2. Install the sprocket (IN) drive chain from the crankshaft.
3. Install the chain oil jet (A).
Note: Tightening torque: 7.8-9.8 Nm.
4. Install the crankshaft so that the key is flush with the mating surface of the main bearing cap. Position the intake and exhaust camshafts so that the top dead center marks (TDC) on the sprockets were flush with the top surface of the cylinder head. As a result, the position of the piston of cylinder No. 1 will be at top dead center (TDC), compression stroke.
5. Install the timing chain guide (A).
Note: Tightening torque: 9.8-11.8 Nm.
6. Install the timing chain.
To fit the chain without slack between each shaft (distribution and crankshaft), follow the order shown: Crankshaft sprocket (A) -> Timing chain guide (IN) -> Intake camshaft sprocket (WITH) -> Exhaust camshaft sprocket (D). The marks on each sprocket must match the marks on the timing chain (colored) during chain installation.
7. Install the chain tensioner lever (IN).
Note: Tightening torque: 9.8-11.8 Nm.
8. Install the automatic chain tensioner (A) and remove the installed stud.
Note: Tightening torque: 9.8-11.8 Nm.
9. After turning the crankshaft 2 turns clockwise (front view), align marks (A), as it shown on the picture.
10. Install the timing chain cover.
Using a scraper, remove the old sealant from the gasket surface.
The places where sealant is applied to the chain cover, cylinder head, cylinder block and frame with cross members must not come into contact with oil, etc.
Before assembling the chain cover, liquid sealant Loctite 5900H or THREEBOND 1217H must be applied between the head and cylinder block.
Parts must be assembled within 5 minutes of sealant application.
Note: Strip width: 2.0 l: 2.5 mm. 2.4 l: 3 mm.
Install the timing chain cover.
Note: Tightening torque:
- 6x25: 7.8-9.8 Nm.
- 8x28: 18.6 - 22.5 Nm.
- 10x45: 39.2 - 44.1 Nm.
- 10x40: 39.2 - 44.1 Nm.
Baking and/or blowing off the timing chain cover must be carried out no later than 30 minutes after assembly.
11. Install the oil pan.
Using a scraper, remove the old sealant from the gasket surface.
Before installing the oil sump, Loctite 5900H or THREEBOND 1217H liquid sealant must be applied between the cylinder block and sump joint faces.
Attention.
- When applying sealant, do not allow sealant to get inside the oil pan.
- Apply sealant to the inside of the mounting bolt holes to prevent oil leakage.
Install the oil pan (A).
Screw the bolts into several holes.
Note: Tightening torque: M6 (WITH): 9.8- 11.8 Nm. M9 (IN): 30.4 - 34.3 Nm.
After assembly, wait at least 30 minutes before filling the engine with oil.
12. Establish a cover of a head of the block of cylinders.
Squeezed out excess sealant on the top surface of the chain cover and cylinder head must be removed before installing the cylinder head cover.
After applying the sealant (Loctite 5900H) assembly must be completed within 5 minutes.
Note: Strip width: 2.5 mm.
Firing and/or blasting of the cylinder head must be carried out no later than 30 minutes after assembly.
Screw in the cylinder head cover bolts as follows: step 1: tightening torque: 3.9-5.9 Nm, step 2: tightening torque: 7.8 - 9.8 Nm.
Attention. Do not reuse the cylinder head gasket.
13. Install breather hose (A).
14. Connect the hose (A) crankcase ventilation and connector (IN) oil control valve to the exhaust valves.
15. Install the ignition coils and connect the connectors to them (WITH).
16. Install the crankshaft pulley (IN).
Note:
- Tightening torque: 166.6 - 176.4 Nm.
- Use flywheel clamp 09231-2B100 to install the crankshaft pulley bolt.
17. Install the water pump pulley
Note. Tightening torque: 7.8-9.8 Nm
18.Install the drive belt tensioner (IN).
Note: Tightening torque: 53.9 -63.7 Nm.
Attention. Tensioner pulley bolt with left-hand thread.
19. Install pulley (A).
Note: Tightening torque: 53.9 - 63.7 Nm.
20. Install bracket (A) air conditioner compressor.
Note: Tightening torque: 19.6 - 23.5 Nm.
21. Screw in the bottom bolts of fastening of the compressor of the conditioner.
Note: Tightening torque: 20.0 - 32.9 Nm.
22. Install the power steering pump to the bracket.
23. Install the drive belt (A) in the following order:
Crankshaft pulley -> A/C compressor pulley -> alternator pulley -> idler pulley -> power steering pump pulley -> idler pulley -> water pump pulley -> tensioner pulley.
Rotate the auto tensioner arm counterclockwise while moving the tensioner bolt with a wrench.
MDPS
HPS
24. Install engine mount bracket (A) and connect the wire «masses».
Note: Tightening torque: 63.7 - 83.4 Nm.
25.Install the side cover.
Note: Tightening torque: 8.8 - 10.8 Nm.
26. Install the front right wheel.
Note: Tightening torque: 88.3 - 107.9 Nm.
27. Install the engine cover (IN).
28. Connect the negative wire (A) to the battery.
Note:
- Fill with engine oil.
- Before connecting wires, clean their clamps and terminals
- battery with sandpaper. Coat attached clamps with grease to prevent corrosion.
- Check for fuel leaks.
- After installing the fuel line, turn the ignition key to the ON position (do not turn on the starter), so that the fuel pump can operate for approximately 2 seconds and the fuel line is pressurized.
- Repeat this operation 2-3 times and check the entire fuel line for leaks.
- Fill the radiator and its reservoir with coolant.
- Remove air from the cooling system.
- Start the engine and warm it up (until the radiator fan turns on 3-4 times).
- Stop the engine and let it cool down. Check the coolant level and top up if necessary. This will remove air from the cooling system.
- Install the radiator cap securely, restart the engine and check for leaks.