3.
Remove the cylinder head cover(A).
Engine removal is not required for this procedure.
Remove the drive belt.
Remove the injector.(Refer to Injector in FL Group).
Remove the cylinder head cover(A).
Remove the engine mounting support bracket.
Set the jack to the engine oil pan
Remove the engine mounting support bracket(A).
Remove the alternator(A).
Remove the water pump pulley(A).
Remove the engine support bracket(A).
Remove the drive belt auto tensioner(A).
Turn the crankshaft pulley, and align its groove with timing mark "T" of the timing chain cover. (No.1 cylinder compression TDC position)
Remove the crankshaft pulley bolt(B) and crankshaft pulley(A).
Use the SST(flywheel stopper, 09231-2A100)(A) to remove the crankshaft pulley bolt, after remove the starter.
Remove the high pressure pump sprocket nut(B) after remove the timing chain cover plug(A).
Use the SST(flywheel stopper, 09231-2A100) to remove the high pressure pump sprocket nut.
Replace O-ring of plug(A) with a new one when reinstalling the plug.
Remove the fuel return hose(A) and the high pressure pipe(B).
Remove the mounting bolts of the high pressure pump(A) and the fuel hoses(B, C).
Install the SST(high pressure pump sprocket stopper, 09331-2A000)(A) to sprocket rotating it clockwise.
Remove the timing chain cover bolt(three bolts)(B).
Install the SST(high pressure pump sprocket remover, 09331-2A000)(A) to timing chain cover with three long bolts(B).
Fix the high pressure pump remover(A) and sprocket stopper(C) with two fixing bolts(D).
Rotate the bolt(E) clockwise till high pressure pump is pushed out.
Remove the SST(09331-2A000) after remove the high pressure pump.
Install the SST(09200-38001, 09200-1C000), the engine support fixture and the adapter, on the enine hanger bracket.
Remove the intercooler pipe(A).
Remove the air conditioning compressor.
Remove the jack from oil pan.
Remove the oil pan(A).
When removing the 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 the ladder frame 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 the ladder frame.
Do not turn over the SST abruptly without tapping. It be result in damage of the SST.
Remove the oil strainer(B).
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 "C" auto tensioner(A).
Before removing auto-tensioner, install a set pin(B) (2.5 mm steel wire) after compressing the tensioner.
Remove the timing chain "C" lever(A) and the timing chain guide "1"(B).
Remove the timing chain guide "2"(A).
Remove the timing chain "C"(A).
Remove the timing chain "A" auto tensioner(A).
Before removing auto-tensioner, install a set pin(B) (2.5 mm steel wire) after compressing the tensioner.
Remove timing chain "A" lever(A) and the timing chain guide "1"(B).
Remove the timing chain "A"(A)with high pressure pump sprocket(B) and crankshaft sprocket(C).
Remove the water pump(A).
Remove the timing chain case(A).
(Engine removal is required for this procedure)
Remove the camshaft sprocket.
Hold the portion(A) of the camshaft with a hexagonal wrench, and remove the bolt(C) with a wrench(B) and remove the camshaft sprocket.
Be careful not to damage the cylinder head and valve lifter with the wrench.
Engine removal is not required for this procedure.
Install the camshaft sprocket and tighten the bolt to the specified torque.
Temporarily install the camshaft sprocket bolt(C).
Hold the portion(A) of the camshaft with a hexagonal wrench, and tighten the bolt(C) with a wrench(B).
Tightening torque :
68.6 ~ 73.5N.m (7.0 ~ 7.5kgf.m, 50.6 ~ 54.2lb-ft)
Install the timing chain case(A) with new gasket.
(Engine removal is required for this procedure)
Tightening torque :
Bolt(B) : 24.5 ~ 30.4N.m (2.5 ~ 3.1kgf.m, 18.1 ~ 22.4lb-ft
Bolt(C) :18.6 ~ 27.5N.m (1.9 ~ 2.8kgf.m, 13.7 ~ 20.3lb-ft)
Bolt(D) : 7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
Bolt(E) : 25.5 ~ 34.3N.m (2.6 ~ 3.5kgf.m, 18.8 ~ 25.3lb-ft
Install the water pump(A).
Tightening torque :
19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lb-ft)
Install the high pressure pump(A), connecting the hoses(B, C).
Tightening torque :
14.7 ~ 19.6N.m (1.5 ~ 2.0kgf.m, 10.8 ~ 14.5lb-ft)
Install the fuel return hose(A) and the high pressure pipe(B).
Tightening torque :
24.5 ~ 28.4N.m (2.5 ~ 2.9kgf.m, 18.1 ~ 21.0lb-ft)
6.9 ~ 10.8N.m (0.7 ~ 1.1kgf.m, 5.1 ~ 8.0lb-ft)-Bolt
Do not reuse the high pressure pipe.
Set the key of crankshaft sprocket to be aligned with the timing mark of timing chain case. As a result of this, place the piston on No.1 cylinder at the top dead center on compression stroke.
After install timing chain "A" with high pressure pump sprocket(B) equipped at the crankshaft sprocket(C), and then install high pressure pump sprocket at the high pressure pump shaft.
The timing mark of high pressure pump sprocket should be aligned with timing mark on the timing chain case.
Pretighten the high pressure pump sprocket nut.
Install timing chain "A" lever(A) and the timing chain guide "1"(B).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Install the timing chain "A" auto tensioner(A) and then remove set pin(B).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Align the timing mark(A) of camshaft sprocket on the vertical center line of crankshaft.
Install the timing chain "C"(A) as following procedure. High pressure pump sprocket → LH camshaft sprocket → RH camshaft sprocket
The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at installing timing chain as shown below illustration.
Install the timing chain guide "2"(A).
Tightening torque :
9.8 ~ 13.7N.m (1.0 ~ 1.4kgf.m, 7.2 ~ 10.1lb-ft)
Install the timing chain "C" lever(A) and the timing chain guide "1"(B).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Install the timing chain "C" auto tensioner(A) and then remove set pin(B).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Install the high pressure pump sprocket nut(A).
Tightening torque :
64.7 ~ 74.5N.m (6.6 ~ 7.6kgf.m, 47.7 ~ 55.0lb-ft)
Use the SST(flywheel stopper, 09231-2A100)(A) to tighten the high pressure pump sprocket nut, after remove the starter.
Apply liquid gasket evenly to the mating surface of timing chain cover.
Standard liquid gasket : LOCTITE 5900
Check that the mating surfaces are clean and dry before applying liquid gasket.
Assemble the timing chain cover in 5 minutes after applying the liquid gasket.
Apply liquid gasket in a 3mm wide bead without stopping.
Install the timing chain cover(A).
Tightening torque :
Bolt (B,C,F) :
19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft)
Bolt(D,E) : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Install the front oil seal by using SST(09231-2A000, 09231-H1100)(A).
Install the oil strainer(B).
Tightening torque :
Bolts : 19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft)
Nuts : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Apply liquid gasket evenly to the mating surface of oil pan.
Standard liquid gasket : LOCTITE 5900
Check that the mating surfaces are clean and dry before applying liquid gasket.
Apply liquid gasket in a 3mm wide bead without stopping.Assemble the oil pan in 5 minutes after applying the liquid gasket.
After assembly, wait at least 30 minutes before filling the engine with oil.
Apply liquid gasket to T-joint before assembling oil pan.
Install the oil pan(A).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Set the jack to the engine oil pan
Remove the SST(09200-38001, 09200-1C000), the engine support fixture and the adapter, from the engine hanger bracket.
Install the crankshaft pulley(A) and crankshaft pulley bolt(B).
Tightening torque :
225.6 ~ 245.2N.m (23.0 ~ 25.0kgf.m, 166.4 ~ 180.8lb-ft)
Use the SST(flywheel stopper, 09231-2A100) to Install the crankshaft pulley bolt, after remove the starter.
Install the drive belt auto tensioner(A).
Tightening torque :
25.5 ~ 30.4N.m (2.6 ~ 3.1kgf.m, 18.8 ~ 22.4lb-ft)
Install the engine support bracket(A).
Tightening torque :
42.2 ~ 53.9N.m (4.3 ~ 5.5kgf.m, 31.1 ~ 39.8lb-ft)
Install the water pump pulley(A).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Install the alternator(A).
Tightening torque :
38.2 ~ 58.8N.m (3.9 ~ 6.0kgf.m, 28.2 ~ 43.4lb-ft)
Install the engine mounting support bracket(A).
Tightening torque :
Nut(D) : 63.7 ~ 83.4N.m(6.5 ~ 8.5kgf.m, 47.0~ 61.5lb-ft)
Bolt(B), Nut(C) : 49.0 ~ 63.7N.m(5.0 ~ 6.5kgf.m, 36.2 ~ 47.0lb-ft)
Remove the jack from oil pan
Install the cylinder head cover(A) with new head cover gasket.
Tightening torque :
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
Standard liquid gasket : LOCTITE 5900
Check that the mating surfaces are clean and dry before applying liquid gasket.
Apply liquid gasket in a 3mm wide bead without stopping.
Assemble the cylinder head cover in 5 minutes after applying the liquid gasket.
After assembly, wait at least 30 minutes before filling the engine with oil.
Apply liquid gasket to T-joint before assembling cylinder head cover.
Install the injectors. (Refer to Injector in FL Group)
Install the drive belt.
