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 OCV filter.
CAUTION:
Keep the OCV filter clean.
2. Install the cylinder head gasket (A) on the cylinder block.
NOTE:
- Be careful of the installation direction.
- Apply liquid gasket (Loctite 5900H) on the edge of cylinder head gasket upside and downside. (At the position 'B')
- After applying sealant, assemble the cylinder head in five minutes.
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.
A. Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.
B. Using the SST(09221-4A000), tighten the cylinder head bolts and plate washers, in several passes, in the sequence shown.
Tightening torque :
32.4 - 36.3Nm (3.3 - 3.7kgf.m, 23.9 - 26.8lb-ft) + (90 - 95°) + (90 - 95°)
CAUTION:
Always use new cylinder head bolt.
5. Install the intake OCV (A).
Tightening torque :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
6. Install the exhaust OCV (A). (Dual CVVT only)
Tightening torque :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
CAUTION:
- Do not reuse the OCV when dropped.
- Keep the OCV filter clean.
- Do not hold the OCV sleeve (A) during servicing.
- When the OCV is installed on the engine, do not move the engine with holding the OCV yoke.
7. Install the camshafts.
NOTE:
Apply a light coat of engine oil on camshaft journals.
(1) Install the exhaust camshaft lower bearing (A). (Dual CVVT only)
(2) Install the camshafts (A).
(3) Install the exhaust camshaft upper bearing (A) to the front bearing cap (A). (Dual CVVT only)
8. Install camshaft bearing caps in their proper locations.
Tightening order.
Group A -> Group B -> Group C.
Tightening torque :
M6 : 10.8 - 12.7N.m(1.1 - 1.3kgf.m, 7.9 - 9.3lb-ft)
M8 : 27.4 - 31.4N.m(2.8 - 3.2kgf.m, 20.2 - 23.1lb-ft)
9. Install the intake CVVT assembly (A) and exhaust CVVT sprocket or camshaft sprocket (B).
[Single CVVT]
[Dual CVVT]
NOTE:
When installing the sprocket bolt or CVVT assembly bolt, fix the camshaft by wrench at position A.
10. Install the water temperature control assembly (A).
Tightening torque :
Bolt : 14.7 - 19.6N.m(1.5 - 2.0kgf.m, 10.8 - 14.5lb-ft)
Nut : 18.6 - 23.5N.m(1.9 - 2.4kgf.m, 13.7 - 17.4lb-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.
11. Install the timing chain.
12. Install the intake and exhaust manifold.
13. Check and adjust the valve clearance.
14. Install cylinder head cover.
(1) The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling cylinder head cover.
(2) After applying sealant, it should be assembled within 5 minutes.
Bead width :2.5mm (0.1in.)
(3) Install the cylinder head cover bolts as following method.
Tightening torque :
1st step : 3.9 - 5.9N.m(0.4 - 0.6kgf.m, 2.9 - 4.3lb-ft)
2nd step : 7.8 - 9.8N.m(0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)
CAUTION:
- Do not reuse cylinder head cover gasket.
- The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was assembled.
15. Install the other parts in the reverse order of removal.
NOTE:
- Refill engine oil.
- Clean the battery posts and cable terminals with sandpaper assemble them, and then apply grease to prevent corrosion.
- Inspect for fuel leakage.
- After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes.
- Repeat this operation two or three times, and then check for fuel leakage at any point in the fuel lines.
- Refill radiator and reservoir tank with engine coolant.
- Bleed air from the cooling system.
- Start engine and let it run until it warms up. (Until the radiator fan operates 3 or 4 times.)
- Turn off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system.
- Put radiator cap on tightly, then run the engine again and check for leaks.