Part 2 of 2
INSTALLATIONNOTE:
- 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 to set the No.1 cylinder piston at TDC.
1. After putting the cylinder head gasket on the cylinder block, install the cylinder head.
CAUTION:
Ensure the LH/RH classification of the cylinder head gasket when installing.
2. Tighten the cylinder head bolts with the plain washers in several steps as following order.
NOTE:
- In assembling washers, the marked surface should face upward.
- In installing the cylinder head bolts, apply engine oil on the thread of the bolts and the surface of the washers.
CAUTION:
Always use new cylinder head bolts.
Tightening torque
22.6 - 26.5Nm (2.3 - 2.7kgf.m, 16.6 - 19.5lb-ft) + 58 - 62° + 43 - 47°
NOTE:
Using the SST(09221-4A000), tighten the bolts which need to be tightened with the angular tightening method.
3. Install the CVVT assembly and camshaft chain sprocket with the dowel pin in the CVVT installed to the intake camshaft. Ensure that the pin will not be installed in the hole for oil feeding.
Tightening torque
66.7 - 78.5Nm(6.8 - 8.0kgf.m, 49.2 - 57.9lb-ft)
NOTE:
After tightening the CVVT bolts, rotate the CVVT assembly housing counterclockwise by hand to seat the lock pin in the CVVT assembly in good position.
CAUTION:
Fix the hexagonal part of the camshaft in a vice when tightening the CVVT bolts. Do not fix the CVVT housing or sprocket in a vice.
4. Install the camshaft in the cylinder head assembly.
A. Intake Camshaft
As for camshaft identification, refer to the table below.
B. Exhaust Camshaft
As for camshaft identification, refer to the table below.
(1) Align the timing marks of the intake and exhaust camshaft chain sprockets and the timing chain.
CAUTION:
Both timing marks should face upward for reassembly.
(2) Install the intake and exhaust camshafts on the cylinder head with the timing marks aligned.
LH camshaft chain timing mark
RH camshaft chain timing mark
5. Install the timing chain tensioner.
(1) Insert the set pin by pressing the timing chain tensioner.
(2) Install the chain tensioner(A) in the cylinder head assembly.
Tightening torque
10.8 - 12.7 N.m (1.1 - 1.3 kgf.m, 8.0 - 9.4 lb-ft)
6. Install the camshaft bearing caps.
Tightening torque
Bearing cap bolt(A: 6•38) - 10.8 - 12.7Nm(1.1 - 1.3kgf.m, 8.0 - 9.4lb-ft)
Bearing cap bolt(B: 8•38) - 20.6 - 22.5Nm(2.1 - 2.6kgf.m, 15.2 - 18.8lb-ft)
NOTE:
When installing the bearing caps, check the marks on them as shown below and install them in its proper position.
A(LH/RH HEAD): L(LH), R(RH)
B(Intake/Exhaust): I(Intake), E(Exhaust)
C(Cap no.): 1,2,3
CAUTION:
When installing the bearing caps, turn the crankshaft to place a piston in the middle of the block because interference between valves and pistons can occur.
7. Using the SST(09214-21000), install the camshaft oil seal.
NOTE:
- Before installing, apply engine oil.
- The camshaft cap surface should adhere to the cylinder head assembly.
- Do not press an eccentric load.
8. Install the camshaft sprocket.
(1) Hold the hexagonal head wrench portion of the camshaft with a vise, and install the bolt.
Tightening torque
88.3 - 107.9Nm (9.0 - 11.0kgf.m, 65.1 - 79.6lb-ft)
(2) In case that the camshaft is replaced with new one, inspect the valve clearances and then install appropriate MLA tappet.
CAUTION:
To prevent the valve from interfering with the piston, rotate the crankshaft sprocket at 3 pitches counterclockwise from the No.1 cylinder piston at TDC position before inspecting the valve clearances.
9. Install the CKP sensor connector bracket(A).
10. Install the bank 1 timing belt rear cover(A).
11. Install the bank 2 timing belt rear cover(A).
NOTE:
The length of the bolt B is longer than that of the bolt C.
12. Install the cylinder head cover.
(1) Remove oil, dust or sealant on the upper surface of the cylinder before assembling cylinder head cover.
(2) Assemble the cylinder head cover within 5 minutes after applying liquid gasket(LOCTITE 5900) on the camshaft cap and packing part.
(3) Tighten the cylinder head cover bolts as following order(A).
Tightening torque
7.8 - 9.8Nm(0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)
NOTE:
- Do not start engine for thirty minutes after assembling the cylinder head cover.
- Do not reuse the cylinder head cover gasket.
13. Install the timing belt.
(1) Align the timing marks of the LH/RH camshaft sprockets.
CAUTION:
To prevent the valve from interfering with the piston, rotate the crankshaft sprocket at 3 pitches counterclockwise from the No.1 cylinder piston at TDC position before aligning the timing marks of the camshaft sprockets.
(2) After aligning the timing marks of the camshaft sprockets, rotate the crankshaft sprocket at 3 pitches clockwise then align the timing mark of the crankshaft sprocket to set the crankshaft to the No.1 cylinder piston at TDC position.
(3) Install the timing belt.
14. Install the water temp. control assembly.
15. Install the engine support bracket.
NOTE:
Over torque can damage thread of cylinder block.
16. Install the intake manifold assembly.
17. Install the exhaust manifold assembly.
18. Install the power steering pump. .
19. Install the drive belt(A).
20. Install the heater hose(A).
21. Connect the brake vacuum hose(A).
22. Install the PCV(Purge Control Valve) hose(A).
23. Connect the engine wiring harness connectors.
(1) Connect the bank 1 CMP sensor connector(A).
(2) Connect the bank 2 front/rear O2 sensor connectors(A,B) and the CKP sensor connector(C).
(3) Connect the bank 2 CMP sensor connector(A) and the WTS(Water Temperature Sensor) connector(B).
(4) Connect the generator connector(A) and the air conditioning compressor connector(B).
(5) Connect the MAP(Manifold Absolute Pressure Sensor) connector(A), the ETC(Electronic Throttle Control) connector(B) and the PCSV(Purge Control Solenoid Valve) connector(C).
(6) Connect the injection harness connector(A), the No.2 VIS(Variable Induction System) connector(B), the No.1/No.2 OCV(Oil Control Valve) connectors(C,D) and the OTS(Oil Temperature Sensor) connector(E).
(7) Connect the injection connectors(A,B,C), the ground lines(D), the condenser connector(E) and the Ignition coil connectors(F).
(8) Connect the bank 1 front/rear O2 sensor connectors(A).
(9) Connect the No.1/No.2 knock sensor connectors(A,B), the oil pressure switch connector(C), the ignition coil harness(D) and the No.1 VIS(Variable Induction System) connector(E).
24. Install the fuel inlet hose(A) from the delivery pipe.
25. Install the upper radiator hose(A) and lower radiator hose(B).
26. Install the air cleaner assembly.
(1) Install the air cleaner assembly.
(2) Connect the breather hose (B) from air cleaner hose.
(3) Connect the MAF connector (A).
(4) Connect the power train control module (PCM) connector (F).
(5) Install the power train control module (PCM) cover (D)
27. Install the air duct(A).
28. Install the engine cover.
29. Refill engine coolant.