10198242

1.

After assembling the timing chain "A" (A) with the timing marks (D) of the high pressure pump sprocket (B) and the crankshaft sprocket (C) aligned, install the sprockets on each shaft. Tighten the high pressure pump nut.

Tightening torque :

78.5 ~ 93.2N.m (8.0 ~ 9.5kgf.m, 57.9 ~ 68.7lb-ft)

note

Set the timing mark (A) of the crankshaft sprocket to be aligned with the cylinder block. As a result of this, the piston of the No.1 cylinder will be at the top dead center on compression stroke.

note

Use the SST (ring gear stopper, 09231-2B100) to tighten the high pressure pump sprocket nut.

2.

Install the timing chain "B" lever (A), the timing chain "A" lever (B) and the timing chain “A” guide (C).

Tightening torque :

Bolt(D): 29.4 ~ 31.4N.m (3.0 ~ 3.2kgf.m, 21.7 ~ 23.1lb-ft)

Bolts(E): 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

note

Do not reuse the tensioner lever and guide fixing bolt. If necessary, the bolt can be reused after removing hardening sealant and then appling sealant (LOCTITE 262, THREEBOND 1324N or equvalent) on the thread of the bolt.

3.

Install the timing chain "A" auto tensioner (A), and then remove the set pin (B).

Tightening torque :

9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

4.

Check that the timing mark (A) of the exhaust camshaft timing gear and the timing mark (B) of the intake camshaft timing gear are aligned as shown in the illustration.

5.

After assembling the timing chain "B" (A) with the timing marks (D) of the high pressure pump sprocket (C) and the camshaft sprocket (B) aligned, install the cam shaft sprocket on the exhaust cam shaft gear.

Tightening torque :

14.7 ~ 19.6N.m (1.5 ~ 2.0kgf.m, 10.8 ~ 14.5lb-ft)

6.

Install the timing chain "B" auto tensioner (A) and guide (B), and then remove the set pin (C).

Tightening torque :

9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

7.

Apply liquid gasket evenly on the mating surface of timing chain cover.

note

●

Standard liquid gasket : LOCTITE 5900H or equivalent

●

Check that the mating surfaces are clean and dry before applying liquid gasket.

●

Install the timing chain cover in 5 minutes after applying the liquid gasket.

●

Apply liquid gasket in a 3mm wide bead without stopping.

●

Remove hardened sealant located on the front between the bock and head.

●

Apply liquid gasket in a 4mm wide bead by a “z” shape on the T-joint.

●

Apply liquid gasket on the front between the bock and head.

8.

Install the timing chain cover (A).

Tightening torque :

Bolt (B) : 19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lb-ft)

Bolt (C, D) : 7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

note

Check the unevenness between the timing chain cover and cylinder head.

Unevenness : 0.20mm(0.0079in) or less

9.

Install the engine support bracket (A) and the drive belt idler (B).

Tightening torque :

42.2 ~ 53.9N.m (4.3 ~ 5.5kgf.m, 31.1 ~ 39.8lb-ft)

10.

Install the front oil seal by using SST (09231-1M100, 09231-H1100)(A).

11.

Install the crankshaft damper pulley (A).

Tightening torque :

196.1N.m (20.0kgf.m, 144.7lb-ft) + 60°

note

Use the SST (ring gear stopper, 09231-2B100) to tighten crank shaft damper pulley bolt.

12.

Install the fead system bracket assembly (A).

Tightening torque :

Bolts (B, C, D) : 19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft)

Bolts (E) : 42.2 ~ 53.9N.m (4.3 ~ 5.5kgf.m, 31.1 ~ 39.8lb-ft)

13.

Install the alternator (A).

Tightening torque :

49.0 ~ 63.7N.m (5.0 ~ 6.5kgf.m, 36.2 ~ 47.0lb-ft)

14.

Install the engine mounting bracket (A).

Tightening torque :

Bolts(B), Nut(C) : 63.7 ~ 83.4N.m (6.5 ~ 8.5kgf.m, 47.0 ~ 61.5lb-ft)

Nut(D) : 78.5 ~ 107.9N.m (8.0 ~ 11.0kgf.m, 57.9 ~ 79.6lb-ft)

15.

Remove the jack from the bottom of the cylinder block.

16.

Apply liquid gasket evenly to the mating surface of the upper oil pan.

note

●

Standard liquid gasket : LOCTITE 5900H or equivalent

●

Check that the mating surfaces are clean and dry before applying liquid gasket.

●

Apply liquid gasket in a 4mm (5mm or above for T-joint and 3.5mm for rear oil seal) wide bead without stopping.

●

Install the oil pan in 5 minutes after applying the liquid gasket.

●

After installing the oil pan, wait at least 30 minutes before filling the engine with oil.

●

Remove liquid gasket overreached from the rear oil seal area after installing.

●

Remove liquid gasket overreached from the contact surface between the cylinder bock and timing chain cover before installing the upper oil pan.

caution

Be careful not to apply an excessive amount of liquid gasket or by a wrong path. If the liquid gasket flows into the holes for installing the rear oil seal case assembly, it may cause the boss crack or contamination.

17.

Install the upper oil pan (A).

(1)

Tighten the bolts in the sequence shown.

Tightening torque :

9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

(2)

Tighten the bolts (A) for transaxle case.

Tightening torque :

39.2 ~ 46.1N.m (4.0 ~ 4.7kgf.m, 28.9 ~ 34.0lb-ft)

18.

Apply liquid gasket evenly to the mating surface of the lower oil pan.

note

●

Standard liquid gasket : LOCTITE 5900H or equivalent

●

Check that the mating surfaces are clean and dry before applying liquid gasket.

●

Apply liquid gasket in a 4mm wide bead without stopping.

●

Install the oil pan in 5 minutes after applying the liquid gasket.

●

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 sequence shown.

Tightening torque :

9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

20.

Install the air compressor (A). (Refer to HA group)

21.

Install the oil filter&cooler assembly (A).

Tightening torque :

19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft)

caution

When installing the oil filter&cooler assembly, check the existence of two O-rings on the mating surface to the cylinder block, and tighten the 4 upper bolts first then tighten the other lower bolt.

22.

Install the cylinder head cover (A) with new head cover gaskets (B, C).

Install the cylinder head cover bolts as following method.

Tightening torque :

Step 1 : 3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)

Step 2 : 8.8 ~ 10.8N.m (0.9 ~ 1.1kgf.m, 6.5 ~ 8.0lb-ft)

note

●

Standard liquid gasket : LOCTITE 5900H or equivalent

●

Check that the mating surfaces are clean and dry before applying liquid gasket.

●

Install the cylinder head cover in 5 minutes after applying the liquid gasket.

●

After installing, wait at least 30 minutes before filling the engine with oil.

●

Remove the harmful material (engine oil, cutting oil and etc) located in the upper area of the cylinder head and the timing chain cover before installing the cylinder head cover.

●

Remove hardened sealant located in the upper area between the cylinder head and the timing chain cover.

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Before installing the cylinder head cover, check that the protrusion of the head cover gasket is assembled exactly into the slot of the head cover.

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Before installing the cylinder head cover, apply liquid gasket to the T-joints on the upper area between the cylinder head and the timing chain cover and the rear area of the cam carrier.

23.

Install the power steering pump (B) and connect the power steering oil hoses (A). (Refer to ST group)

24.

Connect the brake vacuum hose (A).

25.

Connect the breather hose (A)

26.

Connect the engine ground line (A)

27.

Install the injectors and connect the high pressure pipes (B), the fuel return hose (C), EGR vacuum hose (D) [Euro - 4/5 only] and then the injector connectors (A). (Refer to FL group)

[2.2L]