ENGINE UNIT REASSEMBLY

CAUTION / NOTICE / HINT

Note


  • Always be sure to check the tightening torque.

  • If the pressure lines are leaking after installation, they must be replaced.

  • Do not overtighten the pressure lines.

  • All pressure lines may only be reused 3 times. After the 3rd time, they must be replaced.

PROCEDURE


  1. INSTALL NO. 2 OIL NOZZLE SUB-ASSEMBLY


    1. Using an E8 "TORX" socket wrench, install the No. 2 oil nozzle sub-assembly with the bolt.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  2. INSTALL INJECTION PUMP DRIVE GEAR


    1. A01M0E6C01
      *a Cutout
      *b Protrusion

      Align the cutout of the fuel supply pump assembly with the protrusion of the cylinder block and temporarily install the fuel supply pump with the 2 bolts.

    2. Set the chain sub-assembly to the crankshaft.

    3. A01M215C01
      *a 0.5 to 1.0 mm (0.0197 to 0.0394 in.)

      Install SST by rotating the crankshaft as shown in the illustration.

      SST
      PZ4TB-04964-42

      Tech Tips

      The No. 1 piston position is 0.5 to 1.0 mm (0.0197 to 0.0394 in.) lower than the top of the cylinder block.

    4. Install the injection pump drive gear with the chain sub-assembly.

    5. Install the fuel supply pump assembly with the 2 bolts.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }
    6. A01LWRK

      Install the central bolt to the injection pump drive gear.

      Torque:
      65 N*m  { 663 kgf*cm, 48 ft.*lbf }
    7. A01M3D6E04

      Temporarily install the fuel supply pump assembly support with the 4 bolts by hand in the sequence shown in the illustration.

    8. A01M3D6E05

      Tighten the 4 bolts in the sequence shown in the illustration.

      Torque:
      19 N*m  { 194 kgf*cm, 14 ft.*lbf }

  3. INSTALL TIMING CHAIN GUIDE


    1. Using a T45 "TORX" socket wrench, install the timing chain guide with the 2 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  4. INSTALL TIMING CHAIN TENSION ARM


    1. Using a T45 "TORX" socket wrench, install the timing chain tension arm with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  5. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY


    1. Using an E8 "TORX" socket wrench, install the No. 1 chain tensioner assembly with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    2. Remove the 3.0 mm hexagon wrench from the No. 1 chain tensioner assembly.

    3. A01M22AE01

      Remove SST.

      SST
      PZ4TB-04964-42

  6. INSTALL NO. 2 TIMING CHAIN TENSION ARM


    1. Using a T45 "TORX" socket wrench, install the No. 2 timing chain tension arm with the bolt.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  7. INSTALL NO. 2 CHAIN SUB-ASSEMBLY


    1. Install the No. 2 chain sub-assembly to the injection pump drive gear.

  8. INSTALL OIL PUMP DRIVE CHAIN SUB-ASSEMBLY


    1. Install the oil pump drive chain sub-assembly to the crankshaft.

  9. INSTALL TIMING CHAIN COVER PLATE


    1. A01LY9G

      Apply seal packing in a continuous line as shown in the illustration.

      Standard Seal Diameter
      1.5 to 2.0 mm (0.0591 to 0.0787 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the timing chain cover plate within 3 minutes of applying seal packing.

      • Do not start the engine for at least 4 hours after installation.

    2. Using an E8 "TORX" socket wrench, install the timing chain cover plate with the 11 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

    3. Apply a light coat of engine oil to a new O-ring, and install it to the sealing cap.

    4. Install the sealing cap to the timing case housing.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  10. INSTALL REAR ENGINE OIL SEAL

    Click here

  11. INSTALL OIL PUMP WITH VACUUM PUMP ASSEMBLY

    Click here

  12. INSTALL OIL STRAINER SUB-ASSEMBLY

    Click here

  13. INSTALL OIL PAN SUB-ASSEMBLY

    Click here

  14. INSTALL FLYWHEEL WITH DAMPER ASSEMBLY

    Click here

  15. INSTALL CLUTCH DISC ASSEMBLY

    Click here

  16. INSTALL CLUTCH COVER ASSEMBLY

    Click here

  17. INSPECT AND ADJUST CLUTCH COVER ASSEMBLY

    Click here

  18. INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL

    Click here

  19. INSTALL CRANKSHAFT PULLEY

    Click here

  20. SELECT CYLINDER HEAD GASKET

    Click here

  21. INSTALL CYLINDER HEAD GASKET

    Click here

  22. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Click here

  23. INSPECT VALVE LASH ADJUSTER ASSEMBLY

    Click here

  24. INSTALL VALVE LASH ADJUSTER ASSEMBLY

    Click here

  25. INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

    Click here

  26. INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY

    Click here

  27. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    Click here

  28. INSTALL CAMSHAFT AND NO. 2 CAMSHAFT

    Click here

  29. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    Click here

  30. INSTALL OIL FILLER CAP SUB-ASSEMBLY


    1. Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.

  31. INSTALL OIL FILTER ASSEMBLY

    Click here

  32. INSTALL OIL FILTER SUB-ASSEMBLY

    Click here

  33. INSTALL WATER OUTLET


    1. A01LV7N

      Install a new gasket to the water outlet.

    2. Using an E10 "TORX" socket wrench, install the water outlet with the 3 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

  34. INSTALL WATER INLET HOUSING


    1. A01M048

      Apply seal packing in a continuous line as shown in the illustration.

      Standard seal diameter
      2.0 to 2.5 mm (0.0787 to 0.0984 in.)

      Note


      • Remove any oil from the contact surface.

      • Install the water inlet housing within 3 minutes of applying seal packing.

      • Do not start the engine for at least 4 hours after installation.

    2. Using an E11 "TORX" socket wrench, install the water inlet housing with the 5 bolts.

      Torque:
      20 N*m  { 204 kgf*cm, 15 ft.*lbf }

  35. INSTALL THERMOSTAT

    Click here

  36. INSTALL WATER INLET

    Click here

  37. INSTALL WATER BY-PASS PIPE


    1. Using a 5 mm hexagon socket wrench, install the water by-pass pipe to the water inlet housing with the bolt.

      Tech Tips

      Refer to "SPECIFICATIONS - STANDARD BOLT" for the tightening torque.

  38. INSTALL ENGINE WATER PUMP ASSEMBLY

    Click here

  39. INSTALL INJECTOR ASSEMBLY

    Click here

  40. INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY

    Click here

  41. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  42. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  43. INSTALL CRANKSHAFT POSITION SENSOR

    Click here

  44. INSTALL CAMSHAFT POSITION SENSOR

    Click here