3.
Remove the breather hose (B).
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.
Remove the engine cover.
Disconnect the battery negative terminal (A).
Remove the breather hose (B).
Remove the front tires.
Remove the under covers (A).
Disconnect the engine wiring harness connectors and remove the wiring harness protectors.
Disconnect the fuel pressure regulator valve connector (A).
Disconnect the fuel temperature sensor connector (B).
Disconnect the oil pressure switch connector (C).
Disconnect the knock sensor connector (D). (1.4L only)
Disconnect the injector connectors (A).
Disconnect the cam position sensor (CMPS) connector (B).
Disconnect the electric EGR control valve connector (C).
Disconnect the glow plug connector (A).
Disconnect the exhaust gas temperature sensor (#1, #2) connectors (B).
Disconnect the difference pressure sensor connector (C).
Disconnect the lambda sensor connector (D). (1.6L only)
Disconnect the alternator connector (A) and the cable (B).
Disconnect the wiring (A) and then remove the fuse/relay box (B).
Disconnect the engine ground line (A).
Remove the injectors (A), the high pressure pipes (B), the fuel return hose (C) and the turbo charger vacuum hoses (D). (Refer to FL group)
Using the hexagon wrench, turn the tensioner (A) counterclockwise and loosen. Then remove the drive belt (B).
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 engine mounting insulator (A).
Remove the oil level gauge guide (A).
Drain the engine oil and then remove the oil filter&cooler assembly (A) after removing the starter. (Refer to Lubrication system in this group)
Remove the alternator (A). (Refer to Alternator in EEB group).
Remove the water pump pulley (A).
Remove the idler (A) and the drive belt tensioner (B).
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(ring gear stopper, 09231-2B100)(A) to remove the crankshaft pulley bolt.
Remove the idler (A) and the timing chain cover plug (B).
Remove the high pressure fuel pump sprocket nut (C) after fixing the crank shaft.
Use the SST (ring gear stopper, 09231-2B100) to remove the high pressure pump sprocket nut.
Replace O-ring of plug (B) with a new one when reinstalling the plug.
Disconnect the fuel tubes (A).
Unscrew the three high pressure fuel pump mounting bolts (B, C).
Install the high pressure fuel pump sprocket stopper (A) (SST No.: 09331-2A010) with rotating it clockwise.
Install the high pressure fuel pump remover (SST No.:09331-2A010) (A) with three mounting bolts (B).
Fix the high pressure fuel pump remover (SST No.:09331-2A010) (A) and sprocket stopper (C) with two fixing bolts (D).
Rotate the bolt (E) of the high pressure fuel pump remover (SST No.:09331-2A010) (A) clockwise till the high pressure fuel pump is pushed out.
Remove the A/C compressor. (Refer to A/C compressor in HA group)
Fix the engine to the engine support fixture.
Remove the cowl top cover and the cowl complete assembly panel. (Refer to Cowl top cover in BD group)
Remove the head lamp. (Refer to Lighting system in BE group)
Install the engine support fixture and adapter (SST : 09200-38001, 09200-1P000) on the engine room.
Fix the engine to the engine support fixture using the engine hanger.
Remove the jack from the engine oil pan.
Remove the intercooler pipe (A).
Remove the rear roll stopper (A).
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 (A).
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).
Take off the hook of the engine support fixture from the front engine hanger.
Set the jack to the bed plate.
Take off the hook of the engine support fixture from the front engine hanger.
Remove the timing chain case (A).
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.
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.
