Idle Gear Installation

1. Component Views
Idle gear

Part name

1. Power steering oil pump

2. Idle gear B shaft
3. Idle gear A
4. Idle gear B
5. Power steering oil pump idle gear
6. Idle gear cover
7. Pilot bearing
8. Flywheel
9. Crankshaft rear oil seal
10. Flywheel housing
11. Crankshaft rear slinger
12. Plug
13. CKP sensor
14. Flywheel housing stay (RH)
15. Rubber spacer
16. Flywheel housing stay (LH)
17. Oil pan
18. Air compressor
19. Supply pump bracket
20. Fuel supply pump

Tightening torque

1: 48 N・m { 4.9 kgf・m / 35 lb・ft }

2: 44 N・m { 4.5 kgf・m / 32 lb・ft }

3: 31 N・m { 3.2 kgf・m / 23 lb・ft }

4: 110 N・m { 11.2 kgf・m / 81 lb・ft }

5: 157 N・m { 16.0 kgf・m / 116 lb・ft }

6: 134 N・m { 13.7 kgf・m / 99 lb・ft }

7: 19 N・m { 1.9 kgf・m / 14 lb・ft }

8-1: 78 N・m { 8.0 kgf・m / 58 lb・ft }

8-2: 60 °

8-3: 60 to 90 °

9: 96 N・m { 9.8 kgf・m / 71 lb・ft }

10: 8.0 N・m { 0.8 kgf・m / 71 lb・in }

11: 8.0 N・m { 0.8 kgf・m / 71 lb・in }

12: 48 N・m { 4.9 kgf・m / 425 lb・in }

13: 76 N・m { 7.7 kgf・m / 56 lb・ft } M10

13: 73 N・m { 7.4 kgf・m / 54 lb・ft } M12

14: 76 N・m { 7.7 kgf・m / 56 lb・ft }

15: 11 N・m { 1.1 kgf・m / 8 lb・ft }

16: 73 N・m { 7.4 kgf・m / 54 lb・ft }

17: 51 N・m { 5.2 kgf・m / 38 lb・ft }

18: 19 N・m { 1.9 kgf・m / 14 lb・ft }

19: 40 N・m { 4.1 kgf・m / 30 lb・ft } M10

19: 73 N・m { 7.4 kgf・m / 54 lb・ft } M12

2. Idle Gear Installation

1) Install the idle gear B shaft to the cylinder block.

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

2) Apply engine oil to the idle gear B shaft.

3) Referring to the diagram, install idle gear B to the idle gear shaft.

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

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

4) Rotate the crankshaft in the forward direction (clockwise) to align the No. 1 cylinder piston to
compression top dead center.

Note:
 Check with the crankshaft pulley marking and front cover alignment mark.
 5) Align the alignment markings for the crankshaft gear and idle gear A.

6) Apply engine oil to the threaded portions and seating surfaces of the bolts.

7) Apply engine oil to both sides of the washer.

8) Apply engine oil to the bearing surface of idle gear A.

9) Install idle gear A to the cylinder block.

Caution:
 Before installing, make sure that engine oil is entirely applied to the threaded portion and seating
surface of the bolt and both sides of the washer.

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
 1. Valve clearance adjustment
Caution:

 Perform while the engine is cold.

 The bridge makes contact with 2 valves and is horizontal.

Standard: 0.4 mm { 0.016 in } Inlet valve

Standard: 0.4 mm { 0.016 in } Exhaust valve

Measurable valve position

Cylinder #1 #2 #3 #4
position IN EX IN EX IN EX IN EX
No. 1
cylinder
compression ○ ○ ○ ○
top dead
center
No. 4
cylinder
compression ○ ○ ○ ○
top dead
center

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

Measurement point when the No.4 cylinder is at the compression top dead center
1) Completely loosen the adjust screws of the bridge and rocker arm.

2) Rotate the crankshaft in the forward direction (clockwise) to align the No. 1 cylinder piston to
compression top dead center.
1. Front cover marking
2. Crankshaft pulley marking

3) Insert the feeler gauge between the adjust screw and the bridge cap.

1. Rocker arm
2. Rocker arm side adjust screw
3. Rocker arm side adjust screw lock nut
4. Feeler gauge
5. Bridge side adjust screw
6. Bridge side adjust screw lock nut.

4) Tighten the rocker arm side adjust screw, and adjust the valve clearance to the specified value.

Standard: 0.4 mm { 0.016 in }

5) Secure the rocker arm side adjust screw with the lock nut.

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

 6) Lightly screw in the bridge side adjust screw with the feeler gauge inserted.

7) Confirm that the bridge shaft end contacts the adjust screw end, and that the movement of the feeler
gauge becomes stiff.

8) Lightly loosen the bridge side adjust screw so that movement of the feeler gauge becomes
appropriate.

Note:

 If the bridge has risen up or is contacting at an angle, slightly loosen the bridge adjust screw and
adjust so that the valve shaft ends on both sides contact properly.

Standard: 0.1 mm or less { 0.004 in or less } Valve bridge clearance

Caution:

 Adjust the clearance between the end of the valve shaft and the end of the adjust screw to within the
specified value.
 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.

9) Secure the bridge side adjust screw with the lock nut.

Tightening torque: 21.7 N・m { 2.2 kgf・m / 16 lb・ft }

10) Rotate the crankshaft 1 turn, and adjust any remaining valve clearance with the No. 4 cylinder
positioned at the compression top dead center.

4. Injector Harness Installation

1) Install the harness bracket and injector harness as a set to the cylinder head.

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

2) Connect the connector to the lower cover.

 3) Install the injector terminal nut to the injector.

Caution:

 Uniformly tighten the nuts by alternately tightening the nuts separately 2 to 3 times.
 Do not over-tighten the injector terminal nut as it will break the terminal stud.

Tightening torque: 2.0 N・m { 0.2 kgf・m / 18 lb・in }

1. Injector
2. Harness
3. Injector terminal nut

5. Lower Cover Installation

1) Referring to the diagram, apply ThreeBond 1207B to the cam end gasket and cylinder head.

Caution:

 Clean the application surface of the gasket before applying the gasket.

Standard: 3.0 to 4.0 mm { 0.118 to 0.157 in } Bead height

Standard: 3.0 to 4.0 mm { 0.118 to 0.157 in } Bead width

 1. Cam end gasket
2. Liquid gasket

2) Install the cam end gasket to the cylinder head.

3) Install the gasket to the lower cover.

4) Install the lower cover to the cylinder head.

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

5) Connect the injector harness connector to the lower cover.

Caution:

 Push in until the locking claw is completely raised.

1. Lower cover
2. Injector harness connector