id011000505600

Special Service Tool (SST)

49 E011 1A0 Ring gear brake set

49 G028 205 Oil seal installer

Replacement Part

Oil and Chemical Type

Caution

• If the camshaft is rotated with the timing chain removed and the piston at the top dead center position, the valve may contact the piston and the engine could be damaged. When rotating the camshaft with the timing chain removed, rotate it after lowering the piston from the top dead center position.

• When rotating the camshaft using a wrench on the cast hexagon, the wrench may contact the rocker arm and damage the rocker arm. To prevent damage to the rocker arm when holding the camshaft on the cast hexagon, use a wrench on the rear side of the engine as shown in the figure to secure a clearance between the cam.

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• When installing the oil pan, refer to the Oil Pan Installation Note and apply the silicone sealant correctly. If the silicone sealant application position is incorrect or there is any break in the application track, engine oil leakage will occur due to a poor seal.

Note

• Width at the cast hexagon of the camshaft is 22—24 mm {0.87—0.94 in}.

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1.Assemble in the order indicated in the table.

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Oil Pump Chain Assembly Note

1.Verify that the key and knock pin are aligned to the positions shown in the figure.

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2.Temporarily assemble the oil pump driven sprocket.

3.Temporarily tighten the oil pump driven sprocket installation bolt.

4.Align the oil pump chain alignment mark with the balancer shaft sprocket alignment mark.

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Note

• The oil pump chain has an alignment mark in addition to two identification marks.

5.Install the oil pump chain and balancer shaft sprocket as a single unit while aligning the alignment marks on each sprocket and oil pump chain as shown in the figure.

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6.Temporarily tighten the balancer shaft sprocket installation bolt.

7.Install the oil pump chain tensioner.

Caution

• At this stage, do not remove the wire or paper clip installed to the oil pump chain tensioner.

8.Hold the crankshaft using the SST.

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9.Tighten the oil pump driven sprocket installation bolt.

10.Tighten the balancer shaft sprocket installation bolt.

11.Remove the wire or paper clip installed to the oil pump chain tensioner and apply tension to the oil pump chain.

• If a new oil pump chain tensioner is used, remove the installed stopper.

Timing Chain Assembly Note

1.Verify that the timing marks and the key are aligned to the position shown in the figure.

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Note

• The timing mark is not parallel with the upper surface of the cylinder head.

2.Install the timing chain while aligning the marks on each sprocket and the timing chain as shown in the figure.

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3.Install the chain guide (No.1).

4.Install the tensioner arm.

5.Install the chain tensioner.

6.After installing the chain tensioner, remove the installed wire or paper clip, and then apply tension to the timing chain. (Chain tensioner (type A))

• If a new chain tensioner is used, remove the installed stopper.

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7.After installing the timing chain tensioner, remove the installed rod, and then apply tension to the timing chain. (Chain tensioner (type B))

• If a new chain tensioner is used, remove the installed lock pin.

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8.Verify that there is no looseness in the timing chain, and re-verify that each sprocket is in the specified location.

9.Rotate the crankshaft clockwise two turns and inspect the valve timing.

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Note

• The timing mark is not parallel with the upper surface of the cylinder head.

Engine Front Cover Assembly Note

Note

• For a new engine front cover, the positioning pins in the two locations shown in the figure project to the outside of the engine.

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1.If the engine front cover is newly replaced, tap the positioning pins in the two locations to the seal surface side.

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Caution

• If a bolt with sealant adhering to it is used, it could result in cracks in the cylinder head and cylinder block.

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2.When reusing the engine front cover installation bolts, clean any old sealant from the bolts.

Caution

• If oil, dirt and sealant remains on the sealant application area, the silicone sealant will not seal which will cause oil leakage.

3.Completely clean and remove any oil, dirt, silicone sealant or other foreign matter that may be adhering to the engine front cover, cylinder head, and cylinder block.

Caution

• Apply the silicone sealant in a single, unbroken line.

• To prevent silicone sealant from hardening, adhere the engine front cover and the cylinder block firmly within 10 min. after applying silicone sealant. After adhering them, tighten the installation bolts immediately.

4.Install new O-rings to the engine front cover.

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Note

• Install the O-rings so that the tabs of the O-rings recede into the notches.

5.Apply silicone sealant (TB1217D or equivalent) to the engine front cover as shown in the figure.

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Caution

• Apply the silicone sealant so that it goes into the cylinder head gasket.

6.Apply silicone sealant (TB1217D or equivalent) to the areas shown in the figure.

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7.Install the engine front cover to the engine.

Note

• Temporarily install an appropriate bolt to the drive belt auto tensioner installation bolt hole to prevent:

― A silicone sealant adhesion malfunction in the drive belt auto tensioner installation bolt hole.

― A bolt mis-installation due to silicone sealant hardening.

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8.Prepare an appropriate M8 x 1.25 bolt (length 40 mm {1.6 in}).

Caution

• For the number 10 bolt of the tightening order, install the bolt with new washer.

9.Tighten the engine front cover installation bolts in the order shown in the figure.

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Note

• Install stud bolts because there are no stud bolts installed on a new engine front cover.

• If the engine front cover is reused, tighten the stud bolts because they may have loosened.

10.Tighten the engine front cover stud bolts.

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11.Remove the bolt installed to the drive belt auto tensioner installation bolt hole when installing the drive belt auto tensioner.

Oil Pan Assembly Note

1.Completely clean and remove any oil, dirt, sealant or other foreign matter that may be adhering to the cylinder block and oil pan.

2.When reusing the oil pan installation bolts, clean any old sealant from the bolts.

Caution

• Apply the silicone sealant in a single, unbroken line around the whole perimeter.

• To prevent silicone sealant from hardening, adhere the oil pan to the cylinder block within 10 min after silicone sealant is applied. Tighten the installation bolts completely soon after adhering.

• Using bolts with the old silicone sealant adhering could cause cracks in the cylinder block.

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3.Apply silicone sealant (TB1217D or equivalent) to the oil pan along the inside of the bolt holes as shown in the figure.

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4.Install the oil pan using the following procedure:

Caution

• Remove any silicone sealant which oozes out into an oil pan installation bolt hole. If silicone sealant penetrates an oil pan installation bolt hole, the cylinder block could become damaged.

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(1)Install the oil pan to the cylinder block.

(2)Temporarily tighten the two bolts shown in the figure.

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(3)Tighten the bolts in the order shown in the figure.

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Tightening torque

8—11 N·m {82—112 kgf·cm, 71—97 in·lbf}

Front Oil Seal Assembly Note

1.Apply clean engine oil to the inner surface of a new front oil seal.

2.Insert the front oil seal into the engine front cover by hand.

3.Tap the front oil seal in evenly using the SST and a hammer.

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Crankshaft Pulley Lock Bolt Assembly Note

1.Hold the crankshaft using the SST.

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2.Tighten the crankshaft pulley lock bolt in the order shown in the following two steps.

Oil Shower Pipe Assembly Note

1.Install the oil shower pipe in the order shown in the figure.

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Cylinder Head Cover Assembly Note

Caution

• To assure the sealing performance of the cylinder head cover, be careful of the following:

― Verify that the cylinder head cover gasket is inserted into the cylinder head cover groove and install the cylinder head cover.

― Completely clean and remove any oil, dirt, sealant or other foreign matter from the seal surface.

• To prevent silicone sealant from hardening, adhere the cylinder head cover and the cylinder head firmly within 10 min. after applying silicone sealant. After adhering them, tighten the installation bolts immediately.

1.Insert a new cylinder head cover gasket into the cylinder head cover groove.

2.Apply silicone sealant (TB1217D or equivalent) to the areas shown in the figure.

Note

• Apply the silicon sealant so that it does not protrude from the shaded area in the figure.

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3.Install the cylinder head cover.

4.Temporarily tighten the cylinder head cover bolts.

5.Tighten the cylinder head cover bolts in the order shown in the following 3 steps.

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6.Measure the tightening torque again and verify that it is 5.0 N·m {51 kgf·cm, 44 in·lbf} or more.