TIMING CHAIN ASSEMBLY

id011000505600

1.  Assemble in the order indicated in the table.

belbze00000177

1
Crankshaft sprocket
2
Oil pump chain
3
Oil pump sprocket
(See Oil Pump Sprocket Assembly Note.)
4
Oil pump chain guide (If equipped)
5
Oil pump chain tensioner
6
Seal (If equipped)
7
Timing chain
(See Timing Chain Assembly Note.)
8
Chain guide
9
Tensioner arm
10
Chain tensioner
11
Camshaft sprocket, variable valve timing actuator (With variable valve timing mechanism)
(See Camshaft Sprocket, Variable Valve Timing Actuator (With variable valve timing mechanism) Assembly Note.)
12
Front oil seal
(See Front Oil Seal Assembly Note.)
13
Engine front cover
(See Engine Front Cover Assembly Note.)
14
Drive belt idler pulley (If equipped)
15
Water pump pulley
16
Crankshaft pulley
17
Crankshaft pulley lock bolt
(See Crankshaft Pulley Lock Bolt Assembly Note.)
18
Cylinder head cover
(See Cylinder Head Cover Assembly Note)
19
Spark plug
20
Oil level gauge (If equipped)


Oil Pump Sprocket Assembly Note

1.  Temporarily install the crankshaft pulley and crankshaft pulley lock bolt to the crankshaft, and lock the oil pump against rotation as shown in figure.

belbze00000037

2.  Install the oil pump sprocket, and then remove the crankshaft pulley and crankshaft pulley lock bolt.

Tightening torque
Silver bolt: 20—30 N·m {2.1—3.0 kgf·m, 15—22 ft·lbf}
Black bolt: 26—36 N·m {2.7—3.6 kgf·m, 20—26 ft·lbf}


Timing Chain Assembly Note

1.  Install the SST to the camshaft, then align the No. 1 camshaft position with the TDC.

Europe

belbze00000134

Except Europe

belbze00000135
belbze00000172

2.  Remove the cylinder block lower blind plug.

3.  Install the SST as shown in the figure.

Cylinder block lower blind plug hole diameter: M8

belbze00000202

Cylinder block lower blind plug hole diameter: M10

belbze00000085

4.  Turn the crankshaft clockwise so that the crankshaft is in the No.1 cylinder TDC position.

5.  Install the timing chain.

6.  Install the chain tensioner and remove the retaining wire.

belbze00000086


Camshaft Sprocket, Variable Valve Timing Actuator (With variable valve timing mechanism) Assembly Note

1.  Hold the camshaft using a suitable wrench on the cast hexagon as shown in the figure.

2.  Tighten the camshaft sprocket lock bolt.

belbze00000189

Tightening torque

Bolt type

N·m {kgf·m, ft·lbf}
Washer based bolt
With variable valve timing mechanism : 69—75 {7.1—7.6, 50.9—55.3}
Without variable valve timing mechanism : 89—95 {9.1—9.6, 65.7—70.0}
Bolt and washer assembly
69—75
{7.1—7.6, 50.9—55.3}
Bolt with dent on head
69—75
{7.1—7.6, 50.9—55.3}


Front Oil Seal Assembly Note

1.  Apply clean engine oil to the oil seal.

2.  Push the oil seal slightly in by hand.

3.  Compress the oil seal using the SST and a hammer.

belbze00000088
belbze00000180


Engine Front Cover Assembly Note

1.  Apply silicone sealant to the engine front cover as shown.

Caution
•  Install the engine front cover before the applied silicone sealant starts to harden.
•  Completely remove any oil, dirt, sealant, or other foreign matter adhering to the engine front cover and engine front cover installation surface. If any oil, dirt, sealant, or other foreign matter is not removed from the space between the engine front cover and engine front cover installation surface, it may cause a sealing malfunction.

Without crescent grooves at joint sections of cylinder head and cylinder block

belbze00000178
Thickness
A: 2.2—3.2 mm {0.087—0.12 in}
B: 1.5—2.5 mm {0.06—0.098 in}

With crescent grooves at joint sections of cylinder head and cylinder block (L8, LF)

belbze00000206
Thickness
A: 2.2—3.2 mm {0.087—0.12 in}
B: 1.5—2.5 mm {0.06—0.098 in}
C: 2.2—4.3 mm {0.09—0.16 in}
D: 3.3—4.3 mm {0.13—0.16 in}

With crescent grooves at joint sections of cylinder head and cylinder block (L3, L5)

belbze00000197
Thickness
A: 2.2—3.2 mm {0.087—0.12 in}
B: 1.5—2.5 mm {0.06—0.098 in}
C: 2.2—4.3 mm {0.09—0.16 in}
D: 3.3—4.3 mm {0.13—0.16 in}

2.  Install the cylinder head cover bolts in the order as shown in the figure.

belbze00000091

No.

Tightening torque N·m {kgf·m, ft·lbf}
1—18
8.0—11.5 N·m
{81.6—117.2 kgf·cm, 70.9—101.7 in·lbf}
19—22
40—55 {4.1—5.6, 29.7—40.5}
23 (If equipped)
20—30 {2.1—3.0, 15—22}


Crankshaft Pulley Lock Bolt Assembly Note

1.  Install the SST to the camshaft as shown in the figure.

Europe

belbze00000134

Except Europe

belbze00000135
belbze00000172

2.  Verify that No.1 cylinder is at TDC of the compression stroke. (Position counterweight contacts SST.)

3.  To position the crankshaft pulley, temporarily tighten it and, using a suitable bolt (M6 X 1.0), fix the crankshaft pulley to the engine front cover.

am6zzw00000829

4.  Install the SST to the ring gear to lock the crankshaft against rotation.

belbze00000179

5.  Tighten the crankshaft pulley lock bolt in the order shown in the following two steps using the SST (49 D032 316).

Tightening procedure
1.  96—104 N·m {9.8—10.6 kgf·m, 70.9—76.7 ft·lbf}
2.  87°—93°

6.  Remove the bolt (M6 X 1.0) installed to the crankshaft pulley.

7.  Remove the SST from the camshaft.

8.  Remove the SST from the cylinder block lower blind plug hole.

9.  Remove the SST from the ring gear.

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

•  If not aligned, loosen the crankshaft pulley lock bolt and repeat from Step 1.

11.  Install the cylinder block lower blind plug.

am6zzw00000929

Tightening torque
18—22 N·m {1.9—2.2 kgf·m, 13.3—16.2 ft·lbf}


Cylinder Head Cover Assembly Note

Caution
•  Install the cylinder head cover within 10 min of applying the silicone sealant.

1.  Apply silicone sealant to the mating faces as shown in the figure.

belbze00000094

Thickness
4.0—6.0 mm {0.16—0.23 in}

2.  Install the cylinder head cover with a new gasket.

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

belbze00000095

Tightening torque
8.0 —9.5 N·m {82—96 kgf·cm, 71—84 in·lbf}