PR25DD engine: Installation
- Install the valve lifter.
- Install them in the same position from which they were removed.
- If removed, install the camshaft signal plate (INT) and camshaft signal plate (EXH).
- Install the camshaft [INT (2)] and camshaft [EXH (1)].NOTE: The distinction between the intake and exhaust camshaft can be made by the shape of the rear (A) of the exhaust camshaft.
- Install camshaft brackets.
- Install by referring to identification mark on upper surface mark.
- Install so that identification mark can be correctly read when viewed from the exhaust side.
(A)
: Intake side
(B)
: Exhaust side
: Engine front
- Install camshaft bracket (No. 1) and camshaft position sensor bracket.
- Apply a bead of liquid gasket [3.4 - 4.4 mm (0.134-0.173 in)] to camshaft bracket [No. 1 (B)] and camshaft position sensor bracket (A) as shown.
Use Genuine Silicone RTV Sealant or equivalent. Refer to HOW TO USE THIS INFORMATION : Recommended Chemical Products and Sealants .
CAUTION:- The components must be installed within 5 minutes of the liquid gasket application.
- Do not re-tighten bolts after the 5 minutes have elapsed.
- Allow 30 minutes for the liquid gasket to set before adding oil to the engine.
NOTE: Remove liquid gasket that protrudes at locations () shown.
- Apply a bead of liquid gasket [3.4 - 4.4 mm (0.134-0.173 in)] to camshaft bracket [No. 1 (B)] and camshaft position sensor bracket (A) as shown.
- Tighten camshaft bracket bolts in five steps in the order as shown.
Step 1 (bolts 1 - 26)
: 1.96 N.m (0.20 kg-m, 17 in-lb)
Step 2 (bolts 11 - 26)
: 5.88 N.m (0.60 kg-m, 52 in-lb)
Step 3 (bolts 1 - 10)
: 5.88 N.m (0.60 kg-m, 52 in-lb)
Step 4 (bolts 11 - 26)
: 10.41 N.m (1.1 kg-m, 8 ft-lb)
Step 5 (bolts 1 - 10)
: 10.41 N.m (1.1 kg-m, 8 ft-lb)
(A)
: Intake side
(B)
: Exhaust side
CAUTION: After tightening camshaft bracket bolts, be sure to wipe off excessive liquid gasket from the parts listed below.- Mating surface of rocker cover.
- Mating surface of front cover.
- Install the camshaft sprocket [INT (1)] and camshaft [EXH (2)].
- Secure hexagonal part (A) of the camshaft with a suitable tool and tighten the camshaft sprocket bolts to the specified torque.
Camshaft sprocket (INT) bolt
Step 1
: 35.0 N.m (3.6 kg-m, 26 ft-lb)
Step 2
: 28 deg. - 33 deg.
Camshaft sprocket (EXH) bolt
Step 1
: 50.0 N.m (5.1 kg-m, 37 ft-lb)
Step 2
: 45 deg. - 50 deg.
- Secure hexagonal part (A) of the camshaft with a suitable tool and tighten the camshaft sprocket bolts to the specified torque.
- Install the electric valve timing control actuator target into the camshaft sprocket (INT) until the metal ring (A) clips into the groove (B) in the sprocket.CAUTION: Do not reuse electric valve timing control actuator target.NOTE: Apply new engine oil to the electric valve timing control actuator target O-ring if necessary. Make sure that no engine oil is on front face of camshaft sprocket (INT).
- Install the timing chain. Refer to Removal and Installation .
- Install the high pressure fuel pump using the following procedure:
- Rotate the crankshaft pulley (1) clockwise, and align the crankshaft pulley TDC stamp line (no color) (B) with the timing indicator (A).
(C)
: Engraved line (white)
- Check that the flat surface from the high pressure fuel pump mating surface (
) is parallel to the high pressure fuel pump drive cam surface (when the cam is at the lowest position).
- Install a new O-ring onto the high pressure fuel pump.CAUTION:
- Do not reuse O-ring.
- Handle O-ring with bare hands.
- Lubricate O-ring with clean engine oil.
- Do not clean O-ring using solvent.
- Check that the O-ring and its mating part are free of foreign material.
- When installing O-ring, do not scratch it with tool or fingernails. Do not twist or stretch the O-ring.
- Insert O-ring straight into the high pressure fuel pump. Do not decenter or twist it.
- Lubricate high pressure fuel pump lifter and high pressure fuel pump lifter bore with clean engine oil.
- Reinstall the high pressure fuel pump lifter.NOTE: When installing high pressure fuel pump lifter, note the orientation of protrusion (B) and cutout (A) in camshaft bracket, they should be aligned.
- Apply engine oil to the O-ring mating surface on the camshaft bracket and to the O-ring.
- Hand tighten the bolts (A) and then tighten the bolts (A) by alternating sides one rotation at a time until the high pressure fuel pump flange (1) contacts the camshaft bracket.
- Tighten the bolts (A) to the specified torque.
High pressure fuel pump bolts
: 10.0 N.m (1.0 kg-m, 89 in-lb)
- Rotate the crankshaft pulley (1) clockwise, and align the crankshaft pulley TDC stamp line (no color) (B) with the timing indicator (A).
- Install the high pressure fuel tube using the following procedure:CAUTION:
- Do not reuse the high pressure fuel tube.
- If scratches or damage on the end of the high pressure fuel tube are present, do not use it.
- Always tighten in the correct order to the specified tightening torque.
- Check that there is no foreign material on the high pressure fuel tube flare nipple and flare nuts.
- Hand tighten until the high pressure fuel tube (1) flare nuts (A) and (C) contact the seat.CAUTION: When hand tightening the flare nuts, insert them so that they are aligned with the center of the pipe.
- Hand tighten bolt (B).
- Tighten flare nut (A) to the specified torque.
Flare nut
: 23.0 N.m (2.3 kg-m, 17 ft-lb)
- Tighten flare nut (C) to the specified torque.
Flare nut
: 23.0 N.m (2.3 kg-m, 17 ft-lb)
- Again tighten flare nuts to the specified torque in the order of (A) and (C).CAUTION: Before tightening, check that the suitable tool is attached at a 90 deg. angle to the flare nut when working.
Flare nuts
: 23.0 N.m (2.3 kg-m, 17 ft-lb)
- Tighten bolt (B) to the specified torque.
Bolt
: 25.0 N.m (2.6 kg-m, 18 ft-lb)
- Check and adjust valve clearances. Refer to How to Check .
- Installation of the remaining components is in the reverse order of removal.