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.





CAUTION:
Keep clean the OCV filter.

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 mark (B).
- After applying sealant, assemble the cylinder head in fire 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 triple square hexagon wrench, install and tighten the 10 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°)






NOTE:
Always use new cylinder head bolt.

5. Install the OCV(A).

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 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.

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

A. Install the exhaust camshaft lower bearing (A).




B. Install the camshafts (A).




C. Install the exhaust camshaft upper bearing (A).




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

Tightening torque
Step 1
M6 : 5.9N.m( 0.6kgf.m, 4.3lb-ft)
M8 : 14.7N.m( 1.5kgf.m, 10.8lb-ft)
Step 2
M6 : 10.8 - 12.7N.m(1.1 - 1.3kgf.m, 7.9 - 9.4lb-ft)
M8 : 27.5 - 31.4N.m(2.8 - 3.2kgf.m, 20.3 - 23.1lb-ft)





7. Install the water temp 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 - 2.4 kgf.m,13.7 - 17.4 lb-ft)






CAUTION:
- Assemble water temp control assembly and water inlet pipe to water pump assembly before nuts for assembling of water inlet pipe to be tightened.
- Always use a new O-ring.

8. Install the timing chain.
9. Check and adjust valve clearance.
10. Install the cylinder head cover.
A. The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling cylinder head cover.
B. After applying sealant, it should be assembled within 5 minutes.

Bead width :2.5mm(0.1in.)
Sealant :LOCTITE 5900H





C. The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was assembled.
D. Install the cylinder head core bolts as following method.

Tightening torque :
Step 1 : 3.9 - 5.9N.m(0.4 - 0.6kgf.m, 2.9 - 4.3lb-ft)
Step 2 : 7.8 - 9.8N.m(0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)






CAUTION:
Do not reuse cylinder head cover gasket.

11. Install the intake & exhaust manifold.
12. Connect the PCSV connector (A), ECT connector (B), condenser connector (C), CKP sensor connector (D), CMP sensor connector (E) and brake booster vacuum hose (F).




13. Connect the brake booster vacuum hose (D), PCSV hose (C) fuel hose (B) and CMP sensor connector (A).




14. Connect the ETC connector (A) and MAP sensor connector (B).




15. Connect the injector connectors (A) and ignition coil connectors (B).




16. Connect the OCV connector (A).




17. Connect the VIS connector (A), OPS connector (B), knock sensor connector (C) and A/C switch connector (D).




18. Install the heater hoses (A).