ENGINE UNIT REASSEMBLY
CAUTION / NOTICE / HINT
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
INSTALL NO. 2 OIL NOZZLE SUB-ASSEMBLY
Using an E8 "TORX" socket wrench, install the No. 2 oil nozzle sub-assembly with the bolt.
10 N*m
102 kgf*cm
7 ft.*lbf
INSTALL INJECTION PUMP DRIVE GEAR
-
*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.
Set the chain sub-assembly to the crankshaft.
-
*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
Tip: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.
Install the injection pump drive gear with the chain sub-assembly.
Install the fuel supply pump assembly with the 2 bolts.
19 N*m
194 kgf*cm
14 ft.*lbf
-
Install the central bolt to the injection pump drive gear.
65 N*m
663 kgf*cm
48 ft.*lbf
-
Temporarily install the fuel supply pump assembly support with the 4 bolts by hand in the sequence shown in the illustration.
-
Tighten the 4 bolts in the sequence shown in the illustration.
19 N*m
194 kgf*cm
14 ft.*lbf
-
INSTALL TIMING CHAIN GUIDE
Using a T45 "TORX" socket wrench, install the timing chain guide with the 2 bolts.
20 N*m
204 kgf*cm
15 ft.*lbf
INSTALL TIMING CHAIN TENSION ARM
Using a T45 "TORX" socket wrench, install the timing chain tension arm with the bolt.
20 N*m
204 kgf*cm
15 ft.*lbf
INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY
Using an E8 "TORX" socket wrench, install the No. 1 chain tensioner assembly with the 2 bolts.
10 N*m
102 kgf*cm
7 ft.*lbf
Remove the 3.0 mm hexagon wrench from the No. 1 chain tensioner assembly.
-
Remove SST.
SST
PZ4TB-04964-42
INSTALL NO. 2 TIMING CHAIN TENSION ARM
Using a T45 "TORX" socket wrench, install the No. 2 timing chain tension arm with the bolt.
20 N*m
204 kgf*cm
15 ft.*lbf
INSTALL NO. 2 CHAIN SUB-ASSEMBLY
Install the No. 2 chain sub-assembly to the injection pump drive gear.
INSTALL OIL PUMP DRIVE CHAIN SUB-ASSEMBLY
Install the oil pump drive chain sub-assembly to the crankshaft.
INSTALL TIMING CHAIN COVER PLATE
-
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.
Using an E8 "TORX" socket wrench, install the timing chain cover plate with the 11 bolts.
20 N*m
204 kgf*cm
15 ft.*lbf
Apply a light coat of engine oil to a new O-ring, and install it to the sealing cap.
Install the sealing cap to the timing case housing.
20 N*m
204 kgf*cm
15 ft.*lbf
-
INSTALL REAR ENGINE OIL SEAL
INSTALL OIL PUMP WITH VACUUM PUMP ASSEMBLY
INSTALL OIL STRAINER SUB-ASSEMBLY
INSTALL OIL PAN SUB-ASSEMBLY
INSTALL FLYWHEEL WITH DAMPER ASSEMBLY
INSTALL CLUTCH DISC ASSEMBLY
INSTALL CLUTCH COVER ASSEMBLY
INSPECT AND ADJUST CLUTCH COVER ASSEMBLY
INSTALL TIMING GEAR CASE OR TIMING CHAIN CASE OIL SEAL
INSTALL CRANKSHAFT PULLEY
SELECT CYLINDER HEAD GASKET
INSTALL CYLINDER HEAD GASKET
INSTALL CYLINDER HEAD SUB-ASSEMBLY
INSPECT VALVE LASH ADJUSTER ASSEMBLY
INSTALL VALVE LASH ADJUSTER ASSEMBLY
INSTALL NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
INSTALL CAMSHAFT HOUSING SUB-ASSEMBLY
SET NO. 1 CYLINDER TO TDC/COMPRESSION
INSTALL CAMSHAFT AND NO. 2 CAMSHAFT
INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
INSTALL OIL FILLER CAP SUB-ASSEMBLY
Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.
INSTALL OIL FILTER ASSEMBLY
INSTALL OIL FILTER SUB-ASSEMBLY
INSTALL WATER OUTLET
-
Install a new gasket to the water outlet.
Using an E10 "TORX" socket wrench, install the water outlet with the 3 bolts.
10 N*m
102 kgf*cm
7 ft.*lbf
-
INSTALL WATER INLET HOUSING
-
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.
Using an E11 "TORX" socket wrench, install the water inlet housing with the 5 bolts.
20 N*m
204 kgf*cm
15 ft.*lbf
-
INSTALL THERMOSTAT
INSTALL WATER INLET
INSTALL WATER BY-PASS PIPE
Using a 5 mm hexagon socket wrench, install the water by-pass pipe to the water inlet housing with the bolt.
Tip:Refer to "SPECIFICATIONS - STANDARD BOLT" for the tightening torque.
INSTALL ENGINE WATER PUMP ASSEMBLY
INSTALL INJECTOR ASSEMBLY
INSTALL NOZZLE LEAKAGE PIPE ASSEMBLY
INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY
INSTALL ENGINE COOLANT TEMPERATURE SENSOR
INSTALL CRANKSHAFT POSITION SENSOR
INSTALL CAMSHAFT POSITION SENSOR