

Stroke the lash adjuster in engine oil by pushing its cap 4 to 5 times while pushing the ball down slightly using a hard steel wire. Be careful not to give the ball a hard push because the ball weighs just several grams.

If installing with engine oil spilling out of the lash adjuster and air in it, it might make an abnormal noise.

Wipe out oil on the upper surface of the cylinder head.

Install the camshafts.

Pressing the exhaust camshafts, take out the pin from their sprockets.

Put the ladder gaskets (A) on the camshaft bearing ladder.

Install the sealing caps (A) with applying sealant on the grooves (4 places) at the circumference.

Install the camshaft bearing ladder (A) with the sequence and the torque below.

Apply oil on the camshafts sufficiently.

Install the cylinder head cover (A) with the sequence and the torque below.

Install the water outlet duct (A).

Install the EGR pipe & hose assembly (A).

Install the water outlet pipe (A).

Install the glow plug wiring.

Install the injectors, high pressure pipe and delivery pipe. (Refer to FL group)

Install the intake manifold and exhaust manifold. (Refer to Intake and exhaust system in this group)

Install the timing chain. (Refer to Timing system in this group)