Timing gear train installation (4HK1 (Euro5 specification with DPD))

1. Idle gear shaft installation

1. Apply thread locking adhesive to the bolt.

Note

  • Apply LOCTITE 962T to the threaded area of the 3 bolts shown in the diagram.

2. Install the idle gear B shaft to the cylinder block.

Tightening torque: 31 N・m { 3.2 kgf・m / 23 lb・ft }

3. Apply the engine oil to the idle gear B shaft.

2. Idle gear B installation

1. Install the idle gear B to the idle gear shaft.

Note

  • Install the idle gear B in the direction indicated in the diagram.

2. Tighten the bolt using a torque wrench.

Tightening torque: 110 N・m { 11.2 kgf・m / 81 lb・ft }

  1. Idle gear B
  2. Thrust collar
  3. Bolt

3. Idle gear A installation

1. Align the No.1 cylinder to compression top dead center.

Note

  • Rotate the crankshaft in the forward direction to align the No.1 cylinder piston to the top dead center.

2. Align the idle gear A to the alignment mark.

Note

  • Align the marks on the crankshaft gear and idle gear A.

3. Apply the engine oil to the bolt.

Note

  • Apply it to the threaded portion of the bolts and seat surface.

4. Apply the engine oil to the washer.

Note

  • Apply it to both sides of the washers.

5. Apply the engine oil to the idle gear A.

Note

  • Apply it to the bearing surface of the idle gear A.

6. Install the idle gear A to the cylinder block.

Note

  • Before assembling, be sure to confirm that the threaded portion and seat surface of the bolt and both sides of the washer are completely covered in engine oil.

Tightening torque: 157 N・m { 16.0 kgf・m / 116 lb・ft }

  1. Idle gear C
  2. Camshaft gear
  3. Idle gear B
  4. Power steering oil pump gear
  5. Power steering oil pump idle gear
  6. Crankshaft gear
  7. Oil pump drive gear
  8. Supply pump gear
  9. Idle gear A

4. Flywheel housing installation

1. Clean the cylinder block using a scraper.

Note

  • Clean the cylinder block back side.
  • Particularly, clean the liquid gasket that projects out when the crankcase is installed.

2. Apply liquid gasket to the cylinder block.

Note

  • As shown in the drawing, uniformly apply ThreeBond 1207B to the inside of the bolt hole other than those indicated by the arrow.

3. Install the flywheel housing to the cylinder block.

Note

  • Position the cylinder block knock pin to install the flywheel housing.

Tightening torque: 96 N・m { 9.8 kgf・m / 71 lb・ft } Bolt 1, 2

Tightening torque: 38 N・m { 3.9 kgf・m / 28 lb・ft } Bolt 3

Note

  • 3 in the diagram indicates tightening from the cylinder block side.

5. Oil pan installation

1. Apply liquid gasket to the cylinder block.

Note

  • Apply liquid gasket to the aligning surfaces of the cylinder block, front cover and flywheel housing.
  • Liquid gasket used: ThreeBond 1207B

Bead width: 3 mm { 0.12 in }

Caution

  • After applying the liquid gasket, install the oil pan within 5 minutes.

2. Install the oil pan gasket to the cylinder block.

Note

  • Use the flywheel housing, the front cover and the crankcase stud as a guide to assemble the oil pan gasket.

3. Install the oil pan to the cylinder block.

4. Install the rubber to the oil pan.

Note

  • Install the oil pan rubber assembly to the oil pan and fix it by tightening the bolt and nut.

  1. Oil pan rubber
  2. Oil pan
  3. Oil pan gasket

Note

  • After tightening the 1, 2, 3, and 4 locations in the diagram, tighten the others.
  • No particular order is required.

Tightening torque: 11 N・m { 1.1 kgf・m / 97 lb・in }

Caution

  • Recheck the tightening of the oil pan drain plug.

5. Connect the connector to the oil level switch.

6. Insulator installation

1. Install the insulator to the flywheel housing.

  1. Insulator
  2. Right side flywheel housing stay
  3. Flywheel mounting bolt
  4. Left side flywheel housing stay

7. Flywheel housing stay installation

1. Install the flywheel housing stay to the flywheel housing and the crankcase.

Tightening torque: 76 N・m { 7.7 kgf・m / 56 lb・ft } Flywheel installation bolt

Tightening torque: 48 N・m { 4.9 kgf・m / 35 lb・ft } Cylinder block installation bolt A

Tightening torque: 76 N・m { 7.7 kgf・m / 56 lb・ft } Cylinder block installation bolt B

  1. Right side flywheel housing stay
  2. Left side flywheel housing stay
  3. Flywheel mounting bolt
  4. Cylinder block installation bolt A
  5. Cylinder block installation bolt B

8. Idle gear installation

1. Apply the engine oil to the idle gear shaft.

Note

  • Apply it to the gear assembly sections of the idle gear shaft.

2. Install the idle gear shaft to the idle gear.

Note

  • Assemble the power steering oil pump idle gear and shaft.

3. Install the idle gear to the cylinder block.

Note

  • Install the power steering oil pump idle gear and tighten it at its specified torque.

Tightening torque: 134 N・m { 13.7 kgf・m / 99 lb・ft }

9. Idle gear cover installation

1. Install the O-ring to the idle gear cover.

2. Install the idle gear cover to the flywheel housing.

Note

  • Tighten the bolts to the specified torque.

Tightening torque: 19 N・m { 1.9 kgf・m / 14 lb・ft }

10. Crankshaft rear oil seal installation

1. Prepare special tool.


SST: 5-8840-2703-0 - oil seal installer kit

Note

  • Use the contents of the following table for the rear oil seal.
No.Parts numberNameSlingerOil seal
15-8840-2708-0Sleeve
25-8840-2709-0Adapter
35-8840-2710-0Collar
45-8840-2711-0Adapter ring-
55-8840-2713-0Center bolt
65-8840-2714-0Fixing bolt

  1. Slinger
  2. Fixing bolt
  3. Center bolt
  4. Sleeve
  5. Collar
  6. Adapter

Note

  • An engine sleeve 5-8840-2712-0 for engines before '93 May models is included in the oil seal installer kit, but it will not be used with this engine.

2. Install the slinger to the adapter.

Note

  • Insert the slinger to the leading end of the rear adapter.

3. Install the collar to the fixing bolt.

4. Install the adapter to the crankshaft.

  1. Collar
  2. Fixing bolt
  3. Adapter

5. Install the sleeve to the adapter.

Note

  • Put the sleeve on the adapter.

6. Install the center bolt to the sleeve.

Note

  • Tighten it until the sleeve touches the adapter and firmly fit the slinger.

7. Inspect the slinger.

Note

  • After firmly fitting in the slinger, measure the dimension from the crankshaft end to the oil seal lip touching surface.

Standard: 17.0 to 17.6 mm { 0.6693 to 0.6929 in }

  1. Crankshaft
  2. Adapter
  3. 17.0 - 17.6 mm (0.6693 - 0.6929 in)
  4. 10.7 - 10.9 mm (0.4213 - 0.4291 in)
  5. Slinger
  6. Sleeve
  7. Collar

8. Check fluctuation of the slinger.

Note

  • Check there is no fluctuations the 4 directions.

Caution

  • Be careful not to mistake the slinger assembly direction and the front and rear.
  • There is a right, 4-thread screw cut at the rear side, and a left, 4-thread screw cut at the front side.
  • Always replace the slinger and oil seal as a set.

9. Prepare special tool.

  1. Adapter
  2. Fixing bolt
  3. Center bolt
  4. Sleeve
  5. Collar
  6. Adapter ring
  7. Oil seal

10. Install the color to the fixing bolt.

11. Install the adapter to the crankshaft.

  1. Collar
  2. Fixing bolt
  3. Adapter

12. Apply the engine oil to the crankshaft rear oil seal.

Note

  • Apply a thin coat of it to the lip section of the oil seal.

13. Install the crankshaft rear oil seal to the adapter.

Note

  • Set it to the rear adapter.

14. Install the adapter ring to the sleeve.

Note

  • Put the rear adapter ring into the sleeve.

15. Install the center bolt to the sleeve.

  1. Sleeve
  2. Adapter ring

Note

  • Tighten the center bolt all the way to the end until the sleeve touches the adapter, and firmly fit the rear oil seal.

16. Inspect the crankshaft rear oil seal.

Note

  • After firmly fitting the rear oil seal, measure the dimension from the crankshaft end surface to the oil seal surface.

Standard: 7.5 to 8.1 mm { 0.2953 to 0.3189 in }

  1. Crankshaft
  2. Oil seal
  3. 7.5 - 8.1 mm (0.2953 - 0.3189 in)
  4. Collar
  5. Adapter ring
  6. Sleeve
  7. Adapter

17. Check fluctuation of the crankshaft rear oil seal.

Note

  • Check there is no fluctuations the 4 directions.

11. Flywheel installation

Note

  • The following is for the manual transmission vehicles

1. Install the flywheel to the crankshaft.

Note

  • Align to the crankshaft knock pin, and install the flywheel.

2. Install the washer to the flywheel.

3. Apply the disulfide molybdenum grease to the bolt.

Note

  • Apply the disulfide molybdenum grease to the threaded portion and seat surface of the bolt.

4. Install special tool to the flywheel housing.

Note

  • Install the crankshaft stopper onto the flywheel housing starter mounting position.


SST: 5-8840-2230-0 - crankshaft stopper

5. Securely tighten the flywheel to the crankshaft.

Note

  • Tighten the bolts in the order shown in the diagram.

6. Tighten the bolt using a torque wrench.

Tightening torque: 78 N・m { 8.0 kgf・m / 58 lb・ft }

7. Tighten the bolt using special tool.


SST: 5-8840-0266-0 - angle gauge

Specified angle: 120 to 150 °

12. Flexible plate installation

Note

  • The following is for Smoother vehicles

1. Install the spacer to the crankshaft.

Note

  • Align to the crankshaft knock pin to install the spacer.

2. Install the flexible plate to the crankshaft.

Note

  • Align the flexible plate to the spacer center holes and knock pin and install.

3. Install the washer to the flywheel.

Note

  • Align the washer to the knock pin to install.

4. Install special tool to the flywheel housing.

Note

  • Install the crankshaft stopper onto the flywheel housing starter mounting position.


SST: 5-8840-2230-0 - crankshaft stopper

5. Securely tighten the flexible plate to the crankshaft.

Note

  • Tighten the bolts in the order shown in the diagram.

6. Tighten the bolt using a torque wrench.

Tightening torque: 78 N・m { 8.0 kgf・m / 58 lb・ft }

7. Tighten the bolt using special tool.


SST: 5-8840-0266-0 - angle gauge

Specified angle: 120 to 150 °

  1. Flexible plate
  2. Washer
  3. Bolt
  4. Spacer
  5. Crankshaft

13. CKP sensor installation

1. Install the CKP sensor to the flywheel housing.

Tightening torque: 8 N・m { 0.8 kgf・m / 71 lb・in }

14. Power steering oil pump assembly installation

1. Install the power steering oil pump assembly to the flywheel housing.

Note

  • Install the power steering pump and tighten it at its specified torque.

Tightening torque: 43 N・m { 4.4 kgf・m / 32 lb・ft } Flywheel housing section bolt

Tightening torque: 44 N・m { 4.5 kgf・m / 32 lb・ft } Cylinder block section

Note

  • The following is for vehicles without HBB

  1. Flywheel housing section bolt
  2. Cylinder block section bolt

Note

  • The following is for vehicles with HBB

  1. Flywheel housing section bolt
  2. Cylinder block section bolt

15. Vacuum pump assembly installation

1. Install the key to the shaft.

Note

  • Install the key to the vacuum pump shaft.

2. Install the gear to the shaft.

Note

  • Insert the gear into the shaft and tighten the nut at the specified torque.

Tightening torque: 137 N・m { 14.0 kgf・m / 101 lb・ft }

  1. Vacuum pump assembly
  2. Key
  3. O-ring
  4. Gear
  5. Nut

3. Align the No.1 cylinder to compression top dead center.

Note

  • Rotate the crankshaft in the forward direction to align the No.1 cylinder piston to compression top dead center.

4. Remove the plug from the flywheel housing.

5. Install the O-ring to the vacuum pump assembly.

6. Install the vacuum pump to the cylinder block.

Note

  • Align the vacuum pump side casting burr and gear slit.
  • Use the cylinder block stud bolt as a guide to assemble the vacuum pump.
  • Look through the access hole of the flywheel housing to check that the gear slit is near the center of the hole.

Caution

  • If the slit is mis-positioned, do it again.

  1. Casting burr
  2. Slit
  3. Slit location before insertion
  4. Slit location after insertion
  5. Access hole
  6. Vacuum pump

Note

  • After assembling the vacuum pump, the assembly is correct if a line joining the center of the pawl as shown in the diagram, is angled approximately 15 degrees to the level surface of the engine, when looking from the engine front side.

  1. Cylinder block
  2. Vacuum pump
  3. Approx. 15 degrees
  4. Claw

7. Securely tighten the vacuum pump assembly to the cylinder block.

Tightening torque: 40 N・m { 4.1 kgf・m / 30 lb・ft } M10 nut

Tightening torque: 48 N・m { 4.9 kgf・m / 35 lb・ft } M10 bolt

Tightening torque: 76 N・m { 7.7 kgf・m / 56 lb・ft } M12 bolt

Caution

  • Tighten in diagonal order.

16. Supply pump bracket installation

1. Install the O-ring to the fuel supply pump.

2. Install the supply pump bracket to the fuel supply pump.

Note

  • Tighten the bolts in the diagonal order.

Tightening torque: 19 N・m { 1.9 kgf・m / 14 lb・ft }

17. Supply pump coupling assembly installation

1. Install the key to the shaft.

Note

  • Install it to the supply pump shaft.

2. Install the supply pump coupling assembly to the fuel supply pump.

3. Fasten the bolt to the supply pump coupling assembly.

Note

  • Tighten and fix the 2 bolts in the screw holes of the supply pump coupling assembly.

4. Tighten the nut using a torque wrench.

Tightening torque: 64 N・m { 6.5 kgf・m / 47 lb・ft }

  1. Supply pump
  2. Key
  3. O-ring
  4. Supply pump bracket
  5. Nut
  6. Supply pump coupling assembly
  7. Flange bolt

18. Fuel supply pump installation

1. Install the coupling to the vacuum pump.

Note

  • Fit in the coupling with the damper to the vacuum pump.

Caution

  • Check that the coupling rubber dampers are assembled facing alternately.

2. Install the O-ring to the supply pump bracket.

3. Install the fuel supply pump to the vacuum pump.

Caution

  • Install it after aligning the supply pump and the coupling groove of the vacuum pump.
  • Confirm that there is no gap between the supply pump and the vacuum pump, and then tighten the bolt.

Note

  • Tighten the bolts in diagonal order at the specified torque.

Tightening torque: 51 N・m { 5.2 kgf・m / 38 lb・ft }

  1. Fuel supply pump
  2. O-ring
  3. Coupling
  4. Vacuum pump

4. Apply the engine oil to the O-ring.

5. Install the O-ring to the plug.

6. Install the plug to the flywheel housing.

Tightening torque: 8 N・m { 0.8 kgf・m / 71 lb・in }

  1. Plug
  2. O-ring

20. Cylinder head gasket installation

Note

  • Clean the piston head and cylinder block top surface.

1. Measure the piston using a dial gauge.

Note

  • Measure the protrusion amount of the piston.
  • Perform the measurement in 2 places on each cylinder.
  • The measuring positions of the piston head and reference points on the cylinder block side are shown in the diagram below.

  1. Reference point on the top of the cylinder block
  2. 50°
  3. 20°
  4. Measurement point on the piston head
  5. 100 mm { 3.94 in }
  6. 70 mm { 2.76 in }
  7. Measurement point on the piston head
Measurement pointsPiston head4, 7 in the diagram
Reference pointsCylinder block top surface1 in the diagram

2. Calculate average value from measured value.

Note

  • Calculate the average value for the protrusion amount of piston for each cylinder.
  • Find the maximum of the average values of the cylinders.

3. Select the cylinder head gasket.

Note

  • Select the gasket of the appropriate grade using the maximum value.

Caution

  • In the following table, note that there are 3 selections for the piston protrusion amount on the head gasket.

  1. Grade identification hole

4. Apply liquid gasket to the cylinder block.

Note

  • As shown in the diagram, apply ThreeBond 1207B to the aligning surfaces of the cylinder block and flywheel housing.

Bead width: 3 mm { 0.118 in }

Caution

  • After applying the liquid gasket, install the cylinder head within 5 minutes.

  1. Liquid gasket application position

5. Install the cylinder head gasket to the cylinder block.

Note

  • Set the side of the cylinder head gasket marking with the part number facing upward, position and install the cylinder head rear side gear case and dowel together.

21. Cylinder head assembly installation

1. Install the cylinder head assembly to the cylinder block.

Note

  • Position with the cylinder block dowel to gently install the cylinder head assembly.

Caution

  • When installing, do not damage the cylinder head gasket.

2. Apply the disulfide molybdenum grease to the bolt.

Note

  • Apply disulfide molybdenum to the threaded portion of the M14 head bolts and seat surface.

3. Apply the engine oil to the bolt.

Note

  • Apply engine oil to the threaded portion of the M10 head bolts and seat surface.

4. Install the head bolt to the cylinder head.

Note

  • 1 to 18 in the diagram indicate M14 bolts.
  • 19 and 20 in the diagram indicate M10 bolts.
  • 16 in the diagram indicates using a bolt with stud.

5. Tighten the head bolt using a torque wrench.

Note

  • Tighten the M14 bolts 1 to 18 in the order shown in the diagram.

Tightening torque: 98 N・m { 10.0 kgf・m / 72 lb・ft }

6. Tighten the head bolt using a torque wrench.

Note

  • Tighten the M14 bolts 1 to 18 in the order shown in the diagram.

Tightening torque: 147 N・m { 15.0 kgf・m / 108 lb・ft }

7. Tighten the head bolt using special tool.

Note

  • Use an angle gauge to tighten the M14 bolts 1 to 18 in the order shown in the diagram.


SST: 5-8840-0266-0 - angle gauge

Specified angle: 30 to 60 °

8. Tighten the head bolt using a torque wrench.

Note

  • Tighten the M10 bolts 19 and 20 shown in the diagram.

Tightening torque: 38 N・m { 3.9 kgf・m / 28 lb・ft }

22. Bridge installation

1. Apply the engine oil to the bridge.

2. Install the bridge to the cylinder head.

Caution

  • Move it up and down to confirm that it moves smoothly.

23. Bridge cap installation

1. Apply the engine oil to the bridge cap.

Note

  • Thinly apply it to the inner surface of the bridge cap.

2. Install the bridge cap to the bridge.

Caution

  • Do not drop the bridge cap into the cylinder head rear-side gear case or front side oil return hole.

  1. Bridge cap
  2. Bridge

24. Injector installation

1. Install the gasket to the injector.

2. Install the injector to the cylinder head.

25. Injector clamp installation

1. Apply the disulfide molybdenum grease to the bolt.

Note

  • Apply the disulfide molybdenum grease to the threaded portion and seat surface of the injector clamp bolt.

2. Install the injector clamp to the cylinder head.

Note

  • Install the injector clamp and temporarily tighten the injector clamp bolt.

  1. O-ring
  2. Injector
  3. Injector clamp bolt
  4. Injector clamp
  5. O-ring
  6. Gasket

26. Idle gear C installation

Caution

  • When disassembling the idle gear C, assemble it while paying attention to the following points because it is difficult to position the idle gear C shaft.

1. Align the No.1 cylinder to compression top dead center.

Note

  • Position the marking on the crank pulley and the alignment mark on the front cover and set to compression top dead center of the the No.1 cylinder.

  1. Alignment mark
  2. Marking

2. Apply the engine oil to the idle gear C.

Note

  • Apply engine oil to the inner circumference of the idle gear C bushing and the thrust bearing surface.

3. Install the idle gear C to the cylinder head.

Note

  • With the idle gear B assembled, insert the idle gear C from above the cylinder head.

4. Apply the engine oil to the shaft.

Note

  • Apply it to the outer circumference of the shaft.

5. Install the shaft to the idle gear C.

Note

  • Pass from the cylinder head rear surface hole to the gear center hole.

6. Apply the engine oil to the thrust collar.

Note

  • Apply it to the both sides of the thrust collar.

7. Apply the disulfide molybdenum grease to the bolt.

Note

  • Apply it to the threaded portion and seat surface.

8. Temporarily tighten the idle gear C to the cylinder head.

Note

  • Install it together with the thrust collar.

Tightening torque: 40 N・m { 4.1 kgf・m / 30 lb・ft }

9. Loosen the bolt using special tool.

Note

  • Loosen the idle gear C installation bolt using an angle gauge.


SST: 5-8840-0266-0 - angle gauge

Specified angle: 30 to 90 °

  1. Insertion direction
  2. Shaft
  3. Thrust collar
  4. Bolt
  5. Idle gear C
  6. Bushing

10. Install the camshaft bearing to the cylinder head.

Note

  • Install the camshaft bearing lower.

11. Apply the engine oil to the camshaft bearing.

Note

  • Apply it to the inner circumference of the bearing.

12. Install the camshaft to the cylinder head.

Note

  • Assemble the camshaft with the gear installed to mesh with the idle gear C installed to the cylinder head.
  • Install it so that the alignment mark B on the camshaft gear matches the top surface of the cylinder head when the marking on the crank pulley and alignment mark on the front cover are aligned.

13. Install the camshaft bearing to the camshaft bearing cap.

Note

  • Install the camshaft bearing upper.

14. Apply the engine oil to the bolt.

Note

  • Apply it to the threaded portion of the cap bolt.

15. Apply the engine oil to the nut.

Note

  • Apply it to the threaded portion of the cap nut.

16. Install the camshaft bearing cap to the cylinder head.

Note

  • Assemble the caps #2, #3, #4, and #5 of 1 indicated in the diagram.

Tightening torque: 27.5 N・m { 2.8 kgf・m / 20 lb・ft } Cap bolt

Tightening torque: 27.5 N・m { 2.8 kgf・m / 20 lb・ft } Cap nut

Caution

  • Do not assemble the rocker arm.

  1. Camshaft bearing cap

17. Adjust the idle gear shaft.

Note

  • Manually rotate the camshaft gear in the left direction when looking from the engine rear, gently mesh the idle gear C to the direction of the arrow in the diagram, and set the idle gear C shaft position.

Caution

  • Do not force too much when rotating the camshaft gear as backlash can excessively build up.

  1. Camshaft gear
  2. Idle gear C
  3. Idle gear B

18. Securely tighten the idle gear C to the cylinder head.

Tightening torque: 71 N・m { 7.2 kgf・m / 52 lb・ft } Idle gear C bolt

Caution

  • When tightening, be careful that the idle gear C shaft position does not move a lot.

19. Adjust the idle gear C.

Caution

  • After tightening the idle gear C, check the backlash to ensure that the backlash is within the standard value below.

Standard: 0.015 to 0.146 mm { 0.00059 to 0.00575 in }

Note

  • If the camshaft gear does not move with rattling when manually moving the camshaft, the backlash may excessively be built up.
  • If the camshaft gear does not move, check the backlash and readjust the backlash.
  • If the backlash cannot be adjusted, assemble with the service idle gear C shaft 8-97186-398-1.

20. Remove the camshaft bearing cap from the cylinder head.

21. Remove the camshaft from the cylinder head.

Note

  • After inspecting the removed caps and bearings, temporarily reassemble them so they do not become mixed with other parts.

22. Check the backlash of the idle gear C.

Note

  • Use a large-sized flat-blade screwdriver, etc., to check the backlash of the idle gear C while holding down the idle gear B.

Standard: 0.015 to 0.146 mm { 0.00059 to 0.00575 in }

23. Install the camshaft bearing to the cylinder head.

Note

  • Install the camshaft bearing lower.

24. Apply the engine oil to the camshaft bearing.

Note

  • Apply it to the inner circumference of the bearing.

25. Install the camshaft to the cylinder head.

Note

  • Assemble the camshaft with the gear installed to mesh with the idle gear C installed to the cylinder head.
  • Install it so that the alignment mark B on the camshaft gear matches the top surface of the cylinder head when the marking on the crank pulley and alignment mark on the front cover are aligned.

26. Install the camshaft bearing to the camshaft bearing cap.

Note

  • Install the camshaft bearing upper.

27. Apply the engine oil to the bolt.

Note

  • Apply to the threaded portion and seating surface of the cap bolt.

28. Apply the engine oil to the nut.

Note

  • Apply to the threaded portion and seating surface of the cap nut.

29. Install the camshaft bearing cap to the cylinder head.

Note

  • Assemble the caps #2, #3, #4, and #5 of 1 indicated in the diagram.

Tightening torque: 27.5 N・m { 2.8 kgf・m / 20 lb・ft } Cap bolt

Tightening torque: 27.5 N・m { 2.8 kgf・m / 20 lb・ft } Cap nut

Caution

  • Do not assemble the rocker arm.

  1. Camshaft bearing cap

30. Remove the camshaft bearing cap from the cylinder head.

Note

  • Remove the camshaft bearing cap end once, and assemble with the rocker arm shaft assembly.

27. Camshaft installation

1. Align the No.1 cylinder to compression top dead center.

Note

  • Rotate the crankshaft in the forward direction to align the No.1 cylinder piston to the compression top dead center.

2. Apply the engine oil to the camshaft bearing.

Note

  • Apply it to the camshaft bearing lower.

3. Install the camshaft bearing to the cylinder head.

Note

  • Install the camshaft bearing lower.

4. Align the camshaft gear to the alignment mark.

Note

  • Align the camshaft gear end surface and the B mark on the top of the cylinder head.

5. Install the camshaft to the cylinder head.

6. Check the alignment mark of the camshaft gear.

Caution

  • After tightening, check again that the B marks are aligned.

7. Install the camshaft bearing to the camshaft bearing cap.

Note

  • Install the camshaft bearing upper.

8. Apply the engine oil to the camshaft bearing.

Note

  • Apply it to the camshaft bearing upper.

9. Install the camshaft bearing cap to the cylinder head.

Note

  • Face the bearing cap front mark to the engine front side, and install it in numbered order to the cylinder head.

Note

  • Apply engine oil to the threaded portion and seating surface and tighten the bearing cap to the specified torque.

Tightening torque: 27.5 N・m { 2.8 kgf・m / 20 lb・ft }

28. Rocker arm shaft assembly installation

1. Install the bridge cap to the bridge.

Note

  • If the bridge cap is removed, apply engine oil to the inside of the bridge cap, and assemble to the bridge.

Caution

  • Do not drop the bridge cap into the cylinder head rear-side gear case or front side oil return hole.

  1. Bridge cap
  2. Bridge

2. Turn the adjust screw.

Note

  • Loosen the adjust screw of the rocker arm.

3. Apply the engine oil to the roller.

Note

  • Apply it to the rocker arm roller.

4. Install the rocker arm shaft assembly to the cylinder head.

Note

  • Slightly loosen the bolt indicated by the arrow to make installation easier.

5. Apply the engine oil to the bolt.

Note

  • Apply to threads.

6. Apply the engine oil to the nut.

Note

  • Apply to threads.

7. Temporarily tighten the bolt to the rocker arm shaft.

Note

  • Temporarily tighten the rocker arm shaft assembly tightening bolts 2 and 3 in the diagram below.

8. Temporarily tighten the nut to the rocker arm shaft.

Note

  • Temporarily tighten the rocker arm shaft assembly tightening bolt 1 in the diagram below.

9. Securely tighten the rocker arm shaft assembly to the cylinder head.

Note

  • Gradually tighten the whole rocker arm shaft assembly so that it becomes level.
Tightening torque
Nut 1: 27.5 N・m { 2.8 kgf・m / 20 lb・ft }
Bolt 2: 27.5 N・m { 2.8 kgf・m / 20 lb・ft }
Bolt 3: 56 N・m { 5.7 kgf・m / 41 lb・ft }
Bolt 4: 27.5 N・m { 2.8 kgf・m / 20 lb・ft }

  1. Nut
  2. Bolt
  3. Bolt
  4. Bolt

29. Rocker arm shaft assembly adjustment

1. Loosen the adjust screw using the driver.

Note

  • Completely loosen each adjust screw of the bridge and the rocker arm.

2. Align the No.1 cylinder to compression top dead center.

Note

  • Rotate the crankshaft in the forward direction.
  • Align the mark on the crank pulley and the alignment mark of the front cover.

3. Adjust the valve clearance.

Caution

  • Be sure to work while the engine is cool.

Clearance: 0.4 mm { 0.016 in } Inlet valve

Clearance: 0.4 mm { 0.016 in } Exhaust valve

Note

  • When the No.1 cylinder is at the compression top dead center, a circle is marked in the table for adjustment of valve clearance.
Cylinder No.1234
INEXINEXINEXINEX
When the No.1 cylinder is at the compression top dead center



Note

  • Measurement point when the No.1 cylinder is at the compression top dead center

Caution

  • Adjust so that the bridge is level.

Note

  • Insert a thickness gauge set to the specified value between the rocker arm tip and the cap, and tighten the rocker arm adjust screw.

Standard: 0.4 mm { 0.016 in }

Note

  • When the movement of the feeler gauge becomes stiff, fasten the adjust screw nut of the rocker arm.

Tightening torque: 22 N・m { 2.2 kgf・m / 16 lb・ft }

Note

  • When lightly tightening the bridge adjust screw while the feeler gauge is inserted, check that the leading end of the adjust screw and the valve shaft touch and that the movement of the feeler gauge is stiff.

Note

  • Next, check whether the valve shaft end on the opposite side is floating, or touching at an angle.
  • If it is floating or touching at an angle, slightly loosen the bridge adjust screw and adjust the valve shaft ends on both sides to touch properly.

Valve bridge clearance: 0.1 mm { 0.004 in }

Note

  • When both sides of the valve shaft have been adjusted to touch properly, use a flat-blade screwdriver to tighten the bridge adjust screw nut so that it does not rotate.

Tightening torque: 22 N・m { 2.2 kgf・m / 16 lb・ft }

Caution

  • If the bridge adjust screw adjustment is poor, the bridge will be pushed downward at an angle causing problems of seizure or breakage of the bridge guide, so make sure to perform accurate adjustment.

4. Align the No.4 cylinder to compression top dead center.

Note

  • Rotate the crankshaft in the forward direction 360 degrees.
  • Align the mark on the crank pulley and the alignment mark of the front cover.

5. Adjust the valve clearance.

Note

  • When the No.4 cylinder is at the compression top dead center, adjust the valve clearance marked with X in the chart in the same manner.
Cylinder No.1234
Valve arrangementINEXINEXINEXINEX
When the No.4 cylinder is at the compression top dead center


××
××

Note

  • Measurement point when the No.4 cylinder is at the compression top dead center

30. Common rail (fuel rail) assembly installation

1. Install the common rail (fuel rail) assembly to the common rail (fuel rail) bracket.

Tightening torque: 22 N・m { 2.2 kgf・m / 16 lb・ft } Nut side

Tightening torque: 24 N・m { 2.4 kgf・m / 18 lb・ft } Bolt side

31. FRP sensor connect

1. Connect the connector to the FRP sensor.

32. Injection pipe installation

1. Apply the engine oil to the nut.

Note

  • Thinly apply engine oil to the outer circumference of the injector side sleeve nut.

2. Install the injection pipe to the injector and the common rail (fuel rail) assembly.

Note

  • Lightly tighten the sleeve nut with an open-end wrench so that the sleeve nut is airtight to the injector and the common rail (fuel rail) side.

3. Install the clip to the bracket.

Note

  • Tighten the injection pipe clip at the specified torque.

Tightening torque: 8 N・m { 0.8 kgf・m / 71 lb・in }

  1. Injection pipe
  2. Injection pipe clip

4. Securely tighten the injector clamp to the cylinder head.

Note

  • Tighten the injector clamp which is temporarily tightened earlier at the specified torque.

Tightening torque: 30 N・m { 3.1 kgf・m / 22 lb・ft }

5. Securely tighten the injection pipe to the injector and the common rail (fuel rail) assembly.

Tightening torque: 30 N・m { 3.1 kgf・m / 22 lb・ft } Injector side

Tightening torque: 25 N・m { 2.5 kgf・m / 18 lb・ft } Common rail (fuel rail) side

  1. Clamp bolt
  2. Injection pipe

33. Dummy glow plug installation

Note

  • The following applies to models without glow plugs.

1. Install the dummy glow plug to the cylinder head.

Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }

34. Glow plug installation

Note

  • The following applies to models with glow plugs.

1. Install the glow plug to the cylinder head.

Tightening torque: 20 N・m { 2.0 kgf・m / 15 lb・ft }

Caution

  • Do not tighten excessively because tightening beyond the standard may cause damage.

2. Install the glow plug connector to the glow plug.

Tightening torque: 1.0 N・m { 0.10 kgf・m / 9 lb・in }

35. CMP sensor installation

1. Install the CMP sensor to the cylinder head.

Tightening torque: 8 N・m { 0.8 kgf・m / 71 lb・in }

2. Connect the connector to the CMP sensor.

36. Water bypass hose installation

1. Install the water bypass hose to the cylinder head.

37. Engine coolant temperature sensor connect

1. Connect the engine coolant temperature sensor harness to the thermostat housing.

  1. Water bypass hose
  2. Engine coolant temperature sensor

38. Fuel leak off pipe assembly installation

1. Connect the fuel leak-off pipe assembly to the cylinder head.

Tightening torque: 12 N・m { 1.2 kgf・m / 106 lb・in }

2. Install the fuel leak-off pipe assembly to the common rail (fuel rail) assembly and the fuel supply pump.

Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }

3. Connect the fuel hose to the fuel leak-off pipe assembly.

Note

  • Install the leak-off hose to the leak-off pipe and fasten with the clips.

39. Nozzle leak off pipe installation

1. Install the nozzle leak off pipe to the cylinder head assembly and the injector.

Note

  • Fit the new gasket onto the nozzle leak-off pipe, and install leak-off pipe.

Tightening torque: 27 N・m { 2.8 kgf・m / 20 lb・ft } Cylinder head side

Tightening torque: 15 N・m { 1.5 kgf・m / 11 lb・ft } Injector side

2. Install the bracket to the cylinder head assembly.

Note

  • Install the injector harness connector from the inside, and tighten the harness bracket at the specified torque.

Tightening torque: 48 N・m { 4.9 kgf・m / 35 lb・ft }

3. Install the nut to the injector.

Note

  • Install the terminal nut.

Tightening torque: 2 N・m { 0.2 kgf・m / 18 lb・in }

Caution

  • Uniformly tighten the nuts by alternately tightening the nuts separately 2 to 3 times.
  • Do not over-tighten the nut as the terminal stud can be damaged.

  1. Injector
  2. Harness
  3. Terminal nut

40. Cam end gasket installation

1. Apply liquid gasket to the cam end gasket.

Note

  • Apply ThreeBond 1207B to the area 2 indicated in the diagram.

Bead width: 3 to 4 mm { 0.118 to 0.157 in }

2. Apply liquid gasket to the cylinder head.

Note

  • Apply ThreeBond 1207B to the area 2 indicated in the diagram.

Bead width: 3 to 4 mm { 0.118 to 0.157 in }

  1. Cam end gasket
  2. Liquid gasket application area

3. Install the cam end gasket to the cylinder head.

41. Lower cover installation

1. Install the gasket to the lower cover.

2. Install the lower cover to the cylinder head.

Tightening torque: 18 N・m { 1.8 kgf・m / 13 lb・ft }

3. Connect the harness connector to the lower cover.

Note

  • Install the injector harness connector.

Caution

  • Push in until the locking claw is completely raised.

  1. Lower cover
  2. Injector harness connector

42. Cylinder head cover installation

1. Install the gasket to the cylinder head cover.

2. Install the cylinder head cover to the lower cover.

Note

  • Install the cylinder head cover and tighten in the order shown in the diagram.

Tightening torque: 18 N・m { 1.8 kgf・m / 13 lb・ft }

43. Sound insulation cover installation

1. Install the sound insulation cover to the cylinder head cover.

Tightening torque: 8 N・m { 0.8 kgf・m / 71 lb・in }

  1. Sound insulation cover
  2. Cylinder head cover

44. A/C compressor assembly installation

1. Install the A/C compressor assembly to the A/C compressor bracket.

Note

  • Install the compressor as shown in the diagram and tighten at the specified torque.

Tightening torque: 24 N・m { 2.4 kgf・m / 18 lb・ft }

2. Connect the harness connector to the A/C compressor assembly.

45. A/C compressor drive belt installation

1. Install the A/C compressor drive belt to the A/C compressor assembly.

46. A/C compressor drive belt adjustment

1. Adjust tension to a standard value using a tension meter.

Note

  • When adjusting the tension of the belt, do so for both the cooling fan belt and the A/C compressor drive belt.

Caution

  • After adjusting the cooling fan belt, adjust the A/C compressor drive belt.

Note

  • Loosen the tension pulley lock nut.
  • Turn the tension pulley adjust bolt to adjust the belt.
Belt typesAdjustment conditionsFor flex amountSonic tension meter
Amount of flexFrequency of vibrations
A/C compressor drive beltFor a new product: 18 to 23 mm { 0.71 to 0.91 in }: 59 to 73 Hz
When reused: 24 to 27 mm { 0.94 to 1.06 in }: 51 to 59 Hz

Note

  • After adjusting, tighten the adjust plate lock nut at the specified torque.

Tightening torque: 27 N・m { 2.8 kgf・m / 20 lb・ft }

47. Oil drain pipe connect

1. Install the O-ring to the oil drain pipe.

2. Connect the oil drain pipe to the turbocharger assembly.

Note

  • Tighten the bolts to the specified torque.

Tightening torque: 9 N・m { 0.9 kgf・m / 80 lb・in }

48. Water feed pipe connect

1. Connect the water feed pipe to the turbocharger assembly.

Note

  • Install the eye bolt and tighten the eye bolt at the specified torque.

Tightening torque: 27 N・m { 2.8 kgf・m / 20 lb・ft }

49. Water return pipe connect

1. Connect the water return pipe to the turbocharger assembly.

Note

  • Install the eye bolt and tighten the eye bolt at the specified torque.

Tightening torque: 27 N・m { 2.8 kgf・m / 20 lb・ft }

50. Turbocharger feed oil pipe connect

1. Connect the turbocharger feed oil pipe to the turbocharger assembly.

Note

  • Install the eye bolt at the top of the turbocharger and tighten the eye bolt at the specified torque.

Tightening torque: 17 N・m { 1.7 kgf・m / 13 lb・ft }

51. EGR cooler assembly installation

1. Install the EGR duct to the EGR valve and the cylinder head.

Note

  • Install the gasket and temporarily fasten the EGR cooler duct.

2. Install the EGR cooler assembly to the EGR duct.

Note

  • Insert the gasket between the EGR cooler assembly, the 2nd and EGR cooler duct, and temporarily fasten it in place.

3. Install the EGR duct to the exhaust manifold and the cylinder head.

Note

  • Install the gasket and temporarily fasten the EGR cooler duct.

4. Install the EGR cooler assembly to the EGR duct.

Note

  • Temporarily install gaskets on both sides of the EGR cooler assembly 1st.
  • After inserting each bolt, temporarily tighten bolts 2 to 7 at the specified torque using a tool.

Tightening torque: 4 N・m { 0.4 kgf・m / 35 lb・in }

Note

  • The procedure is the same as the tightening order indicated in the diagram.
  • Temporarily tighten bolts 8 to 14 until bolts 8 to 14 are not seated.
  • Then, tighten the bolts 2 to 14 at the specified torque as shown below.
  • EGR valve and inlet cover bolt 2

Tightening torque: 24 N・m { 2.4 kgf・m / 18 lb・ft }

Note

  • Tighten the EGR cooler duct, EGR cooler assembly and exhaust EGR cooler duct at the specified torque in the order shown in the diagram.
  • EGR valve and EGR cooler duct bolt 3

Tightening torque: 24 N・m { 2.4 kgf・m / 18 lb・ft }

Note

  • EGR cooler duct and cylinder head bolt 4

Tightening torque: 104 N・m { 10.6 kgf・m / 77 lb・ft }

Note

  • EGR cooler assembly 1st and rear EGR cooler bracket bolt 5

Tightening torque: 40 N・m { 4.1 kgf・m / 30 lb・ft }

Note

  • EGR cooler duct and EGR cooler assembly 2nd bolt 6

Tightening torque: 28 N・m { 2.9 kgf・m / 21 lb・ft }

Note

  • EGR cooler assembly 1st and EGR cooler assembly 2nd bolt 7
  • Nut 8 - Nut 11 of the exhaust EGR cooler duct and exhaust manifold

Tightening torque: 35 N・m { 3.6 kgf・m / 26 lb・ft }

Note

  • Exhaust EGR cooler duct and EGR cooler assembly 1st bolt 12

Tightening torque: 28 N・m { 2.9 kgf・m / 21 lb・ft }

Note

  • EGR cooler exhaust bracket and front EGR cooler bracket bolt 13

Tightening torque: 40 N・m { 4.1 kgf・m / 30 lb・ft }

Note

  • Exhaust EGR cooler duct and EGR cooler exhaust bracket bolt 14

Tightening torque: 40 N・m { 4.1 kgf・m / 30 lb・ft }

52. EGR heat protector installation

1. Install the EGR heat protector to the EGR duct.

Note

  • Tighten at the specified torque.

Tightening torque: 10 N・m { 1.0 kgf・m / 89 lb・in }

53. Water rubber hose connect

1. Connect the water rubber hose to the EGR cooler assembly.

Note

  • Connect the water pipe and rubber hose.
  • Install the clip to the specified position.

54. Oil level gauge guide tube installation

1. Install the oil level gauge guide tube to the crankcase.

55. Oil level gauge installation

1. Install the oil level gauge to the oil level gauge guide tube.

56. Radiator upper hose connect

1. Connect the radiator upper hose to the water outlet pipe.

Tightening torque: 5 N・m { 0.5 kgf・m / 44 lb・in }

57. Intake hose connect

1. Connect the intake hose to the turbocharger assembly.

Note

  • Tighten the hose clamp at the specified torque.

Tightening torque: 7.5 N・m { 0.8 kgf・m / 66 lb・in }

Caution

  • Use a new hose clamp.

58. Air duct connect

1. Connect the air duct to the turbocharger assembly.

Note

  • Tighten the clamp at the specified torque.

Tightening torque: 8 N・m { 0.8 kgf・m / 71 lb・in }

Caution

  • Use a new clamp.

59. PCV pipe connect

1. Connect the PCV pipe to the air duct.

Tightening torque: 9 N・m { 0.9 kgf・m / 80 lb・in }

2. Connect the connector to the actuator.

Note

  • Install the connector to the turbocharger actuator.

  1. Bolt
  2. PCV pipe
  3. Clamp
  4. Intake hose
  5. Clamp
  6. Connector

61. Starter motor installation

1. Install the starter motor to the clutch housing.

Note

  • Install the starter motor to the clutch housing with a bolt, and tighten at the specified torque.

Tightening torque: 127 N・m { 13.0 kgf・m / 94 lb・ft }

2. Connect the earth cable to the starter motor.

Note

  • Connect the front frame harness connector.

62. Engine ground cable connect

1. Connect the engine ground cable to the frame.

63. Coolant filling

1. Remove the plug from the water outlet pipe.

Note

  • Remove the air bleeding plug from the water outlet pipe.
  • Except for light-duty 4WD models

  1. Radiator cap
  2. Air bleeder plug

2. Disconnect the water rubber hose from the EGR cooler.

3. Replenish the radiator with coolant.

Note

  • Fill with coolant of the specified concentration up to the brim of the air bleeder plug.

Caution

  • Fill slowly to prevent air from entering the system.

Note

  • For EGR coolers with air bleeding plugs, remove the EGR cooler air bleeding plug, and with the amount that the radiator cap inlet water level has dropped, fill with tap water up to the brim and then reinstall the air bleeding plug.

  1. EGR cooler
  2. Air bleeder plug

4. Connect the water rubber hose to the EGR cooler.

5. Install the plug to the water outlet pipe.

Note

  • Install the air bleeding plug to the water outlet pipe.

Tightening torque: 23.5 N・m { 2.4 kgf・m / 17 lb・ft }

Note

  • While manually press the radiator upper hose several times to remove air from inside the hose, refill with an amount of engine coolant equivalent to the level between the remaining coolant and the radiator cap inlet.

Caution

  • Repeat until the coolant level no longer decreases.

Note

  • The following applies to 2WD models.

6. Install the radiator cap to the radiator.

  1. Radiator cap

Note

  • The following applies to 4WD models.

7. Install the radiator cap to the outlet pipe.

  1. Radiator cap (Radiator side)
  2. Radiator cap (Engine side)
  3. Upper hose

8. Remove the reserve tank cap from the radiator reserve tank.

9. Replenish the radiator reserve tank with coolant.

Note

  • Fill the radiator reserve tank with coolant up to the MAX line.

  1. Radiator reserve tank
  2. MAX line
  3. MIN line

10. Install the reserve tank cap to the radiator reserve tank.

11. Start the engine.

Caution

  • Idle the engine for at least 5 minutes.

12. Deactivate the engine.

Note

  • The following applies to 2WD models.

13. Remove the radiator cap from the radiator.

  1. Radiator cap

Note

  • The following applies to 4WD models.

14. Remove the radiator cap from the outlet pipe.

Caution

  • Remove from the engine side radiator cap for light-duty 4WD models.

  1. Radiator cap (Radiator side)
  2. Radiator cap (Engine side)
  3. Upper hose

15. Replenish the radiator with coolant.

Note

  • Fill with coolant up to the brim of the radiator cap inlet with an amount of coolant equal to the difference between the current coolant level and the radiator cap.
  • The following applies to 2WD models.

16. Install the radiator cap to the radiator.

  1. Radiator cap

Note

  • The following applies to 4WD models.

17. Install the radiator cap to the outlet pipe.

  1. Radiator cap (Radiator side)
  2. Radiator cap (Engine side)
  3. Upper hose

18. Start the engine.

Note

  • Turn the heater fan OFF and warm-up the engine by raising the engine speed.
  • Increase the engine speed to around 2000 rpm and run the engine for 5 minutes once the needle of the engine coolant temperature gauge reaches the center.

19. Inspect the thermostat.

Note

  • Touch the radiator upper hose, and confirm that the coolant in the hose has become warm.

Caution

  • If the radiator upper hose has not become warm, raise the engine speed to continue to warm it up.
  • Do not try determining it by using only an engine coolant temperature gauge and the hot air coming out of the heater.

Caution

  • Idle the engine for 5 minutes or more.

20. Deactivate the engine.

Note

  • Stop the engine and let it cool.
  • Check that the engine coolant has sufficiently cooled.

Warning

  • Do not loosen the radiator cap or reserve tank cap when coolant is hot, as doing so may result in burns caused by the release of steam or hot water.

Note

  • The following applies to 2WD models.

21. Remove the radiator cap from the radiator.

  1. Radiator cap

Note

  • The following applies to 4WD models.

22. Remove the radiator cap from the outlet pipe.

Caution

  • Remove the engine side radiator cap for light-duty 4WD models.

  1. Radiator cap (Radiator side)
  2. Radiator cap (Engine side)
  3. Upper hose

23. Replenish the radiator with coolant.

Note

  • Fill with coolant up to the brim of the radiator cap inlet with an amount of coolant equal to the difference between the current coolant level and the radiator cap.
  • The following applies to 2WD models.

24. Install the radiator cap to the radiator.

  1. Radiator cap

Note

  • The following applies to 4WD models.

25. Install the radiator cap to the outlet pipe.

  1. Radiator cap (Radiator side)
  2. Radiator cap (Engine side)
  3. Upper hose

Note

  • Repeat steps 18 to 25 until the coolant level no longer lowers.

Caution

  • Refill to the MAX line the following morning if the coolant level of the radiator sub-tank has decreased.

26. Lower the cab.

64. Battery ground cable connect

1. Lower vehicle.

2. Connect the battery ground cable to the battery.

3. Lower the cab.

65. Fuel air bleed

Note

  • Air removal procedure when the fuel runs out
  • Before starting engine

1. Install the hose to the plug.

Note

  • Connect an appropriate hose to the air removal plug of the priming pump.
  • Prepare the fuel pan.

  1. Priming pump
  2. Plug

2. Turn the plug.

Note

  • Sufficiently loosen the air removal plug on the priming pump.

3. Drain air from the fuel feed hose.

Note

  • Press and hold the priming pump until the air is completely removed.

4. Close the plug.

Note

  • Sufficiently tighten the air removal plug on the priming pump.

Caution

  • Tighten the air removal plug and completely wipe away the excess fuel in the vicinity.

5. Supply fuel with the fuel supply pump.

Note

  • Press the priming pump 10 times or more to feed air in the fuel system from the supply pump to the return pipe.

6. Start the engine.

Note

  • Without depressing the accelerator pedal, start the engine and keep the engine running for 5 seconds or longer.

7. Operate the accelerator pedal.

Note

  • Depress the accelerator pedal all the way to rev the engine to its maximum speed and then release the pedal. Repeat this step for several times.

Caution

  • When the removal of the air is insufficient, engine trouble may occur, so make sure to perform all of these procedures.

Note

  • Air removal procedure when the fuel filter was replaced
  • Before starting engine

8. Install the hose to the plug.

Note

  • Connect an appropriate hose to the air removal plug of the fuel filter.
  • Prepare the fuel pan.

  1. Vinyl hose
  2. Plug

9. Turn the plug.

Note

  • Sufficiently loosen the air removal plug on the fuel filter.

10. Drain air from the fuel filter assembly.

Note

  • Press and hold the priming pump until the air is completely removed.

11. Close the plug.

Note

  • Sufficiently tighten the air removal plug on the fuel filter.

Caution

  • Tighten the air removal plug and completely wipe away the excess fuel in the vicinity.

12. Supply fuel with the fuel supply pump.

Note

  • Press the priming pump 20 times or more to feed air in the fuel system from the supply pump to the return pipe.

13. Start the engine.

Note

  • Without depressing the accelerator pedal, start the engine and keep the engine running for 5 seconds or longer.

14. Operate the accelerator pedal.

Note

  • Depress the accelerator pedal all the way to rev the engine to its maximum speed and then release the pedal. Repeat this step for several times.

Caution

  • When the removal of the air is insufficient, engine trouble may occur, so make sure to perform all of these procedures.