1. Install the oil seal to the chain cover.
NOTE:
Use a new oil seal.
| ST 499585700 | OIL SEAL GUIDE |
Oil seal press-fit position:
Chain cover end face — Position of −1 mm (−0.0394 in) from the chain cover end face
|
(A) |
Chain cover |
(B) |
Oil seal |
(C) |
Oil seal press-fit position (Chain cover end face — Position of −1 mm (−0.0394 in) from the chain cover end face) |
2. Attach the scavenger pump and vacuum pump O-ring to the cylinder head.
NOTE:
• Use new O-rings.
• The O-ring is installed between the intake cam sprocket and exhaust cam sprocket.
3. Apply liquid gasket to the mating surfaces of the cylinder block, cylinder head, oil pan upper, and generator bracket as shown in the figure.
Liquid gasket:
THREE BOND 1217G (Part No. K0877Y0100) or equivalent
4. Apply liquid gasket to the mating surface of the chain cover.
NOTE:
Install within 5 min. after applying liquid gasket.
Liquid gasket:
THREE BOND 1217G (Part No. K0877Y0100) or equivalent
Liquid gasket applying diameter:
3.5±0.5 mm (0.1378±0.0197 in)
5. Attach the chain cover, and tighten the bolts in numerical order as shown in the figure.
Tightening torque:
(1) — (36)
10 N·m (1.0 kgf-m, 7.4 ft-lb)
(37) — (39)
33 N·m (3.4 kgf-m, 24.3 ft-lb)
6. Attach the oil level gauge and oil level gauge guide to the chain cover.
NOTE:
• Use a new O-ring to the end of the oil level gauge guide.
• Apply engine oil to the tip of the oil level gauge guide.
Tightening torque:
6.4 N·m (0.7 kgf-m, 4.7 ft-lb)
7. Install the camshaft position sensor. 
8. Install the vacuum pump.
9. Install the scavenger pump.
10. Install the crank pulley.
11. Install the V-belt tensioner.
12. Install the V-belts.
13. Install the catalytic converter and DPF.
14. Install the radiator.
15. Install the radiator main fan motor assembly.
16. Install the radiator sub fan motor assembly.
17. Install the air intake duct and hose.
18. Install the air intake boot.
19. Install the air intake duct.
20. Connect the connector and terminal B to the generator, and attach the collector cover bracket.
Tightening torque:
Collector cover bracket
6.4 N·m (0.7 kgf-m, 4.7 ft-lb)
Generator terminal B
15 N·m (1.5 kgf-m, 11.1 ft-lb)
21. Install the collector cover.
22. Lift up the vehicle.
23. Connect the radiator outlet hose to the radiator.
24. Connect the radiator main fan connector and radiator sub fan connector.
• Radiator main fan connector
• Radiator sub fan connector
25. Attach the water hose and oil balance hose.
|
(A) |
Water hose |
(B) |
Oil balance hose |
26. Install the air intake duct and air duct hose.
Tightening torque:
Air intake duct
3 N·m (0.3 kgf-m, 2.2 ft-lb)
Air intake boot
5 N·m (0.5 kgf-m, 3.7 ft-lb)
|
(A) |
Air intake duct |
(B) |
Air duct hose |
27. Install the turbo protector.
NOTE:
Use a new bolt for bolt (A) shown in the figure below.
Tightening torque:
25 N·m (2.5 kgf-m, 18.4 ft-lb)
28. Install the under cover.
29. Lower the vehicle.
30. Fill engine oil.
31. Fill engine coolant.
32. Connect the ground cable to battery.