Replace the timing chain and • Faulty cylinder head gasket and/or cracking or other damage to the cylinder head andengine block cooling system.. Oil consumption may or may not causethe e
Trang 1ENGINE AND TRANSAXLE ASSEMBLY
CYLINDER HEAD ASSEMBLY
Trang 2Closes (ABDC) 34Opens (BBDC) 46Exhaust valve
Closes (ATDC) 4
Cylinder head
Flatness of gasket surface 0.03mm (0.0012in) for width
0.09mm (0.0035in) for lengthIntake 0.025mm (0.0010in) for width
0.160mm (0.0063in) for length
camshaft Exhaust 35.700 ~ 35.900mm (1.4055 ~ 1.4134in)
Intake 35.537 ~ 35.737mm (1.3991 ~ 1.4070in)
Cam height
RHcamshaft Exhaust 35.452 ~ 35.652mm (1.3957 ~ 1.4036in)
LH camshaft 20.944 ~ 20.960mm (0.8246 ~ 0.8252in)Journal outer
Diameter RH camshaft 20.944 ~ 20.960mm (0.8246 ~ 0.8252in)
Bearing oil clearance 0.040 ~ 0.077mm (0.0016 ~ 0.0030in)
End play 0.10 ~ 0.20mm (0.0039-0.0079in)
Valve
Intake 93.0mm (3.6614in)Valve length
Exhaust 93.7mm (3.6890in)Intake 5.455 ~ 5.470mm (0.2148 ~ 0.2154in)Stem outer
diameter Exhaust 5.435 ~ 5.450mm (0.2140 ~ 0.2146in)
Face angle 45.5 ~ 45.75
Trang 3Description Specifications (D4FA) LimitIntake 1.1mm (0.0433in)
Thickness of
valve head
(margin) Exhaust 1.2mm (0.0472in)
Intake 0.030 ~ 0.057mm (0.0012 ~ 0.0022in)Valve stem to
valve guide
clearance Exhaust 0.050 ~ 0.077mm (0.0020 ~ 0.0030in)
Valve guide
Intake 5.500 ~ 5.512mm (0.2165 ~ 0.2170in)Inner diameter
Exhaust 5.500 ~ 5.512mm (0.2165 ~ 0.2170in)Intake 31.3 ~ 31.7mm (1.2323 ~ 1.2480in)Length
Exhaust 31.3 ~ 31.7mm (1.2323 ~ 1.2480in)
Valve seat
Intake 0.8 ~ 1.4mm (0.0315 ~ 0.0551in)Width of seat
contact Exhaust 1.2 ~ 1.8mm (0.0472 ~ 0.0709in)
31.0±1.6kg/23.5mm(68.3±3.5 lb/0.9252in)
Cylinder block
Cylinder bore 75.000 ~ 75.030mm (2.9528 ~ 2.9539in)
Flatness of gasket surface Less than 0.05mm (0.0020in) (Overhaul)
Less than 0.03mm (0.0012in) (Per 1 Cylinder)
Piston
Piston outer diameter 74.930 ~ 74.960mm (2.9500 ~ 2.9512in)
Piston to cylinder clearance 0.060 ~ 0.080mm (0.0024 ~ 0.0031in)
No 1 ring groove 1.83 ~ 1.85mm (0.0720 ~ 0.0728in)
No 2 ring groove 1.82 ~ 1.84mm (0.0717 ~ 0.0724in)Ring groove
width
Oil ring groove 3.02 ~ 3.04mm (0.1189 ~ 0.1197in)
Piston ring
No 1 ring 0.09 ~ 0.13mm (0.0035 ~ 0.0051in)
No 2 ring 0.08 ~ 0.12mm (0.0031 ~ 0.0047in)Side clearance
Oil ring 0.03 ~ 0.07mm (0.0012 ~ 0.0028in)
No 1 ring 0.20 ~ 0.35mm (0.0079 ~ 0.0138in)
No 2 ring 0.35 ~ 0.50mm (0.0138 ~ 0.0197in)End gap
Oil ring 0.20 ~ 0.40mm (0.0079 ~ 0.0157in)
Piston pin
Piston pin outer diameter 27.995 ~ 28.000mm (1.1022 ~ 1.1024in)
Trang 4Description Specifications (D4FA) LimitPiston pin hole inner diameter 28.004 ~ 28.010mm (1.1025 ~ 1.1028in)
Piston pin hole clearance 0.004 ~ 0.015mm (0.0002 ~ 0.0006in)
Connecting rod small end hole
inner diameter 28.022 ~ 28.034mm (1.1032 ~ 1.1037in)
Connecting rod small end hole clearance 0.022 ~ 0.039mm (0.0009 ~ 0.0015in)
Connecting rod
Connecting rod big end inner diameter 49.000 ~ 49.018mm (1.9291 ~ 1.9298in)
Connecting rod bearing oil clearance 0.025 ~ 0.043mm (0.0010 ~ 0.0017in)
Side clearance 0.050 ~ 0.302mm (0.0020 ~ 0.0119in) 0.4mm (0.0157in)
Crankshaft
Main journal outer diameter 53.972 ~ 53.990mm (2.1249 ~ 2.1256in)
Pin journal outer diameter 45.997 ~ 46.015mm (1.8109 ~ 1.8116in)
Main bearing oil clearance 0.024 ~ 0.042mm (0.0009 ~ 0.0017in)
End play 0.08 ~ 0.28mm (0.0031 ~ 0.110in)
Oil quantity (Total) 5.3 L (5.60 US qt, 4.66 lmp qt)
Oil quantity (Oil pan) 4.8 L (5.07 US qt, 4.22 lmp qt)
Oil quantity (Oil filter) 0.5 L (0.53 US qt, 0.44 lmp qt)
Oil quality Above API CH-4, Above ACEA B4
Oil pressure (Idle) (Oil temperature : 80 C) 78.4kpa (0.8kg/cm², 11.3psi)
Cooling system
Cooling method Forced circulation with cooling fan
Coolant quantity 5.3 ~ 5.5L (5.60 ~ 5.81US qt, 4.66 ~ 4.84lmp qt)
Type Wax pellet typeOpening temperature 85±1.5 C (185.0±2.7 F)
(Lift : 0.35mm(0.0138in))Thermostat
Pull openingtemperature
100 C (212 F)(Lift : 8mm(0.3150in))Main valve opening
pressure
93.16 ~ 122.58kpa(0.95 ~ 1.25kg/cm², 13.51 ~ 17.78psi)Radiator cap
Vacuum valve openingpressure
0.98 ~ 4.90 kpa(0.01 ~ 0.05kg/cm², 0.14 ~ 0.71 psi)
Trang 5Description Specifications (D4FA) Limit
Water temperature sensor
20 C (68 F) 2.45±0.14 kResistance
80 C (176 F) 0.3222 k
Trang 6support bracket fixing bolt 2 68.6 ~ 93.2 7.0 ~9.5 50.6 ~68.7Front roll stopper bracket and sub
frame fixing bolt 3 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0Front roll stopper insulator and front roll stopper
support bracket fixing bolt,nut 1 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0Rear roll stopper bracket and sub
frame fixing bolt 3 49.0 ~ 63.7 5.0 ~ 6.5 36.2 ~ 47.0Rear roll stopper insulator and rear roll stopper
support bracket fixing bolt,nut 1 49.0 ~63.7 5.0 ~6.5 36.2 ~47.0
Main moving system
Connecting rod cap bolt 8 12.7 + 90 1.3 + 90 9.4 + 90Crankshaft main bearing cap bolt (long) 10 24.5 + 90 2.5 + 90 18.1 + 90Crankshaft main bearing cap bolt (short) 10 32.4 ~ 36.3 3.3 ~ 3.7 23.9 ~ 26.8Flywheel bolt (M/T) 8 68.6 ~ 78.5 7.0 ~ 8.0 50.6 ~ 57.9Drive plate bolt (A/T) 8 68.6 ~ 78.5 7.0 ~ 8.0 50.6 ~ 57.9
Timing chain
Timing chain cover bolt (8 X 70) 7 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5Timing chain cover bolt (8 X 60) 2 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5Timing chain cover bolt (8 X 35) 1 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5Timing chain cover bolt (6 X 35) 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7Timing chain cover bolt (6 X 28) 7 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7Timing chain case bolt (8 X 22) 4 24.5 ~ 30.4 2.5 ~ 3.1 18.1 ~ 22.4Timing chain case bolt (8 X 32) 1 18.6 ~ 27.5 1.9 ~ 2.8 13.7 ~ 20.3Timing chain case bolt (6 X 35) 1 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7
Trang 7Cylinder head
Engine cover bolt 4 7.8 ~ 11.8 0.8 ~ 1.2 5.8 ~ 8.7Cylinder head cover bolt 13 6.9 ~ 9.8 0.7 ~ 1.0 5.1 ~ 7.2Camshaft bearing cap bolt (Reamer bolt) 16 12.7 ~ 13.7 1.3 ~ 1.4 9.4 ~ 10.1Camshaft bearing cap bolt (Standard bolt) 6 12.7 ~ 13.7 1.3 ~ 1.4 9.4 ~ 10.1Engine hanger bolt (Front) 2 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1Engine hanger bolt (Rear) 1 47.1 ~ 51.0 4.8 ~ 5.2 34.7 ~ 37.6Cylinder head bolt 10 49.0+90 +120 5.0+90 +120 36.2+90 +120
Cooling system
Water pump pulley bolt 3 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7Water pump bolt (8 X 50) 2 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1Water pump bolt (8 X 70) 1 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1Thermostat housing bolt 1 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7Thermostat housing nut 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7Water return pipe assembly bolt 2 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1Water temperature sensor 1 24.5 ~ 34.3 2.5 ~ 3.5 18.1 ~ 25.3Water outlet fitting nut 2 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1
Lubrication system
Oil filter assembly bolt 4 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5Oil cooler assembly bolt 4 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7
Oil level gauge bolt 1 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5Oil pan bolt (6 X 20) 16 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7Oil pan bolt (6 X 65) 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7Oil pan bolt (6 X 85) 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7Oil pan and transaxle fixing bolt 3 29.4 ~ 41.2 3.0 ~ 4.2 21.7 ~ 30.4Oil pan drain plug 1 34.3 ~ 44.1 3.5 ~ 4.5 25.3 ~ 32.5Oil screen bolt 1 19.6 ~ 26.5 2.0 ~ 2.7 14.5 ~ 19.5Oil screen nut 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7Oil pressure switch 1 14.7 ~ 21.6 1.5 ~ 2.2 10.8 ~ 15.9
Trang 8Tightening torque
Intake and exhaust system
Intake manifold and cylinder head fixing nut 2 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5Intake manifold and cylinder head fixing bolt 7 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5Exhaust manifold and cylinder head fixing nut 8 29.4 ~ 34.3 3.0 ~ 3.5 21.7 ~ 25.3Exhaust manifold heat cover and exhaust
manifold fixing bolt 3 14.7 ~ 19.6 1.5 ~ 2.0 10.8 ~ 14.5WCC assembly fixing nut 3 29.4 ~ 34.3 3.0 ~ 3.5 21.7 ~ 25.3Air cleaner lower cover fixing bolt 3 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2Throttle body and surge tank fixing bolt 4 18.6 ~ 27.5 1.9 ~ 2.8 13.7 ~ 20.3Exhaust manifold and front muffler fixing nut 2 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4Front muffler fixing clip bolt 1 29.4 ~ 39.2 3.0 ~ 4.0 21.7 ~ 28.9Front muffler and center muffler fixing nut 2 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4Center muffler and main muffler fixing nut 2 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4
Trang 9COMPESSION PRESSURE
INSPECTION EA53A61E
NOTE
If the there is lack of power, excessive oil
consump-tion or poor fuel economy, measure the compression
pressure.
1 Warm up and stop engine
Allow the engine to warm up to normal operating
tem-perature
2 Remove the injectors(A) (Refer to FL Gr.)
A
LCGF003A
3 Check the cylinder compression pressure
1) Insert a compression gauge into the injector hole
ECKD001X
2) Fully open the throttle
3) While cranking the engine, measure the
2,059kPa (21.0kg/cm², 298psi)Difference between each cylinder :294.20kPa (3.0kg/cm², 42.67psi) or less
5) If the cylinder compression in 1 or more cylinders
is low, pour a small amount of engine oil into thecylinder through the spark plug hole and repeatstep 1) through 3) for cylinders with low compres-sion
• If adding oil helps the compression, it is likely
that the piston rings and/or cylinder bore areworn or damaged
• If pressure stays low, a valve may be
stick-ing or seatstick-ing is improper, or there may beleakage past the gasket
4 Reinstall the injectors
Trang 10TROUBLESHOOTING E2396869
Loose or improperly installed engine flywheel Repair or replace the flywheel
as required
Worn piston rings
(Oil consumption may or may not causethe engine to misfire.)
Inspect the cylinder for a loss
of compression
Repair or replace as required
Engine misfire with
abnormal internal
lower engine noises
Worn crankshaft thrust bearings Replace the crankshaft and bearings
as required
Stuck valves
(Carbon buildup on the valve stem can causethe valve not to close properly.)
Repair or replace as required
Excessive worn or mis-aligned timing chain Replace the timing chain and
• Faulty cylinder head gasket and/or cracking
or other damage to the cylinder head andengine block cooling system
• Coolant consumption may or may not
cause the engine to overheat
• Inspect the cylinder head and
engine block for damage tothe coolant passages and/or afaulty head gasket
• Repair or replace as required.
Worn valves, valve guides and/or valvestem oil seals Repair or replace as required.
Engine misfire
with excessive oil
consumption
Worn piston rings
(Oil consumption may or may not causethe engine to misfire)
Inspect the cylinder for a loss
of compressionRepair or replace as required
Incorrect oil viscosity Drain the oil
Refill with the correct viscosity oil
Engine noise on
start-up, but only
lasting a few seconds
Worn crankshaft thrust bearing Inspect the thrust bearing and
crankshaft
Repair or replace as required
Low oil pressure Repair or replace as required
Broken valve spring Replace the valve spring
Worn or dirty valve lifters Replace the valve lifters
Stretched or broken timing chain and/ordamaged sprocket teeth
Replace the timing chain and sprockets
Worn timing chain tensioner, if applicable Replace the timing chain tensioner
as required
Worn camshaft lobes Inspect the camshaft lobes
Replace the camshaft and valvelifters as required
Worn valve guides or valve stems Inspect the valves and valve guides,
then repair as required
Upper engine noise,
Trang 11Symptom Suspect area Remedy
Low oil pressure Repair or replace damaged
components as required
Loose or damaged flywheel Repair or replace the flywheel
Damaged oil pan, contacting the oil pump screen Inspect the oil pan
Inspect the oil pump screen
Repair or replace as required
Oil pump screen loose, damaged or restricted Inspect the oil pump screen
Repair or replace as required
Excessive piston-to-cylinder bore clearance Inspect the piston and cylinder bore
Repair as required
Excessive piston pin-to-bore clearance Inspect the piston, piston pin and
the connecting rod
Repair or replace as required
Excessive connecting rod bearing clearance Inspect the following components
and repair as required
• The connecting rod bearings.
• The connecting rods.
• The crankshaft.
• The crankshaft journal.
Excessive crankshaft bearing clearance Inspect the following components
and repair as required
• The crankshaft bearings.
• The crankshaft journals.
Lower engine noise,
Low oil pressure Repair or replace as required
Excessive connecting rod bearing clearance Inspect the following components
and repair as required
• The connecting rod bearings.
• The connecting rods.
• The crankshaft.
Engine noise under
load
Excessive crankshaft bearing clearance Inspect the following components
and repair as required
• The crankshaft bearings.
• The crankshaft journals.
• The cylinder block crankshaft
bearing bore
Trang 12Symptom Suspect area Remedy
Hydraulically locked cylinder
Seized crankshaft or connecting rod bearings Inspect crankshaft and connecting
rod bearing
Repair or replace as required
Bent or broken connecting rod Inspect connecting rods
Repair or replace as required
Engine will not crank
(crankshaft will not
rotate)
Broken crankshaft Inspect crankshaft
Repair or replace as required
Trang 13SPECIAL SERVICE TOOLS E986315E
Torque angle adapter
Trang 14Tool (Number and name) Illustration Use
High pressure pump sprocket remover
LCGF157A
Installation of crankshaft rear oil seal
Front cover oil seal installer
Trang 15Tool (Number and name) Illustration Use
Removal of oil pan
Engine support fixture＆adapter
(09200-38001, 09200-1C000)
AMJF002B
Support of engine
Trang 16TIMING SYSTEM
TIMING CHAIN
COMPONENT E85E1C8A
19.6 ~ 26.5 (2.0 ~ 2.7, 14.5 ~ 19.5)
3 Cylinder head cover
4 Cylinder head gasket
5 Alternator
6 Water pump pulley
7 Engine support bracket
8 Drive belt auto tensioner
14 High pressure pump
15 Timing chain cover
27.5 ~ 29.4 (2.8 ~ 3.0, 20.3 ~ 21.7)
6.9 ~ 9.8 (0.7 ~ 1.0, 5.1 ~ 7.2)
14.7 ~ 19.6 (1.5 ~ 2.0, 10.8 ~ 14.5) 9.8 ~ 11.8
9.8 ~ 11.8 (1.0 ~ 1.2, 7.2 ~ 8.7) 42.2 ~ 53.9
18.6 ~ 27.5 (1.9 ~ 2.8, 13.7 ~ 20.3)
8
11
14
9.8 ~ 11.8 (1.0 ~ 1.2, 7.2 ~ 8.7)
9.8 ~ 11.8 (1.0 ~ 1.2, 7.2 ~ 8.7)
12
19.6 ~ 26.5 (2.0 ~ 2.7, 14.5 ~ 19.5)
Trang 173 Timing chain "C" auto tensioner
4 Timing chain "C" lever
5 Timing chain guide "1"
68.6 ~ 73.5 (7.0 ~ 7.5, 50.6 ~ 54.2)
24.5 ~ 30.4 (2.5 ~ 3.1, 18.1 ~ 22.4) 9.8 ~ 13.7
(1.0 ~ 1.4, 7.2 ~ 10.1)
15
14
7.8 ~ 11.8 (0.8 ~ 1.2, 5.8 ~ 8.7)
23
6 Timing chain guide "2"
7 Timing chain "A"
8 High pressure pump sprocket
9 Crankshaft sprocket
10 Timing chain "A" auto tensioner
11 Timing chain "A" lever
12 Timing chain guide "1"
13 Timing chain case
14 Timing chain case gasket
15 Camshaft sprocket
LDJF002A
Trang 18REMOVAL E5A01FA9
Engine removal is not required for this procedure
1 Remove the drive belt(A)
9 10
13 7
Trang 196 Remove the water pump pulley(A).
LCGF009A
NOTE
Use the SST(flywheel stopper, 09231-2A100)(A) to remove the crankshaft pulley bolt, after remove the starter.
Trang 20LCGF090A
11 Remove the high pressure pump sprocket nut(B) after
remove the timing chain cover plug(A)
LCGF091A
NOTE
• Use the SST(flywheel stopper, 09231-2A100) to
remove the high pressure pump sprocket nut.
A
LCGF090A
• Replace O-ring of plug(A) with a new one when
reinstalling the plug.
12 Remove the high pressure pump pipe(A) (Refer to FLGr.)
Trang 2116 Install the SST(high pressure pump sprocket remover,
09331-2A000)(A) to timing chain cover with three long
bolts(B)
17 Fix the high pressure pump remover(A) and sprocket
stopper(C) with two fixing bolts(D)
18 Rotate the bolt(E) clockwise till high pressure pump is
pushed out
19 Remove the SST(09331-2A000) after remove the
high pressure pump
A
D B
LCGF160A
20 Install the SST(09200-38001, 09200-1C000), the
en-gine support fixture and the adapter, on the enine
hanger bracket
09200-38001 09200-1C000
LCGF150A
21 Remove the jack from oil pan
LDIF001A
22 Remove the oil pan(A)
23 Remove the oil strainer(B)
A B
LCGF010A
NOTE
Using the SST(09215-3C000) and remove the oil pan.
Be careful not damage the contact surtaces of oil pan.
09215-3C000
Trang 2224 Remove the timing chain cover(A)
D D
Remove thoroughly sealant and oil etc left at the
seal-ing surface after remove the chain cover and oil pan.
(If any impurities are left at the sealing face, oil may
leak after reassembly even with the sealant
Before removing auto-tensioner, install a set pin(B)
(ø2.5 mm steel wire) after compressing the tensioner.
26 Remove the timing chain "C" lever(A) and the timingchain guide "1"(B)
Trang 2329 Remove the timing chain "A" auto tensioner(A).
A B
LCGF016A
NOTE
Before removing auto-tensioner, install a set pin(B)
(ø2.5 mm steel wire) after compressing the tensioner.
30 Remove timing chain "A" lever(A) and the timing chain
Trang 2434 Remove the timing chain case(A).
(Engine removal is required for this procedure)
A B
C
D
B
LCGF027A
35 Remove the camshaft sprocket
1) Hold the portion(A) of the camshaft with a
hexagonal wrench, and remove the bolt(C) with
a wrench(B) and remove the camshaft sprocket
Be careful not to damage the cylinder head and
valve lifter with the wrench.
Trang 25INSTALLATION E95FE08A
Engine removal is not required for this procedure
1 Install the camshaft sprocket and tighten the bolt to
the specified torque
1) Temporarily install the camshaft sprocket bolt(C)
2) Hold the portion(A) of the camshaft with a
hexagonal wrench, and tighten the bolt(C) with
2 Install the timing chain case(A) with new gasket
(Engine removal is required for this procedure)
C D B
LCGF027A
3 Install the water pump(A)
Tightening torque :19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.5 ~ 18.1lb-ft)
CAUTION Apply coolant to the o-ring before installing the water pump.
A
LCGF026A
Trang 264 Install the power steering pump bracket(A).
TDC
LCGF093A
8 After install timing chain "A" with high pressure pumpsprocket(B) equipped at the crankshaft sprocket(C),and then install high pressure pump sprocket at thehigh pressure pump shaft
NOTE
The timing mark of high pressure pump sprocket should be aligned with timing mark on the timing chain case.
A B
Trang 2710 Install timing chain "A" lever(A) and the timing chain
11 Install the timing chain "A" auto tensioner(A) and then
remove set pin(B)
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
A B
A
Mark
Mark
LCGF015A
Trang 2814 Install the timing chain guide "2"(A).
A B
Trang 29Use the SST(flywheel stopper, 09231-2A100)(A) to
tighten the high pressure pump sprocket nut, after
re-move the starter.
A
LCGF090A
18 Apply liquid gasket evenly to the mating surface of
timing chain cover
NOTE
• Standard liquid gasket : LOCTITE 5900
• Check that the mating surfaces are clean and dry
before applying liquid gasket.
• Assemble the timing chain cover in 5 minutes
af-ter applying the liquid gasket.
• Apply liquid gasket in a 3mm wide bead without
stopping.
Liquid gasket
LCGF096A
19 Install the timing chain cover(A)
Tightening torque :Bolt (B,C,F) :19.6 ~ 26.5N.m (2.0 ~ 2.7kgf.m, 14.5 ~ 19.5lb-ft)Bolt(D,E) : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
A
C
D D
C B B
D
D D
D D
E E F
Trang 3021 Install the oil strainer(B).
• Standard liquid gasket : LOCTITE 5900
• Check that the mating surfaces are clean and dry
before applying liquid gasket.
• Apply liquid gasket in a 3mm wide bead without
stopping.Assemble the oil pan in 5 minutes after
applying the liquid gasket.
• After assembly, wait at least 30 minutes before
filling the engine with oil.
• Apply liquid gasket to T-joint before assembling
oil pan.
Liquid gasket
LCGF098A
Bed plate Timing chain
cover
T - joint
Timing chain case
LCGF099A
23 Install the oil pan(A)
Tightening torque :9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
24 Set the jack to the engine oil pan
LDIF001A
25 Remove the SST(09200-38001, 09200-1C000), theengine support fixture and the adapter, from the en-gine hanger bracket
09200-38001 09200-1C000
Trang 3126 Install the crankshaft pulley(A) and crankshaft pulley
Use the SST(flywheel stopper, 09231-2A100)(A) to
Install the crankshaft pulley bolt, after remove the
A
LCGF008A
28 Install the engine support bracket(A)
Tightening torque :42.2 ~ 53.9N.m (4.3 ~ 5.5kgf.m, 31.1 ~ 39.8lb-ft)
A
LCGF007A
Trang 3229 Install the water pump pulley(A).
6.5kgf.m, 36.2 ~ 47.0lb-ft)
C
A B
ADJF027A
32 Remove the jack from oil pan
LDIF001A
Trang 3333 Install the cylinder head cover(A) with new head cover
5 4
• Standard liquid gasket : LOCTITE 5900
• Check that the mating surfaces are clean and dry
before applying liquid gasket.
• Apply liquid gasket in a 3mm wide bead without
stopping.
• Assemble the cylinder head cover in 5 minutes
after applying the liquid gasket.
• After assembly, wait at least 30 minutes before
filling the engine with oil.
• Apply liquid gasket to T-joint before assembling
cylinder head cover.
T - joint
Apply liquid gasket
Trang 34ENGINE AND TRANSAXLE
• To avoid damage, unplug the wiring
connec-tors carefully while holding the connector
2) Remove the air cleaner upper cover(B)
A
B
ADJF003A
Trang 353) Disconnect the ECM connector(A) and ECM
con-nector(B) (A/T only)
4) Remove the air cleaner element and air cleaner
lower cover(C)
C
B A
ADJF007A
Trang 3611 Remove the fuel hose(A).
Trang 3717 Remove the engine wire harness connectors and wire
harness clamps from cylinder head and the intake
ADJF014A
3) Disconnect the injector connector(A)
4) Disconnect the EGR(Emission Gas
Recircula-tion) solenoid valve connector(B)
Trang 3812) Disconnect the swirl valve actuator connector(A).
13) Disconnect the fuel pressure regulator connector
15) Remove the ground cable(A) from the engine
mounting and body
A
ADJF020A
18 Remove the transaxle wire harness connectors and
control cable from transaxle (A/T)
1) Disconnect the transaxle range switch connector
(A)
2) Disconnect the vehicle speed sensor
connec-tor(B)
A B
6) Remove the ground cable(C) from the transaxleand body
A B
C
Trang 397) Remove the transaxle control cable(A).
A
ADJF024A
19 Remove the power steering oil hose(A) and drain the
power steering oil
22 Remove the inter cooler lower hose(A)
A
ADJF025A
23 Remove the front muffler heat protector(A)
24 Remove the front muffler(B)
B A
ADJF026A
Trang 4025 Remove the nuts(B,D), bolt(C) and engine mounting
LDJF010A
27 Remove the front tires.(Refer to DS group)
28 Remove the ABS wheel speed sensor(A)