1.
Remove the cooling fan (A) and pan clutch (B).
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.
Remove the cooling fan (A) and pan clutch (B).
Compressing the tensioner (A) with a wrench in a left hand by turning it clockwise, start removing the drive belt (B) from the water pump side idler.
Conform to what is described above because tension of the belt in this engine is higher than ones of other engines for preventing a slip.
Remove the drive belt tensioner (A).
Remove the oil separator & pipe (A), and glow control unit (B).
Remove the power steering pump (A) and bracket (B).
Remove the alternator bracket (A).
Remove the fan pulley assembly (A), water pump pulley (B) and Idler (C).
Remove the vacuum pump (A).
Do not disassemble the vacuum pump.
Remove the crankshaft pulley (A) with its washer (B) and mounting bolt (C).
Use the SST (09231-2J100) to fix the crankshaft when remove the crankshaft pulley bolt.
Remove the chain caps (C) and loosen the front chain cover mounting bolts(A-20EA, B-4EA).
Remove the front chain cover (A).
Remove the hydraulic tensioner (A).
Remove the timing chain with the chain guide and the tensioner lever.
Remove the high pressure fuel pump sprocket.
Remove the upper head seal.
Remove the water pump (A) with its gasket.
Remove the high pressure pump. (Refer to FL group)
Remove the camshaft and the cylinder head assembly.
Remove the chain case mounting bolts.
Remove the chain case assembly (C).
Applying sealant (A) on the groove and checking the O-rings (B) seated firmly, install the chain case assembly (C) within fifteen minutes.
Tighten the chain case mounting bolts with the specified torque.
Tightening torque
6×16(★) :
13.7 ~ 15.7N.m (1.4 ~ 1.6kgf.m, 10.1 ~ 11.6lb-ft)
8×35(▲) :
19.6 ~ 25.5N.m (2.0 ~ 2.6kgf.m, 14.5 ~ 18.8lb-ft)
Install the water pump (A) with a new gasket.
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Install the high pressure pump.
Install the camshaft and the cylinder head assembly.
Applying sealant, install the upper head seal.
Install the high pressure fuel pump sprocket.
Tightening torque :
64.7 ~ 74.5N.m (6.6 ~ 7.6kgf.m, 47.7 ~ 55.0lb-ft)
Install the timing chain (B), aligning the timing marks (E) on the camshaft sprocket (C) and the crankshaft sprocket (D).
After timing chain's installation, fix the camshaft system by using the SST(09231-3A000).
Install the chain guide (F) and the tensioner lever (G).
Tightening torque :
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
If you have difficulty in installing of the lower chain guide, turn the drive plate or move the SST a little bit.
Install the hydraulic tensioner (A).
Tightening torque :
39.2 ~ 49.0Nm (4.0 ~ 5.0kgf.m, 28.9 ~ 36.2lb-ft)
Confirm that the timing marks are on the right position and remove the SST(09351-3A000).
Applying sealant on the front chain cover sealing surface, install the front chain cover within a fifteen minutes.
Tighten the front chain cover mounting bolts (A-20EA, B-4EA).
Tightening torque
A - 20EA :
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
B - 4EA :
19.6 ~ 25.5N.m (2.0 ~ 2.6kgf.m, 14.5 ~ 18.8lb-ft)
Applying sealant on the groove of the chain caps (C), install the caps within a fifteen minutes.
Tightening torque :
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
Install it after removing sealant from the camshaft bearing ladders.
Install the crankshaft pulley (A) with its washer (B) and tighten the mounting bolt (C).
Tightening torque :
186.3 ~ 205.9Nm (19.0 ~ 21.0kgf.m, 137.4 ~ 151.8lb-ft) + 58° ~ 62°
Use the SST (09231-2J100) to fix the crankshaft when install the crankshaft pulley bolt.
Install the vacuum pump (A).
When reassembling, check if the O-ring is damaged and apply sealant.
Align the nod of the pump.
The two bolts (B) of the three mounting ones should be sealed with the LOCTITE.
Tightening torque :
7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
Install the fan pulley assembly (A), water pump pulley (B) and Idler (C).
Tightening torque
A : 63.7 ~ 73.5N.m (6.5 ~ 7.5kgf.m, 47.0 ~ 54.2lb-ft)
B : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
C : 34.3 ~ 44.1N.m (3.5 ~ 4.5kgf.m, 25.3 ~ 32.5lb-ft)
Install the alternator bracket (A).
Tightening torque
B : 42.2 ~ 53.9N.m (4.3 ~ 5.5kgf.m, 31.1 ~ 39.8lb-ft)
C : 33.3 ~ 41.2N.m (3.4 ~ 4.2kgf.m, 24.6 ~ 30.4lb-ft)
Install the power steering pump (A) and bracket (B).
Tightening torque :
19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft)
Install the oil separator & pipe (A), and glow control unit (B).
Tightening torque
A : 7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)
B : 8.8 ~ 13.7N.m (0.9 ~ 1.4kgf.m, 6.5 ~ 10.1lb-ft)
Install the drive belt tensioner (A).
Compressing the tensioner (A) with a wrench in a left hand by turning it clockwise, put on the drive belt (B) lastly with the water pump side idler.
Conform to what is described above because tension of the belt in this engine is higher than ones of other engines for preventing a slip.
Install the cooling fan (A) and pan clutch (B).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
