Part 2
2UR-GSE ENGINE MECHANICAL: ENGINE UNIT: REASSEMBLY (Continued)
23. INSTALL NO. 2 CHAIN TENSIONER ASSEMBLY (for Bank 2)
(a) Install the No. 2 chain tensioner assembly with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) While raising the No. 2 chain tensioner assembly, insert a 1.0 mm (0.0394 in.) pin into the hole to fix it in place.
24. INSTALL CHAIN SUB-ASSEMBLY (for Bank 2)
HINT
The crankshaft timing gear, camshaft timing gear assembly and camshaft timing exhaust gear assembly will be installed with the No. 1 chain sub-assembly and No. 2 chain sub-assembly connected to the gears.
(a) Align the No. 1 chain's orange mark plates with the camshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration.
(b) Align the No. 1 chain's orange mark plate with the crankshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration.
(c) Align the No. 2 chain's mark plates (yellow) with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly, and attach the No. 2 chain to the gears as shown in the illustration.
(d) Install the crankshaft timing gear to the crankshaft.
(e) Align and attach the knock pin of the No. 1 camshaft with the pin hole of the camshaft timing gear assembly.
(f) Using the hexagonal portion of the No. 2 camshaft, align and attach the knock pin of the No. 2 camshaft with the pin hole of the camshaft timing exhaust gear assembly.
(g) Remove the pin from the No. 2 chain tensioner assembly.
25. INSTALL NO. 1 CHAIN VIBRATION DAMPER (for Bank 2)
(a) Install the No. 1 chain vibration damper with the 2 bolts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
26. INSTALL CHAIN TENSIONER SLIPPER (for Bank 2)
(a) Install the chain tensioner slipper.
HINT
If you cannot install the chain tensioner slipper due to the tension of the chain, use the hexagonal portion of the camshaft to loosen the chain, and then install the chain tensioner slipper.
27. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 2)
(a) Move the stopper plate upward to release the lock, and fully push the plunger into the No. 1 chain tensioner assembly.
(b) Move the stopper plate downward to set the lock, and insert a 2 mm hexagon wrench into the hole of the stopper plate.
(c) Install the No. 1 chain tensioner assembly with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(d) Remove the hexagon wrench from the No. 1 chain tensioner assembly.
28. INSTALL NO. 3 CHAIN TENSIONER ASSEMBLY
(a) Install the No. 3 chain tensioner assembly with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
(b) While raising the No. 3 chain tensioner assembly, insert a 1.0 mm (0.0394 in.) pin into the hole to fix it in place.
29. INSTALL CHAIN SUB-ASSEMBLY (for Bank 1)
HINT
The crankshaft timing sprocket, camshaft timing gear assembly and camshaft timing exhaust gear assembly will be installed with the No. 1 chain sub-assembly and No. 2 chain sub-assembly connected to the gears.
(a) Align the No. 1 chain's orange mark plates with the camshaft timing gear's timing mark, and attach the chain to the gear as shown in the illustration.
(b) Align the No. 1 chain's orange mark plate with the crankshaft timing sprocket's timing mark, and attach the chain to the gear as shown in the illustration.
(c) Align the No. 2 chain's mark plates (yellow) with the timing marks of the camshaft timing gear assembly and camshaft timing exhaust gear assembly, and attach the No. 2 chain to the gears as shown in the illustration.
(d) Install the crankshaft timing sprocket to the crankshaft.
(e) Align and attach the knock pin of the No. 3 camshaft with the pin hole of the camshaft timing gear assembly.
(f) Using the hexagonal portion of the No. 4 camshaft, align and attach the knock pin of the No. 4 camshaft with the pin hole of the camshaft timing exhaust gear assembly.
NOTICE:
Because the gears' timing mark positions may shift due to looseness of the No. 1 chain, use the hexagonal portion of the camshaft to hold the No. 3 camshaft in place until the No. 1 chain tensioner is installed.
(g) Remove the pin from the No. 3 chain tensioner.
30. INSTALL NO. 1 CHAIN VIBRATION DAMPER (for Bank 1)
(a) Install the No. 1 chain vibration damper with the 2 bolts.
Torque : 21 Nm (214 kgf-cm, 15 ft-lbf)
(b) Remove the hexagon wrench from the No. 1 chain tensioner assembly.
31. INSTALL CHAIN TENSIONER SLIPPER (for Bank 1)
(a) Install the chain tensioner slipper.
HINT
If you cannot install the chain tensioner slipper due to the tension of the chain, use the hexagonal portion of the camshaft to loosen the chain and install the chain tensioner slipper.
32. INSTALL NO. 1 CHAIN TENSIONER ASSEMBLY (for Bank 1)
(a) Move the stopper plate upward to release the lock, and fully push the plunger into the No. 1 chain tensioner assembly.
(b) Move the stopper plate downward to set the lock, and insert a 2 mm hexagon wrench into the hole of the stopper plate.
(c) Install the No. 1 chain tensioner assembly and gasket with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
33. TIGHTEN CAMSHAFT TIMING GEAR ASSEMBLY
(a) for Bank 1:
(1) Using a wrench, hold the hexagonal portion of the No. 3 camshaft.
(2) Using a 12 mm socket hexagon wrench, tighten the camshaft timing gear assembly with a new bolt.
Torque : 79 Nm (806 kgf-cm, 58 ft-lbf)
(3) Using a wrench to hold the hexagonal portion of the No. 4 camshaft, tighten the camshaft timing exhaust gear assembly with the bolt.
Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf)
(b) for Bank 2:
(1) Using a wrench, hold the hexagonal portion of the No. 1 camshaft.
(2) Using a 12 mm socket hexagon wrench, tighten the camshaft timing gear assembly with a new bolt.
Torque : 79 Nm (806 kgf-cm, 58 ft-lbf)
(3) Using a wrench to hold the hexagonal portion of the No. 2 camshaft, tighten the camshaft timing exhaust gear assembly with the bolt.
Torque : 100 Nm (1020 kgf-cm, 74 ft-lbf)
34. INSPECT NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Temporarily install the crankshaft pulley bolt.
(b) Rotate the crankshaft clockwise, and check that the timing marks on the crankshaft timing gear and camshaft timing gears are as shown in the illustration.
(c) Remove the crankshaft pulley bolt.
35. INSPECT VALVE CLEARANCE Adjustments
36. ADJUST VALVE CLEARANCE Adjustments
37. INSTALL OIL REFLECTOR PLATE LH (for Bank 1)
(a) Install the oil reflector plate LH with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
38. INSTALL OIL REFLECTOR PLATE RH (for Bank 2)
(a) Install the oil reflector plate RH with the 2 bolts.
Torque : 10 Nm (102 kgf-cm, 7 ft-lbf)
39. INSTALL INLET WATER PIPE Installation
40. INSTALL SCAVENGING PUMP ASSEMBLY Installation
41. INSTALL NO. 3 OIL PIPE Installation
42. INSTALL NO. 2 OIL PIPE Installation
43. INSTALL NO. 1 OIL PIPE Installation
44. INSTALL WATER PUMP ASSEMBLY
(a) Install the water pump assembly and new water pump gasket with the 5 bolts.
Torque : 20 Nm (204 kgf-cm, 15 ft-lbf)