Part 3 of 4
Air Vent Procedure[In case of HLA alone]
1. Stroke HLA in gas oil 4 - 5 times by pushing its cap while pushing the ball down slightly by hard steel wire.
NOTE:
Take care not to severely push hard steel wire down since ball is several grams(g).
[After installed on vehicle]
NOTE:
After installed on engine, HLA might give out unusual noise if air is mingled. Then apply slow racing as below.
1. Racing at idle rpm for 1 - 3 minutes.
2. Repeat the racing with below pattern.
3. Check the abnormal noise during racing. (Usually, abnormal noise would be removed after 10 - 30 times racing above pattern. If there is abnormal noise after 30 times racing, find another reason except aeration in HLA)
4. Racing 5 times more after removing the abnormal noise.
5. Stop the air vent procedure after checking removing of abnormal noise for 1 - 3 minutes at idle rpm.
Reassembly
NOTE:
- Thoroughly clean all parts to be assembled.
- Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
- Replace oil seals with new ones.
1. Install the valves.
(1) Using the SST(09222-28200), push in the new valve stem seals.
NOTE:
- Do not reuse old valve stem seals.
- Incorrect installation of the seal could result in oil leakage past the valve guides.
(2) Install the valve, valve spring and spring retainer.
NOTE:
Place valve springs so that the smaller outer diameter side faces toward the valve spring retainer and then install the retainer.
(3) Using the SST(09222 - 3K000, 09222-3C300), compress the spring and install the retainer locks. After installing the valves, ensure that the retainer locks are correctly in place before releasing the valve spring compressor.
(4) Lightly tap the end of each valve stem two or three times with a soft hammer or the wooden handle of a hammer to ensure proper seating of the valve and retainer lock.
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).
(1) The sealant locations on cylinder head gasket, cylinder block and timing chain lower case must be free of engine oil and etc.
(2) Before assembling the cylinder head gasket, the liquid sealant LT5900H or equivalent should be applied on the gap between cylinder block and timing chain lower case.
The part must be assembled within 5 minutes after sealant was applied.
NOTE:
Refer to below illustration to apply the sealant.
Bead width :
3.5 - 4.5 mm (0.1378 - 0.1772 in)
Sealant locations :
1.5 - 2.5mm (0.0591 - 0.0984 in)
from timing chain lower case inner surface
Recommended sealant :Liquid sealant LT5900H or equivalent
(3) Apply sealant on cylinder head gaskets after assembling cylinder head gaskets on cylinder block.
The part must be assembled within 5 minutes after sealant was applied.
NOTE:
Be careful of the installation direction.
(4) Install the LH/RH cylinder heads (A).
NOTE:
Wipe away any excess liquid sealant that may appear after assembling cylinder heads.
2. Install the cylinder head bolts.
(1) Do not apply engine oil on the cylinder head bolts.
(2) Using SST(09221-4A000), install and tighten the cylinder head bolts and plate washers, in several passes, in the sequence shown.
Tightening torque
Cylinder head bolts (1 - 10) :
32.4 - 36.3N.m(3.3 - 3.7kgf.m, 23.9 - 26.8lb-ft) +
88°~92°+ 118°~122°
Flange bolts (11 - 12) :
33.3 - 36.3N.m(3.4 - 3.7kgf.m, 24.6 - 26.8lb-ft)
NOTE:
Always use new cylinder head bolts.
[RH]
[LH]
3. Install the LH/RH camshaft carrier assemblies.
(1) Apply liquid sealant on the bottom surface of the carrier.
Bead width :
2.5 - 3.5mm (0.0984 - 0.1377in.)
Sealant location :
1.0 - 2.0mm (0.0393 - 0.0787in.)
from carrier bottom face chamber edge
Recommended sealant :
Liquid sealant LT 5900 or equivalent
[LH]
[RH]
NOTE:
- The part must be assembled within 5 minutes after sealant was applied.
- To apply the sealant continuously on hatched area of carrier bottom face.
- If when sealant is applied to cylinder head top face, sealant position to be same with position that is applied to carrier rail position.
- To remove oil, dust, etc. on the top face of cylinder head and the bottom face of carrier.
(2) Install the LH/RH camshaft carriers (A).
Tightening torque
Carrier bolts :
18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb-ft)
*LH engine hanger & carrier bolts (2EA) :
18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft)
NOTE:
To assemble the camshaft bearing caps within 5 minutes after assembling camshaft carrier.
4. Assemble the CVVT and camshaft assembly.
Tightening torque :
73.5 - 83.4N.m(7.5 - 8.5kgf.m, 54.2 - 61.5lb-ft)
A. Align the CVVT groove with camshaft drill point.
B. Assemble the camshaft to the dowel pin of CVVT assembly. At this time, attend not to be assembled to oil hole of camshaft.
C. Hold the hexagonal head wrench portion of the camshaft with a vise, and install the bolt to the CVVT assembly.
D. Do not rotate the CVVT assembly when the camshaft is assembled to the dowel pin of CVVT assembly.
5. Install the roller finger follower and the hydraulic lash adjuster assembly (A).
(1) Until installing HLA shall be held upright so that engine oil in HLA should not spill and assured that dust does not adhere to HLA.
(2) HLA shall be inserted tenderly to the cylinder head not to spill engine oil from HLA. In case of spilling, air vent shall be done in accordance with the air vent procedure.
6. Install the LH/RH CVVT and camshaft assemblies (A).
NOTE:
Install the camshaft & CVVT assemblies from front to engine backward (1) and then put the camshaft rear down slightly (2).
Take care not to damage camshaft journal, cam lobe and the camshaft carrier journal.
CAUTION:
- Apply a light coat of engine oil on camshaft journals.
- Assemble the timing mark of CVVT to the same level of cylinder head top surface.
- Make sure the right, left bank, intake, exhaust side camshaft are correct before assembling.
- Turn the crankshaft to set the No.1 piston at TDC position.
Camshaft identification mark
7. Install the timing chain to the CVVT sprocket.
NOTE:
- Make sure the crankshaft is at TDC position.
- Align the chain installation mark of the crankshaft sprocket and the timing mark of the chain link, and then install the chain.
NOTE:
In case of marking the timing chain links corresponding to the chain installation marks on the sprocket with an identification for on-vehicle repair (for cylinder head assembly, timing chain tensioner, CVVT, camshaft, HLA or etc.), align all of the chain installation mark of the sprocket and the timing marked chain links for reassembly.
NOTE:
To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure.
Crankshaft sprocket -> Timing chain guide -> Exhaust CVVT sprocket -> Intake CVVT sprocket. (LH Bank)
Crankshaft sprocket -> Timing chain guide -> Intake CVVT sprocket -> Exhaust CVVT sprocket. (RH Bank)
When reassembling the timing chain, make sure all of the chain installation mark of the sprocket and the timing marked chain links (orange color) are aligned.
8. Install the LH/RH camshaft bearing caps (A) and the camshaft thrust bearing caps (B).
Tighten the bolts in order to below sequence.
Tightening torque
10mm bolts :
11.8 - 13.7 N.m (1.2 - 1.4 kgf.m, 8.7 - 10.1 lb-ft)
12mm bolts :
18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb-ft)
[RH]
[LH]
CAUTION:
Be sure to install the thrust bearing cap and bearing cap bolts in the correct position and facing direction.
9. Install the LH/RH fuel pump adapters (A) and the roller tappets (B).
Tightening torque :
18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb-ft)
10. Install the LH/RH cam to cam guides (A).
Tightening torque :
9.8 - 11.8Nm (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
11. Confirm that the LH/RH timing chain tensioner is transport position by pressed as below.
The hook must be around the pin.
[LH]
[RH]
12. Install the LH timing chain guide bolt (B) and then the LH timing chain tensioner (A).
(1) Install the timing chain tensioner in the hole on the cylinder head by hand.
(2) Tighten the tensioner mounting bolts.
Tightening torque :
Timing chain guide bolt :
21.6 - 25.5Nm (2.2 - 2.6kgf.m, 15.9 - 18.8lb-ft)
Timing chain tensioner bolt :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)
NOTE:
- Confirm identification mark 'L' on the tensioner flange.
- The tensioner ratchet should be top ward.
13. Install the RH timing chain guide bolt (B) and then the RH timing chain tensioner (A).
(1) Install the timing chain tensioner in the hole on the cylinder head by hand.
(2) Tighten the tensioner mounting bolts.
Tightening torque :
Timing chain guide bolt :
21.6 - 25.5Nm (2.2 - 2.6kgf.m, 15.9 - 18.8lb-ft)
Timing chain tensioner bolt :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)
NOTE:
- Confirm identification mark 'R' on the tensioner flange and the gasket hole.
- The tensioner ratchet should be top ward.
14. Set tension of the LH/RH timing chain tensioner.
(1) LH Bank
A. To set tension of the timing chain tensioner, push the timing chain tensioner arm outward to the end.
(Tensioner plunger moves back about 2 - 3mm (0.0787 - 0.1181in.))
B. Tension of the timing chain tensioner will set after the lock is released.
If the tensioner tooth is visible, tension setting is completed.
(2) RH Bank
A. To set tension of the timing chain tensioner, push the timing chain tensioner arm outward to the end.
(Tensioner plunger moves back about 2 - 3mm (0.0787 - 0.1181in.))
B. Tension of the timing chain tensioner will set after the lock is released.
If the tensioner tooth is visible, tension setting is completed.
(3) After setting tension of the LH, RH timing chain tensioner, check timing mark again.
A. Make sure the chain installation mark of the sprocket and the timing marked chain links are aligned.
B. Rotate the crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm the timing marks on the LH, RH intake and exhaust CVVT and the RH cylinder head upper surfaces are aligned.
15. After rotating the crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm the timing mark.
NOTE:
Always turn the crankshaft clockwise.
Turning the crankshaft counter clockwise before building up oil pressure in the hydraulic timing chain tensioner may result in the chain disengaging from the sprocket teeth.
16. Install the water temperature control assembly (A) and the water outlet fitting assembly (B) with new O-ring and new gasket.
Tightening torque
Water temperature control assembly bolts :
16.7 - 19.6 N.m (1.7 - 2.0 kgf.m, 12.3 - 14.5 lb-ft)
Water outlet fitting bolts (M8) :
16.7 - 19.6 N.m (1.7 - 2.0 kgf.m, 12.3 - 14.5 lb-ft)
Water outlet fitting bolt (M6) :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)
17. Install the water outlet pipe (A) and the water inlet pipe (B).
Tightening torque :
9.8 - 11.8Nm (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
NOTE:
- Use new O-rings when reassembling.
- Never apply sort of oil on O-ring and O-ring groove of pipe end.
- O-ring must be free from scratching damage.
- Make clean the contact face before assembly.
- Insert pipe after to be wetting O-ring or inside of attaching hole by water or antifreeze.
NOTE:
Install the drain plug (A).
Tightening torque :
96.1 - 100.0N.m(9.8 - 10.2kgf.m,70.9 - 73.8lb-ft)
18. Install the LH/RH timing chain upper covers.
(1) Install the new timing chain upper cover gaskets (A).
(2) Before assembling the timing chain upper cover, the liquid sealant LT5900H or equivalent should be applied on upper cover.
The part must be assembled within 5 minutes after the sealant was applied.
Bead width :Ø2.5 ± 0.5mm (0.1 ± 0.002in)
Area (A) (4EA) :Ø4.0 ± 0.5mm (0.16 ± 0.002in)
NOTE:
- Clean the sealing face before assembling two parts.
- Remove harmful foreign materials on the sealing face before applying sealant.
- When applying sealant gasket, sealant must not protrude into the inside of upper cover.
- To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.
(3) Install the LH/RH timing chain upper covers (A).
Tightening torque :
9.8 - 11.8Nm (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
19. Install the LH/RH intake/exhaust oil control valves (OCV) (A).
Tightening torque :
9.8 - 11.8N.m ( 1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
NOTE:
- Do not reuse the OCV when dropped.
- Keep the OCV clean.
- Do not hold the OCV sleeve (A) during servicing.
- When the OCV is installed on the engine, do not move the engine while holding the OCV yoke.
