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 OCV filter.





NOTE:
Keep clean the OCV filter.

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





NOTE:
Be careful of the installation direction.

3. Place the cylinder head carefully in order not to damage the gasket with the bottom part of the end.
4. 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 triple square hexagon wrench, install and tighten the 10 cylinder head bolts and plate washers, in several passes, in the sequence shown.

Tightening torque
34.3Nm (3.5kgf.m, 25.3lb-ft) + 90° + 90°


NOTE:
Always use new cylinder head bolt.




5. Install OCV(A) and OTS (B).

Tightening torque
OCV : 9.8 - 11.76Nm(1.0 - 1.2kgf.m, 7.23 - 8.67lb-ft)
OTS : 19.6 - 23.52Nm(2.0 - 2.4kgf.m, 14.46 - 17.35lb-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 CVVT and camshaft sprocket.

Tightening torque
53.9 - 63.7Nm(5.5 - 6.5 kgf.m, 39.7 - 47.0lb-ft)






NOTE:
Hold the hexagonal head wrench portion of the camshaft with a vise, and install the bolt and CVVT assembly.

7. Install camshafts (A).





NOTE:
Apply a light coat of engine oil on camshaft journals.

8. Install camshaft bearing caps in their proper locations.
Tightening order.
Group A -> Group B -> Group C.

Tightening torque
M6 : 10.78 - 12.74Nm(1.1 - 1.3kgf.m, 7.95 - 9.39lb-ft)
M8 : 27.44 - 31.36Nm(2.8 - 3.2kgf.m, 20.24 - 23.14 lb-ft)





9. Install timing chain.
10. Check and adjust valve clearance.
11. Install the exhaust manifold.
12. Install the intake manifold.
13. Install water temp control assembly (A).

Tightening torque
Bolt : 14.7 - 21.56Nm(1.5 - 2.2kgf.m, 10.84 - 15.90lb-ft)
Nut : 19.6 - 26.46Nm(2.0 - 2.7kgf.m, 14.46 - 19.52lb-ft)






NOTE:
- Assemble water temp control assembly and water inlet pipe to water pump assembly before nuts for assembling of water inlet pipe to be tightened.
- Insert after wetting O-ring or inner surface of thermostat housing.
- Always use a new O-ring.

14. Install delivery pipe (A), brake hose(B), and PCSV hose (C).




15. Install the PCSV connector (A), WTS connector (B), condenser connector (C), and CKP sensor connector (D).




16. Install ignition coil connector (A).




17. Install the engine wire harness connectors.
(1) Install the ETC connector(B), CMP connector(C), knock sensor connector(D).




18. Install the injector connectors (A).




19. Install the OCV connector(A), OTS connector(B), P/S switch connector(C).




20. Install the A/C switch (A), alternator connect (B), and oil pressure switch (C).




21. Install heater hoses(A).




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




23. Install under cover.
24. Install the intake air hose and air cleaner assembly.
(1) Install the AFS(B) connector.
(2) Install the breather hose(C) from air cleaner hose.
(3) Install the ECU connector.
(4) Install the intake air hose and air cleaner(A).




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