Installation

Installation

NOTE:
- Thoroughly clean all parts to be assembled.
- Always use a new head and manifold gasket.
- The cylinder head gasket is a metal gasket. Take care not to bend it.
- Rotate the crankshaft, set the No. 1 piston at TDC.

1. Install the cylinder head gasket (A) on the cylinder block.





NOTE:
Be careful of the installation direction.

2. Place the cylinder head quietly in order not to damage the gasket with the bottom part of the end.
3. Install cylinder head bolts.
(1) Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.
(2) Using 8mm and 10mm hexagon wrench, install and tighten the 10 cylinder head bolts and plate washers, in several passes, in the sequence shown.

Tightening torque
M10 :
22.6 - 26.5 (2.3 - 2.7, 16.6 - 19.5) + (60° ~ 65°) + (60° ~ 65°)
M12 :
27.5 - 31.4 (2.8 - 3.2, 20.3 - 23.1) + (60° ~ 65°) + (60° ~ 65°)





4. Install OCV filter (A).

Tightening torque
40.2 - 50.0Nm (4.1 - 5.1kgf.m, 29.7 - 36.9lb-ft)






NOTE:
Always use a new OCV filter gasket.
Keep clean the OCV filter.

5. Install OCV (A).

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






CAUTION:
- Do not reuse the OCV when dropped.
- Keep clean the OCV.
- Do not hold the OCV sleeve during servicing.
- When the OCV is installed on the engine, do not move the engine with holding the OCV yoke.

6. Install the camshafts.
(1) Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain sprocket as shown.




(2) Install the camshafts (A) and bearing caps (B).

Tightening torque
13.7 - 14.7Nm (1.4 - 1.5kgf.m, 10.1 - 10.8lb-ft)





(3) Install the timing chain auto tensioner (A).

Tightening torque
7.8 - 9.8Nm (0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)





(4) Remove the auto tensioner stopper pin (B).
7. Check and adjust valve clearance.
8. Using the SST (09221-21000), install the camshaft bearing oil seal.




9. Install the camshaft sprocket.
10. Install the timing belt.
11. Install the cylinder head cover.
(1) Install the cylinder head cover gasket (A) in the groove of the cylinder head cover(B).





NOTE:
- Before installing the head cover gasket, thoroughly clean the head cover gasket and the groove.
- When installing, make sure the head cover gasket is seated securely in the corners of the recesses with no gap.

(2) Apply liquid gasket to the head cover gasket at the corners of the recess.





NOTE:
- Use liquid gasket, loctite No. 5999.
- Check that the mating surfaces are clean and dry before applying liquid gasket
- After assembly, wait at least 30 minutes before filling the engine with oil.

(3) Install the cylinder head cover (A) with the 12bolts(B). Uniformly tighten the bolts in several passes.

Tightening torque
7.8 - 9.8N.m (0.8 - 1.0kgf.m, 5.8 - 7.2 lb-ft)





12. Install the intake manifold.
13. Install the exhaust manifold.
14. Install the PCV.
15. Install the spark plug cable. .
16. Install the accelerator and the auto-cruise cables.
17. Install the bake booster hose.
18. Install the PCSV hose.
19. Install the fuel inlet hose (A).




20. Install the engine wire harness connectors and wire harness clamps to the cylinder head and the intake manifold.
(1) Front heated oxygen sensor connector.
(2) Knock sensor connector (D).
(3) Four fuel injector connectors.
(4) CMP connector (C).
(5) PCSV connector (E).
(6) ISA connector (B).
(7) TPS connector (A).




(8) Ignition coil connector (D).
(9) ECT sensor connector (C).
(10) Oil temperature sensor connector (B).
(11) OCV connector (A).




21. Install the heater hoses (A).




22. Install the upper radiator hose (A) and lower radiator hose (B).




23. Install the intake air hose and air cleaner assembly.
24. Install the engine cover (A).




25. Connect the negative terminal to the battery.
26. Fill with engine coolant.
27. Start the engine and check for leaks.
28. Recheck engine coolant level and oil level.