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2
Turn
crankshaft until
No I
pis
ton
is
at
T D
C
on
its
compression
stroke
3
Make
sure
thai camshaft
sprock
et
location
notch
and plate
oblong
groove
are
aligned
at
their
correct
positions
4
When
installing
cylinder
head
make
sure
that
all
valves
are
apart
from heads of
pistons
5
Do not
rotate
crankshaft and
camshaft
separately
or
valves will
hit
heads of
pistons
6
Temporarily
tighten
two
bolts
CD V
sJiown
in
Fig
re
EM 96
Tightening
torque
2
kg
m
14
ft b
15
Install crankshaft
sprocket
and
oil
pump
drive
gear
and
fit
oil
thrower
Note
Make
sure
lhat
maling
marks of
crankshaft
sprocket
face
10
Cront
16
Install
timing
chain
Noles
a
Make
sure
that crankshaft and
cam
shaft
keys point
upwards
Fuel
pump drive
earn
2
Chain
guide
3
Chain tensioner
4
Crank
sprocket
5
earn
sprocket
6
Chai
guide
EM439
b Set
timing
chain
by
OOgning
its
mating
marks with those oC crank
shaft
sprocket
and camshaft
sprock
et at
the
right
hand side There
are
forty
four chain links between
two
mating
marks of
timing
chain
c
NO 2
hole
is
Cactory
adjusted
When
chain stretches
excessively
adjust
camshaft
sprocket
at
No
3
hole
d Use
a
set
of
timing
marks and
location
hole numbers
Engine
Mechanical
17
Install chain slack side
guide
to
cylinder
block
18
Install chain
tensioner
Note
Adjust protrusion
oC
chain ten
sioner
spindle
to
0
mm
0 in
Fig
EM 98
lmtalling
chain tensioner
19
Press
new
oil seal
in
front
cover
Notes
a
Front
cover
oil seal should be
reo
placed
when Cront
cover
is
disas
sembled
b BeCore
pressing
oil seal into Cront
cover
give
coating
of
engine
oil
to
periphery
of oil seal
c
This
oil
seal
is
a
threaded seal
type
which has
improved sealing
charac
teristics
Do
not
apply
grease
to
sealing
lip
20
Install front
cover
with
gasket
in
place
1
Timing
mark
2
Timing
mark
EM545
Fig
EM 99
Installing
fronl
COlHlr
Notes
a
Apply
sealant
to
Cront
cover
and
corners
oC upper section of
cylinder
block
as
shown in
Figure
EM 78
EM 24
b Install Cront
cover
with head
gasket
in
place
c
Check
height
diCCerence between
cylinder
block upper Cace and Cront
cover
upper Cace
DifCerence
must
be less than
0 1 5
mm
0 0059 in
d
Note that difCerent
types
oC bolts
are
used
e
Before
installing
front
cover
on
cylinder
block
apply
coating
oC
engine
oil
10
sealing lip
of
oil
seal
EMS11
Fig
EM lOD Front
cover
bolts
Tightening
torque
Size M8
0
3 15
in
1
0
to
1
3
kg
m
7
2
to
9
4
ft lb
Size
M6
0
2 36
in
0
4
to
0 6
kg
m
2
9
to 4
3 ft lb
21
Install
crankshaft
pulley
and
water
pump
assembly
then
set
No
I
piston
at
ToO C
on
its
compression
stloke
Crankshaft
pulley
nu I
tightening torque
12
to
16
kg
m
B7
to
116
ft
lb
EM546
Fig
EM Ol
lnstallingcran
haft
pulley
and
water
pump
22
Finally
tighten
head bolts
to
the
specified
torque
in
three
steps
according
to
the
lightening
sequence
shown
in
Figure
EM 96
Note thai
Iwo
types
of bolts
are
used
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