Installation

INSTALLATION
1. Install crankshaft sprocket on crankshaft.





2. Position crankshaft so that No.1 piston is set at T.D.C. on compression stroke.





3. Install R.H. idler sprocket and chain guides.





4. Position lower timing chain on R.H. idler sprocket by aligning the mating mark on the R.H. idler sprocket with the silver mating mark on the lower timing chain.





5. Install L.H. idler sprocket with lower timing chain.

- Line up mating marks on lower timing chain with mating marks on L.H. idler sprocket and crankshaft sprocket.

6. Install chain guide and chain tensioner.





7. Position upper timing chains on idler sprockets by aligning the mating marks on the idler sprockets with the gold mating marks on the upper timing chains.





8. Install oil pump drive spacer, front cover and alternator adjusting bar.
- Before installing front cover, remove all traces of liquid gasket from mating surface and grooves using a scraper and then completely clean any oil stains.
- Also remove traces of liquid gasket from mating surface of cylinder block.
- Apply a continuous bead of liquid gasket to mating surface of front cover.
- Use Genuine Liquid Gasket or equivalent.








- Wipe off excessive liquid gasket.

9. Install oil filter bracket.
10. Install oil strainer.





11. Install crankshaft pulley.
12. Set No.1 piston at T.D.C. on its compression stroke.
13. Install oil pan.
14. Install water pump.

- Before installing water pump, remove all traces of liquid gasket from mating surface and groove using a scraper.
- Also remove traces of liquid gasket from mating surface of front cover and water pipe.
- Apply a continuous bead of liquid gasket to mating surface of water pump.
- Use Genuine Liquid Gasket or equivalent.

15. Install water pump pulley.
16. Install water pipe.





17. Turn crankshaft until No.1 piston is set at approximately 120° before T.D.C. on compression stroke to prevent interference of valves and pistons.





18. Install cylinder heads with new gaskets.

- Before installing cylinder head gaskets, apply a continuous bead of liquid gasket to mating surface of cylinder block.
- Be sure to install washers between bolts and cylinder head.
- Do not rotate crankshaft and camshaft separately, or valves will strike piston heads.





- Tightening procedure:

a. Tighten all bolts to 39 Nm (4.0 kg-m, 29 ft-lb).

b. Bolts of A type: Turn A bolts 65 to 70 degrees clockwise with Tool or suitable angle wrench.

Bolts of B type: Turn B bolts 70 to 75 degrees clockwise with Tool or suitable angle wrench. If angle wrench is not available, tighten all bolts to 123 Nm (12.5 kg-m, 90 ft-lb)

c. Loosen all bolts completely.








d. Tighten all bolts to 34 to 44 Nm (3.5 to 4.5 kg-m, 25 to 33 ft-lb).

e. Bolts of A type: Turn A bolts 65 to 70 degrees clockwise with Tool or suitable angle wrench.

Bolts of B type: Turn B bolts 70 to 75 degrees clockwise with Tool or suitable angle wrench.

If angle wrench Is not available, tighten all bolts to 118 to 127 Nm (12.0 to 13.0 kg-m, 87 to 94 ft-lb).

19. Install cylinder head outside bolts.
20. Install exhaust camshafts, camshaft brackets and rocker arms.





- Install exhaust camshafts, noting their identification marks.





- Position camshaft
R.H. exhaust camshaft key at about 10 o'clock
L.H. exhaust camshaft key at about 12 o'clock











- Install camshaft brackets in their original positions.
- Before installing L.H. exhaust camshaft end bracket, remove all traces of liquid gasket from mating surface, and then completely clean any oil stains.
- Also remove traces of liquid gasket from mating surface of cylinder head.
- Apply a continuous bead of liquid gasket to mating surface of L.H. exhaust camshaft end bracket.
- Use Genuine Liquid Gasket or equivalent.





21. Install R.H. V.T.C. assembly.
22. Install R.H. camshaft sprocket.

Line up mating marks on R.H. upper timing chain with mating marks on R.H. V.T.C. assembly and R.H. camshaft sprocket.

23. Install R.H. chain tensioner.





Before installing chain tensioner, press-in sleeve until hook can be engaged on pin. Make sure that hook used to retain chain tensioner is released.





There are two types of chain tensioner. Be careful not to install L.H. chain tensioner onto R.H cylinder head.





24. Turn crankshaft clockwise to set No.1 piston at T.D.C. compression stroke.








25. Install L.H. V.T.C. assembly
26. Install: L.H. camshaft sprocket.

Line up mating marks on L.H. upper timing chain with mating marks on L.H. V.T.C. assembly and L.H. camshaft sprocket.

27. Install L.H. chain tensioner

- Make sure that upper timing chains are in the correct position.





28. Install crankshaft position sensors.

Make sure that position of camshaft and rotor position of crank shaft position sensor are as shown.





29. Install R.H. and L.H. upper front covers.

- Before installing R.H. and L.H. upper front covers, remove all traces of liquid gasket from mating surface and groove using a scraper, and completely clean any oil stains.
- Also remove traces of liquid gasket from mating surface of cylinder head.
- Apply a continuous bead of liquid gasket to mating surface of R.H. and L.H. upper front covers.
- Use Genuine Liquid Gasket or equivalent.

30. Install R.H and L.H. upper chain guides.





31. Install R.H. and L.H. rocker covers.

- Before installing rocker covers, remove all traces of liquid gasket from mating surface of rocker cover to cylinder head, and then completely clean any oil stains.
- Apply a continuous bead of liquid gasket to mating surface of rocker cover gaskets and cylinder heads.
- Use Genuine Liquid Gasket or equivalent.





Rocker cover tightening procedure.

1 Tighten nuts 1-2-12-11-9-14 in that order to 4 Nm (0.4 kg-m, 2.9 ft-lb)
2 Tighten nuts 1 to 14 as indicated in image to 8 to 10 Nm (0.8 to 1.0 kg-m, 5.8 to 7.2 ft-lb).





32. Reinstall any parts removed in reverse order of removal

- When installing injector tube assembly refer to "Injector Removal and Installation.
- When installing V.T.C. solenoid valve, always use new O-rings, and apply engine oil to new O-rings.