Note: Tightening torque: 78.5-93.2 Nm.
Note: The alignment mark must be aligned (A) crankshaft sprockets with cylinder block. In this case, the piston of cylinder No. 1 will be set to the position of the top dead center of the compression stroke.
Note: Tighten the high pressure fuel pump sprocket nut, securing the ring gear with a special stopper (09231-2B100) (A).
2. Install the lever (A) chains «IN» timing gear drive, lever (IN) chains «A» timing gear drive and guide (WITH) chains «A» timing gear drive.
Note: Tightening torque:
- Bolt (D): 29.4-31.4 Nm.
- bolts (E): 9.8-11.8 Nm.
Do not reuse the tensioner arm and guide bolt. If necessary, the bolt can be reused after removing the solid sealant and applying sealant to the threaded part of the bolt (LOCTITE 262, THREEBOND 1324N or equivalent).
3. Install the auto tensioner (A) chains «A» timing gear drive and remove the dowel pin (IN).
Note: Tightening torque: 9.8-11.8 Nm.
4. Make sure the installation mark (A) exhaust camshaft gears and alignment mark (IN) the intake camshaft gears are aligned as shown.
5. After installing the chain (A) «IN» timing gear drive and matching alignment marks (D) asterisks (WITH) high pressure pump and sprocket (IN) camshaft, install the camshaft sprocket onto the exhaust camshaft gear.
Note: Tightening torque: 14.7-19.6 Nm.
6. Install auto tensioner (A) chains «IN» timing gear drive and guide (IN), then remove the dowel pin (IN).
Note: Tightening torque: 9.8-11.8 Nm.
7. Apply sealant to the mating surfaces of the timing chain cover.
Note:
- Standard sealant: LOCTITE 5900H or equivalent.
- Ensure mating surfaces are clean and dry before applying sealant.
- After applying the sealant, wait five minutes and install the timing chain cover.
- Apply the sealant in a 3 mm wide bead without stopping.
- Remove the hard sealant at the front between the block and the head.
- Apply a 4 mm thick bead of sealant in the shape of a letter «G» on a T-connection.
Apply sealant to the front between the block and head.
8. Install the cover (A) timing chain drive.
Note:
Torque:
- bolts (IN): 19.6 - 24.5 Nm.
- bolts (C, D): 7.8 - 11.8 Nm.
Note:
- Check for surface unevenness between timing chain and cylinder head.
- Roughness: 0.20mm or less.
9. Install the support bracket (A) engine and intermediate roller (IN) drive belt.
Note: Tightening torque: 42.2 - 53.9 Nm.
10. Install the front oil seal using the special tool (09231-1M100, 09231-H1100) (A).
11. Install pulley (A) crankshaft vibration damper.
Note: Tightening torque: 196.1 Nm + tighten 60°.
Tighten the bolt of the crankshaft vibration damper, fixing the ring gear with a special stopper (09231-2B100) (A).
12. Install bracket (A) complete attachment drive systems.
Note: Tightening torque:
- bolts (B, C, D): 19.6 - 26.5 Nm.
- bolts (E): 42.2.0-53.9 Nm.
MDPS type
HPS type
13. Install the generator (A).
Note: Tightening torque: 49.0 - 63.7 Nm.
14. Install bracket (A) engine mounts.
Note: Tightening torque: Bolts (IN), nuts (WITH): 63.7-83.4 Nm.
15. Remove the jack from under the cylinder block.
16. Apply sealant evenly to mating surfaces of upper oil pan.
Note:
- Standard sealant: LOCTITE 5900H or equivalent.
- Ensure mating surfaces are clean and dry before applying sealant.
- Apply a bead of sealant 4 mm thick (5 mm or more for T-connection; 3.5mm for rear oil seal), do not stop.
- After applying the sealant, wait five minutes and install the oil pan.
- After installing the oil pan, wait at least 30 minutes before filling the engine with oil.
- After installation, remove excess sealant in the area of the rear oil seal.
- Before installing the upper oil pan, remove excess sealant squeezed out from the contact surface between the cylinder block and the timing chain cover.
Attention. Try not to apply too much sealant or apply sealant in the wrong direction. If sealant enters the rear oil seal housing assembly holes, it may cause contamination or cracking.
17. Install the upper oil pan (A).
(1) Tighten the bolts in the order shown.
Note: Tightening torque: 9.8-11.8 Nm.
(2) Tighten the bolts (A) gearbox housing.
Note: Tightening torque: 39.2-46.1 Nm
18. Apply sealant evenly to mating surfaces of lower oil pan.
Note:
- Standard sealant: LOCTITE 5900H or equivalent.
- Ensure mating surfaces are clean and dry before applying sealant.
- Apply sealant in a continuous bead 4 mm thick.
- After applying the sealant, wait five minutes and install the oil pan.
- After installing the oil pan, wait at least 30 minutes before filling the engine with oil.
19. Install the lower oil pan. Tighten the bolts in the order shown.
Note: Tightening torque: 9.8 - 11.8 Nm.
20. Install an air compressor (A).
21. Install oil filter and oil cooler assembly (A).
Note: Tightening torque: 19.6-26.5 Nm.
Attention. When installing the oil filter and oil cooler assembly, check for O-rings on the mating surface with the cylinder block. Tighten the top 4 bolts first, then tighten the remaining bottom bolt.
22. Install the cover (A) cylinder heads using new gaskets (B, C).
Tighten the cylinder head cover bolts as follows.
Torque:
- 1 step: 3.9-5.9 Nm.
- 2nd step: 8.8-10.8 Nm.
Note:
- Standard sealant: LOCTITE 5900H or equivalent.
- Ensure mating surfaces are clean and dry before applying sealant.
- After applying the sealant, wait five minutes and install the cylinder head cover.
- After installation, wait at least 30 minutes before filling the engine with oil.
- Remove harmful material before installing cylinder head (engine oil, coolant) at the top of the cylinder head and timing chain cover.
- Remove the hard sealant at the top between the cylinder head and the timing chain cover.
- Before installing the cylinder head cover, make sure that the protrusion of the head cover gasket is installed exactly in the hole in the head cover.
- Before installing the cylinder head cover, apply sealant to the T-connections at the top between the cylinder head and the timing chain and at the rear of the camshaft holder.
23. Install the pump (IN) power steering and connect the oil hoses (A) hydraulic booster. (HPS only).
24. Connect the vacuum hose (A).
25. Connect the hose (A) breather.
26. Connect the wire (A) «masses» engine.
27. Install nozzles and connect pipes (IN) high pressure fuel return hose (WITH) and vacuum hose (D) exhaust gas recirculation systems (EGR), then connect the connectors (A) nozzles.
Standard power
Reduced power
Note: Do not reuse the high pressure fuel line and injector gaskets.
28. Connect the engine harness connectors.
(1) Plug connector (A) differential pressure sensor. (With particulate filter).
(2) Plug connector (IN) exhaust gas temperature sensor. (With particulate filter).
(3) Plug connector (WITH) oxygen sensor.
(4) Plug connector (D) camshaft position sensor (CMPS).
(5) Plug connector (A) generator and wire (IN).
(6) Plug connector (WITH) starter and wire (D).
(7) Plug connector (E) air compressor switch.
29. Install drive belt (A).
30. Install the side cover (A).
31. Install the cover (A) engine.
32. Connect the negative (A) wire to the battery.
Note: Tightening torque: 4.0-6.0 Nm.