Repair Procedures

Removal

[2.0 Non-BSM]
1. Remove the timing chain.
2. Remove the oil pump mechanical tensioner (B).
3. Remove the oil pump chain guide (D).




4. Remove the oil pump (A) and oil pump chain.





[2.4 BSM]
1. Remove the timing chain.


NOTE:

2. Install a set pin after compressing the balance shaft chain tensioner.
3. Remove the balance shaft chain hydraulic tensioner (A).
4. Remove the balance shaft chain tensioner arm (B).
5. Remove the balance shaft chain guide (C).




6. Remove the oil pump & balance shaft module (A) and balance shaft chain (B).





CAUTION:
Do not disassemble the oil pump & balance shaft module.

Installation

[2.0 Non-BSM]




1. The key of crankshaft should be aligned with the mating face of main bearing cap. As a result of this, the piston of No.1 cylinder is placed at the top dead center on compression stroke.
2. Assemble the crankshaft sprocket on the crankshaft as the front mark on the crankshaft sprocket to be outward.
3. Tighten the oil pump tensioner bolt(A) after placing the tensioner spring on the dowel pin located in ladder frame, and then insert stopper pin to fix the tensioner(B).

Tightening torque :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)

4. Assemble the oil pump chain on the crankshaft sprocket.
5. Assemble the oil pump assembly (C) on the ladder frame as placing oil pump sprocket in to oil pump.

Tightening order
[M8*79 bolt type]
(1) Tighten the bolts in order number as shown with seating torque 25.5 N.m (2.6 kgf.m, 18.8 lb-ft) and then loosen the bolts as reverse tightening order (3-2-1).
(2) Tighten the bolts as specified tightening order in same increments as follows.

Tightening torque
1 step :
6.9 - 10.8 N.m (0.7 - 1.1 kgf.m, 5.1 - 8.0 lb-ft)
2nd step :
14.7 - 18.6 N.m (1.5 - 1.9 kgf.m, 10.8 - 13.7 lb-ft)
3rd step :
23.5 - 27.4 N.m (2.4 - 2.8 kgf.m, 17.4 - 20.2 lb-ft)

[M9*181.5 bolt type]
(1) Tighten the bolts in order number as shown with seating torque 29.4 N.m (3.0 kgf.m, 21.7 lb-ft) and then loosen the bolts as reverse tightening order (3-2-1).
(2) Tighten the bolts as specified tightening order in same increments as follows.

Tightening torque
1 step :
7.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 5.8 - 8.7 lb-ft)
2nd step :
17.7 - 11.6 N.m (1.8 - 12.2 kgf.m, 13.0 - 15.9 lb-ft)
3rd step :
27.5 - 31.4 N.m (2.8 - 3.2 kgf.m, 20.3 - 23.1 lb-ft)




6. Install the oil pump chain guide (D) then remove the stopper pin.

Tightening torque :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)

[2.4 BSM]
1. The key of crankshaft should be aligned with the mating face of main bearing cap. As a result of this, the piston of No.1 cylinder is placed at the top dead center on compression stroke.
2. Confirm the balance shaft & oil pump module timing mark.
Timing marks to be visually aligned with centers of adjacent cast timing notches.




3. Install balance shaft & oil pump module (A) with the chain (B) and sprocket (C).





NOTE:
The timing marks of balance shaft & oil pump module sprocket and crankshaft sprocket should be matched with the timing marks (color link) of balance shaft chain.





Tightening order
[4 Bolts TYPE]
A. Tighten the bolts in order number as shown with seating torque 25.5 N.m (2.6 kgf.m, 18.8 lb-ft) and then loosen the bolts as reverse tightening order (4-3-2-1).
B. Using the SST (09221-4A000), tighten the bolts as specified tightening order in same increments as follows.

Tightening torque
M8*179 :
14.7 - 18.6 N.m (1.5 - 1.9 kgf.m, 10.8 - 13.7 lb-ft) + 58 - 62° + 58 - 62°
M9*181.5 :
22.6 - 26.5 N.m (2.3 - 2.7 kgf.m, 16.6 - 19.5 lb-ft) + 103° ~ 107°





[6 Bolts TYPE]
A. Tighten the bolts in order number as shown with seating torque 29.4 N.m (3.0kgf.m, 21.7 lb-ft) and then loosen the bolts as reverse tightening order (6-5-4-3-2-1).
B. Using the SST (09221-4A000), tighten the bolts as specified tightening order in same increments as follows.

Tightening torque
M9*181.5 (A) :
22.6 - 26.5 N.m (2.3 - 2.7 kgf.m, 16.6 - 19.5 lb-ft) + 88 - 92°
M9*95 (B) :
22.6 - 26.5 N.m (2.3 - 2.7 kgf.m, 16.6 - 19.5 lb-ft) + 43 - 47°




4. Install the balance shaft chain guide (D).

Tightening torque :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)

5. Install the balance shaft chain tensioner arm (C).

Tightening torque :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)

6. Install the balance shaft chain hydraulic tensioner (B) then remove the stopper pin (A).

Tightening torque :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)




7. Confirm the timing marks.