Repair procedures

Removal

CAUTION:
- Use fender covers to avoid damaging painted surfaces.
- To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

NOTE:
Mark all wiring and hoses to avoid misconnection.

WARNING:
In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and injector, there may be injury caused by leakage of the high pressure fuel. So don't do any repair work right after engine stops.

1. Remove the drive belt.

2. Remove the drive belt idler.

3. Remove the alternator.

4. Remove the alternator bracket.

5. Remove the engine room under cover.
6. Remove the crankshaft damper pulley.

7. Remove the water pump.

8. Remove the air cleaner assembly.
(Intake and Exhaust System - "Air Cleaner")
9. Remove the high pressure fuel pump.

10. Remove the cylinder head cover.

11. Remove the engine mounting support bracket.

12. Remove the timing chain cover(A).






Installation

1. Install the timing chain cover.
(1) Before installing, remove the hardened sealant from the cylinder block and ladder frame surface.
(2) Apply the liquid gasket(TB 1217H or LOCTITE 5900H) on the surface between the cylinder head and the cylinder block.

Width :3 - 5mm (0.1181 - 0.1969in.)




(3) Apply the liquid gasket, THREE BOND 1282B or THREE BOND 1216E on the water pump contact parts (A) of the timing chain cover and THREE BOND 1217H or LOCTITE 5900H on the rest parts (B).
Reassemble the cover within 5 minutes.

Width :3.5 - 4.5 mm (0.1378 - 0.1772 in)

CAUTION:
Remove oil or dust on the surface surely.

(4) Align the dowel pin of the cylinder block and the holes of the oil pump.
(5) Tighten the bolts to install the timing chain cover (A).

Tightening torque
M8 bolts :
18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft)
M6 bolts :
9.8 - 11.8 Nm (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)




2. Install in the reverse order of removal.