Installation

Installation

1. Install the tensioner adapter (A) and the timing chain guide bolts (B).

Tightening torque :
Tensioner adapter bolts:
21.6 - 25.5Nm (2.2 - 2.6kgf.m, 15.9 - 18.8lb-ft)
Timing chain guide bolts :
21.6 - 25.5Nm (2.2 - 2.6kgf.m, 15.9 - 18.8lb-ft)

2. Install the crankshaft sprocket (A) with the friction plates (B).

NOTE:
Completely fix the four friction plate clips and the sprocket groove.
Align the key-home of the friction plate with the key-home of the sprocket.
Be careful for the clip not to be folded.
The block is placed at bottom up before install the timing chain system and timing chain cover assembly.

CAUTION:
The mark of friction plate should be placed top. (Engine is placed bottom up)

3. Install the oil pump chain (C) with the oil pump sprocket (B) and oil pump chain tensioner (A).

Tightening torque :
A : 9.8 - 11.8Nm (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
B : 21.6 - 25.5Nm (2.2 - 2.6kgf.m, 15.9 - 18.8lb-ft)

4. Install the timing chain with the timing chain tensioner arm (A) , the timing chain guide (B) and the timing chain locking tool (SST : 09231-2J600) (C).

Tightening torque :
Timing chain tensioner arm bolts :
21.6 - 25.5Nm (2.2 - 2.6kgf.m, 15.9 - 18.8lb-ft)

NOTE:
Align the timing mark of the friction plate and crankshaft sprocket.

5. Install the timing chain lower cover (A).

NOTE:
Assemble the timing chain lower cover with engine bottom up condition.

(1) The sealant locations on chain lower cover and on counter parts (cylinder head, cylinder block, and lower oil pan) must be free of engine oil and etc.
(2) Install the new gasket (A) to the timing chain lower cover.

(3) Apply liquid sealant TB1217H or LT 5900H on timing chain lower cover. The part must be assembled within 5 minutes after sealant was applied.
Sealant should be applied in a continuous beed in each of the areas indicated below.

Bead width :dia.2.5 ± 0.5mm

NOTE:
During timing chain lower cover installation, care not to take off applied sealant on the timing chain lower cover by contact with other parts.

(4) The dowel pins on the cylinder block and holes on the timing chain lower cover should be used as a reference in order to assemble the timing chain lower cover to be in exact position.

Tightening torque :
23.5 - 27.5Nm (2.4 - 2.8kgf.m, 17.4 - 20.3lb-ft)

(5) The firing and/or blow out test should not be performed within 30 minutes after the timing chain lower cover was assembled.
6. Install the cylinder head assembly.

NOTE:
Before install the cylinder head assembly, place the engine up right.

7. Install the camshaft assembly.
8. Remove the SST from the timing chain guide and the timing chain tensioner arm.
9. Install the timing chain to the camshaft sprocket.

NOTE:
To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure.
Crankshaft sprocket -> Timing chain guide -> Exhaust camshaft sprocket -> Intake camshaft sprocket. (LH Bank)
Crankshaft sprocket -> Timing chain guide -> Intake camshaft sprocket -> Exhaust camshaft sprocket. (RH Bank)
The timing mark of each sprockets should be matched with timing mark (color link) of timing chain during installation.

10. Install the timing chain tensioner.

Tightening torque :
78.5 - 88.3N.m (8.0 - 9.0kgf.m, 57.9 - 65.1lb-ft)

11. After rotating the crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm the timing mark.

NOTE:
Always turn the crankshaft clockwise.
Turning the crankshaft counter clockwise before building up oil pressure in the hydraulic timing chain tensioner may result in the chain disengaging from the sprocket teeth.

12. Install the O-ring to the water temperature control assembly (A).

13. Install the water temperature control assembly (A).

Tightening torque :
16.7 - 19.6N.m (1.7 - 2.0kgf.m, 12.3 - 14.5lb-ft)

14. Install the water pump (A).

Tightening torque :
19.6 - 24.5Nm (2.0 - 2.5kgf.m, 14.5 - 18.1lb-ft)

15. Using SST(09231-2J300, 09231-H1100), Install the front oil seal (A).

16. Install the crankshaft pulley (A).

Tightening torque :
392.3 - 402.1Nm(40.0 - 41.0kgf.m,289.3 - 296.6lb-ft)

NOTE:
Use the SST(flywheel stopper, 09231-2B100) to Install the crankshaft pulley bolt, after remove the starter.

17. Install the upper oil pan.
(1) Using a gasket scraper, remove all the old packing material from the gasket surfaces.
(2) Before assembling the oil pan, the liquid sealant TB1217H should be applied on upper oil pan.
The part must be assembled within 5 minutes after the sealant was applied.

Bead width :2.5mm(0.1in)

NOTE:
- Clean the sealing face before assembling two parts.
- Remove harmful foreign materials on the sealing face before applying sealant.
- When applying sealant gasket, sealant must not protrude into the inside of oil pan.
- To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.

(3) Install the upper oil pan.

Uniformly tighten the bolts in several passes.

Tightening torque :
9.8 - 11.8Nm (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)

18. Install the lower oil pan.
(1) Using a gasket scraper, remove all the old packing material from the gasket surfaces.
(2) Before assembling the oil pan, the liquid sealant TB1217H or LT5900H should be applied on lower oil pan.
The part must be assembled within 5 minutes after the sealant was applied.

Bead width :2.5mm(0.1in)

Uniformly tighten the bolts in several passes.

Tightening torque :
9.8 - 11.8Nm (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)

19. Install the oil filter and oil cooler assembly (A).

Tightening torque :
Oil filter assembly bolts :
19.6 - 23.5Nm ( 2.0 - 2.4kgf.m, 14.5 - 17.4lb-ft)
Oil cooler bolts :
9.8 - 11.8Nm (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)

20. Install the drive belt tensioner (A).

Tightening torque :
19.6 - 23.5Nm (2.0 - 2.4kgf.m, 14.5 - 17.4lb-ft)

21. Install the water pump pulley (A).

Tightening torque :
18.6 - 23.5Nm (1.9 - 2.4kgf.m, 13.7 - 17.4lb-ft)

NOTE:
Tighten every bolt diagonally.

22. Install the cooling fan pulley (A).

Tightening torque :
76.5 - 80.4Nm ( 7.8 - 8.2kgf.m, 56.4 - 59.3lb-ft)

CAUTION:
The cooling fan pulley bolt is left-hand thread.
To assemble the bolt screw it counterclockwise.

23. Install the air conditioner compressor (A).

24. Install the alternator bracket (A).

Tightening torque :
Bolts (B) 4EA :
29.4 - 41.2N.m (3.0 - 4.2kgf.m, 21.7 - 30.4lb-ft)
Bolt (C) 1EA :
19.6 - 26.5N.m ( 2.0 - 2.7kgf.m, 14.5 - 19.5lb-ft)

25. Install the power steering pump.

26. Install the removed parts.