1.
Disconnect the negative terminal (A) from the battery.
Engine removal is not required for this procedure.
Use fender covers to avoid damaging painted surfaces.
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
Mark all wiring and hoses to avoid misconnection.
Turn the crankshaft pulley, and align its groove with the timing mark of the timing chain cover.
(No.1 cylinder TDC/compression position)
Disconnect the negative terminal (A) from the battery.
Remove the engine cover (A).
Remove the side cover (A).
Using the hexagon wrench, turn the tensioner counterclockwise and loosen. Then remove the drive belt.
Disconnect the engine wire harness connectors and remove the wire harness clamps from the cylinder head cover.
Disconnect the difference pressure sensor connector (A). (With DPF) [Euro - 5 only]
Disconnect the exhaust gas temperature sensor connector (B). (With DPF) [Euro - 5 only]
Disconnect the lambda sensor connector (C). [Euro - 4/5 only]
Disconnect the cam position sensor (CMPS) connector (D).
Disconnect the alternator connector (A) and the cable (B).
Disconnect the starter connector (C) and the cable (D).
Disconnect the air compressor switch connector (E).
Disconnect the injector connectors (A) and remove the injectors, the high pressure pipes (B), the fuel return hose (C) and EGR vacuum hose (D) [Euro - 4/5 only]. (Refer to FL group)
Disconnect the engine ground line (A)
Disconnect the breather hose (A)
Disconnect the brake vacuum hose (A).
Disconnect the power steering oil hoses (A) and remove the power steering pump (B). (Refer to ST group)
Remove the cylinder head cover (A).
Drain the engine oil, and then remove the oil filter&cooler assembly (A).
Drain the engine oil in the oil filter before removing the assembly. (Refer to Lubrication system in this group)
Remove the air compressor (A). (Refer to HA group)
Remove the lower oil pan (A).
Remove the upper oil pan (A).
When removing the upper or lower oil pan, use the SST (09215-3C000) in order not to damage the surface between the cylinder block and the oil pan.
Insert the SST between the oil pan and cylinder block (or upper oil pan) by tapping it with a plastic hammer in the direction of ① arrow.
After tapping the SST with a plastic hammer along the direction of ② arrow around more than 2/3 edge of the oil pan, remove it from cylinder block (or upper oil pan).
Do not turn over the SST abruptly without tapping. It may be result in damage of the SST.
Remove the engine mounting bracket.
Set the jack to the bottom of the cylinder block.
Be careful not to damage the balance shaft & oil pump module.
Remove the engine mounting bracket (A).
Remove the alternator (A).
Remove the fead system bracket assembly (A).
Remove the engine support bracket (A) and the drive belt idler (B).
Set the No.1 cylinder to TDC/compression position.
Turn the crankshaft pulley and align its groove with the timing mark of the timing chain cover.
Do not rotate engine counterclockwise.
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.
If not, turn the crankshaft one revolution (360°). (Do not rotate engine counterclockwise.)
Remove the crankshaft damper pulley (A).
Do not press the pulley or apply the excessive force to prevent the rubber part from being deformed.
Use the SST (ring gear stopper, 09231-2B100) to remove the crankshaft pulley bolt, after remove the starter.
Remove the timing chain cover (A)
Remove thoroughly sealant and oil etc left at the sealing surface after remove the chain cover and oil pan. (If any impurities are left at the sealing face, oil may leak after reassembly even with the sealant application.)
Remove the timing chain "B" auto tensioner (A) and guide (B).
Before removing the auto tensioner, install a set pin (C) (ø2.5 mm steel wire) after compressing the tensioner.
Remove the timing chain "B" (A) with the camshaft sprocket (B).
Remove the timing chain "A" auto tensioner (A).
Before removing the auto tensioner, install a set pin (B) (ø2.5 mm steel wire) after compressing the tensioner.
Remove the timing chain "B" lever (A), the timing chain "A" lever (B) and the timing chain “A” guide (C).
After removing the high pressure pump sprocket nut, install the sprocket stopper (A) of the SST (high pressure pump remover, 09331-1M100).
Rotate the bolt (B) of the SST clockwise till the high pressure pump sprocket is pushed out.
Remove the timing chain "A" (A) with the high pressure pump sprocket (B) and crankshaft sprocket (C).
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)
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.
Use the SST (ring gear stopper, 09231-2B100) to tighten the high pressure pump sprocket nut.
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)
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.
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)
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.
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)
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)
Apply liquid gasket evenly on the mating surface of timing chain cover.
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.
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)
Check the unevenness between the timing chain cover and cylinder head.
Unevenness : 0.20mm(0.0079in) or less
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)
Install the front oil seal by using SST (09231-1M100, 09231-H1100)(A).
Install the crankshaft damper pulley (A).
Tightening torque :
196.1N.m (20.0kgf.m, 144.7lb-ft) + 60°
Use the SST (ring gear stopper, 09231-2B100) to tighten crank shaft damper pulley bolt.
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)
Install the alternator (A).
Tightening torque :
49.0 ~ 63.7N.m (5.0 ~ 6.5kgf.m, 36.2 ~ 47.0lb-ft)
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)
Remove the jack from the bottom of the cylinder block.
Apply liquid gasket evenly to the mating surface of the upper oil pan.
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.
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.
Install the upper oil pan (A).
Tighten the bolts in the sequence shown.
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Tighten the bolts (A) for transaxle case.
Tightening torque :
39.2 ~ 46.1N.m (4.0 ~ 4.7kgf.m, 28.9 ~ 34.0lb-ft)
Apply liquid gasket evenly to the mating surface of the lower oil pan.
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.
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)
Install the air compressor (A). (Refer to HA group)
Install the oil filter&cooler assembly (A).
Tightening torque :
19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft)
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.
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)
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.
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.
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.
Install the power steering pump (B) and connect the power steering oil hoses (A). (Refer to ST group)
Connect the brake vacuum hose (A).
Connect the breather hose (A)
Connect the engine ground line (A)
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)
Do not reuse the high pressure pipe and injector gasket.
Connect the engine wire harness connectors.
Connect the difference pressure sensor connector (A). (With DPF) [Euro - 5 only]
Connect the exhaust gas temperature sensor connector (B). (With DPF) [Euro - 5 only]
Connect the lambda sensor connector (C). [Euro - 4/5 only]
Connect the cam position sensor (CMPS) connector (D).
Connect the alternator connector (A) and the cable (B).
Connect the starter connector (C) and the cable (D).
Connect the air compressor switch connector (E).
Install the drive belt (A).
Install the side cover (A).
Install the engine cover (A).
Connect the negative terminal (A) to the battery.
