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.
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) : 25.5 ~ 34.3N.m (2.6 ~ 3.5kgf.m, 18.8 ~ 25.3lb-ft)
Replace the hook of the engine support fixture to the front engine hanger.
Replace the hook of the engine support fixture to the front engine hanger.
Remove the jack from the bed plate.
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 fuel pump (B, C) and connect the fuel tubes (A).
Tightening torque :
Bolts (B) : 14.7 ~ 19.6N.m (1.5 ~ 2.0kgf.m, 10.8 ~ 14.5lb-ft)
Bolts (C) : 19.6 ~ 25.5N.m (2.0 ~ 2.6kgf.m, 14.5 ~ 18.8lb-ft)
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 fuel 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)
Tighten the high pressure pump sprocket nut (A) at specified tightening torque.
Tightening torque :
64.7 ~ 74.5N.m (6.6 ~ 7.6kgf.m, 47.7 ~ 55.0lb-ft)
Use the SST(ring gear stopper, 09231-2B100)(A) to tighten the high pressure pump sprocket nut.
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)
Bolt (G) : 42.2 ~ 54.0N.m (4.3 ~ 5.5kgf.m, 31.1 ~ 39.8lb-ft)
Install the front oil seal by using SST(09231-2A000, 09231-H1100) (A).
Install the oil strainer (A).
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)
Install the rear roll stopper (A).
Tightening torque :
Bolts (B) : 49.0 ~ 63.7N.m (5.0 ~ 6.5kgf.m, 36.1 ~ 47.0lb-ft)
Bolt (C) : 107.9 ~ 127.5N.m (11.0 ~ 13.0kgf.m, 79.6 ~ 94.0lb-ft)
Install the intercooler pipe (A).
Tightening torque :
Clamp (B) : 4.9 ~ 6.9N.m (0.5 ~ 0.7kgf.m, 3.6 ~ 5.1lb-ft)
Bolt (C) : 6.9 ~ 10.8N.m (0.7 ~ 1.1kgf.m, 5.1 ~ 8.0lb-ft)
It is allowed to plaster cleaning liquid or alcohol on the connecting surfaces of hose and pipe, but all kinds of oil is prohibited.
The clip wing must be located on the position mark of hose and must not run over it.
The groove of hose must be in line with the protrusion of the pipe or turbocharger.
The band must be located on the position mark of hose and must not run over it.
Tighten the torque control cap until it separated. If a torque control cap has already removed, tighten the screw at the specified torque.
Remove the engine support fixture.
Set the jack to the engine oil pan.
Remove the engine support fixture and adapter (SST : 09200-1P000) from the engine room.
Install the cowl top cover. (Refer to Cowl top cover in BD group)
Install the A/C compressor. (Refer to A/C compressor in HA group)
Install the timing chain cover plug (B) and the idler (A).
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(ring gear stopper, 09231-2B100) to Install the crankshaft pulley bolt.
Install the drive belt tensioner (B) and the idler (A).
Tightening torque :
A : 24.5 ~ 34.3N.m (2.5~ 3.5kgf.m, 18.1 ~ 25.3lb-ft)
B : 25.5 ~ 30.4N.m (2.6 ~ 3.1kgf.m, 18.8 ~ 22.4lb-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). (Refer to Alternator in EEB group)
Tightening torque :
38.2 ~ 58.8N.m (3.9 ~ 6.0kgf.m, 28.2 ~ 43.4lb-ft)
Install the oil filter&cooler assembly (A) and then install the starter. (Refer to Lubrication system in this group)
Tightening torque :
19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft)
Install the oil level gauge guide (A).
Tightening torque :
19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft)
Install the engine mounting support bracket.
Install the engine mounting insulator (A).
Tightening torque :
49.0 ~ 63.7N.m (5.0 ~ 6.5kgf.m, 36.1 ~ 47.0lb-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 the engine oil pan.
Install the cylinder head cover (A) with new head cover gasket.
Tightening torque :
1st : 3.9 ~ 5.9N.m (0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)
2st : 8.8 ~ 10.8N.m (0.9 ~ 1.1kgf.m, 6.5 ~ 8.0lb-ft)
Standard liquid gasket : LOCTITE 5900
Check that the mating surfaces are clean and dry before applying liquid gasket.
Apply liquid gasket in a 7mm (0.28in) 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 drive belt (B) after turning the tensioner (A) counterclockwise.
Install the injectors (A), the high pressure pipes (B), the fuel return hose (C) and the turbo charger vacuum hoses (D). (Refer to FL group)
Do not reuse the high pressure pipe.
Connect the engine ground line (A).
Install the fuse/relay box (B) and then connect the wiring (A).
Install the wiring harness protectors and connect the engine wiring harness connectors.
Connect the fuel pressure regulator valve connector (A).
Connect the fuel temperature sensor connector (B).
Connect the oil pressure switch connector (C).
Connect the knock sensor connector (D). (1.4L only)
Connect the injector connectors (A).
Connect the cam position sensor (CMPS) connector (B).
Connect the electric EGR control valve connector (C).
Connect the glow plug connector (A).
Connect the exhaust gas temperature sensor (#1, #2) connectors (B).
Connect the difference pressure sensor connector (C).
Connect the lambda sensor connector (D). (1.6L only)
Connect the alternator connector (A) and the cable (B).
Install the under covers (A).
Tightening torque :
6.9 ~ 10.8N.m (0.7 ~ 1.1kgf.m, 5.1 ~ 8.0lb-ft)
Install the front tires.
Install the breather hose (B).
Connect the battery negative terminal (A).
Install the engine cover.
