Part 3
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, 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 cylinder head.
NOTE:
Remove the extruded sealant 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)
[RH]
[LH]
3. Assemble the CVVT and camshaft assembly.
Tightening torque :
73.5 - 83.4N.m(7.5 - 8.5kgf.m, 54.2 - 61.5lb-ft)
A. Assemble the camshaft to the dowel pin of CVVT assembly. At this time, attend not to be assembled to oil hole of camshaft.
B. Hold the hexagonal head wrench portion of the camshaft with a vise, and install the bolt to the CVVT assembly.
C. Do not rotate the CVVT assembly when the camshaft is assembled to the dowel pin of CVVT assembly.
4. Install the roller finger follower and the hydraulic lash adjuster (HLA) assembly (A).
5. Install the LH/RH CVVT and camshaft assembly (A).
NOTE:
- 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.
6. Install the timing chain to the CVVT sprocket.
NOTE:
- Make sure the crankshaft is at TDC position.
- Align the chain installation mark (A) of the crankshaft sprocket and the timing mark (A) 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 are aligned.
7. Install the camshaft bearing caps and the camshaft thrust bearing cap.
Tighten the bolts in order to below sequence.
Tightening torque :
1st step :
6.9 - 7.8N.m ( 0.7 - 0.8kgf.m, 5.1 - 5.8lb-ft)
2nd step :
13.7 - 14.7N.m (1.4 - 1.5kgf.m, 10.1 - 10.8lb-ft)
NOTE:
Be careful the right, left bank, intake, exhaust side before assembling.
A : L(LH),R(RH)
B : I(Intake), E(Exhaust)
C : Journal number
D : Front mark
CAUTION:
Be sure to install the thrust bearing cap and bearing cap bolts in the correct places.
8. Install the cam to cam guide (A).
Tightening torque :
9.8 - 11.8Nm (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
9. Install the LH timing chain guide bolt (B) and then the LH timing chain tensioner (A).
(1) Install the timing chain tensioner & plug bolt in the hole on the cylinder head by hand.
(2) Tighten the plug bolt with the specified torque while pressing the timing chain on the LH intake CVVT.
Tightening torque :
Timing chain guide bolt :
21.6 - 25.5Nm (2.2 - 2.6kgf.m, 15.9 - 18.8lb-ft)
Timing chain tensioner plug bolt :
78.5 - 88.3N.m(8.0 - 9.0kgf.m, 57.9 - 65.1lb-ft)
NOTE:
1. Do not reuse the timing chain tensioner.
2. Make sure the timing chain tensioner is at compressed transport position state.
3. Install the timing chain tensioner with the oil hole facing the plug bolt.
10. Install the RH timing chain guide bolt (B) and then the RH timing chain tensioner (A).
(1) Install the timing chain tensioner & plug bolt in the hole on the cylinder head by hand.
(2) Tighten the plug bolt with the specified torque while pressing the timing chain on the RH intake CVVT.
Tightening torque :
Timing chain guide bolt :
21.6 - 25.5Nm (2.2 - 2.6kgf.m, 15.9 - 18.8lb-ft)
Timing chain tensioner plug bolt :
78.5 - 88.3N.m(8.0 - 9.0kgf.m, 57.9 - 65.1lb-ft)
NOTE:
1. Do not reuse the timing chain tensioner.
2. Make sure the timing chain tensioner is at compressed transport position state.
3. Install the timing chain tensioner with the oil hole facing the plug bolt.
11. Set tension of the timing chain tensioner.
(1) LH Bank
A. Press the timing chain on the LH intake CVVT by hand with the timing mark "L" on the LH intake and exhaust CVVT and the LH cylinder head upper surface aligned.
B. To set tension of the timing chain tensioner, push the timing chain tensioner arm outward with a force about 150N (15.3kgf, 33.7lbf).
C. To check the tension of the timing chain tensioner, push the timing chain tensioner arm outward strongly. The distance between the cylinder head surface and end of tensioner plunger should be about 20mm (0.79inch).
(2) RH Bank
A. To align the timing mark "R" on the RH intake and exhaust CVVT and the RH cylinder head upper surface, turn the exhaust CVVT about 20° counterclockwise while pressing the timing chain on the intake CVVT by hand with all of the chain installation mark of the sprocket and the timing marked chain links aligned.
B. To set tension of the timing chain tensioner, push the timing chain tensioner arm outward with a force about 150N (15.3kgf, 33.7lbf).
C. To check the tension of the timing chain tensioner, push the timing chain tensioner arm outward strongly. The distance between the tensioner body and end of tensioner plunger should be about 3.5mm (0.14inch).
(3) After setting tension of the LH, RH timing chain tensioner, check timing 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.
12. 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.
13. Install the water temperature control assembly (A) and the water outlet fitting assembly (B) with new O-ring and new gasket.
Tightening torque :
16.7 - 19.6N.m (1.7 - 2.0kgf.m, 12.3 - 14.5lb-ft)
14. 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)
15. Install the alternator (A).
Tightening torque :
29.4 - 41.2N.m (3.0 - 4.2kgf.m, 21.7 - 30.4lb-ft)
16. Install the oil control valve (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.
17. Use the SST (09231-2J500, 09231-H1100) install the timing chain upper cover oil seal (A).
18. Apply sealant to the timing chain upper cover.
(1) Using a gasket scraper, remove all the old packing material from the gasket surfaces.
(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)
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.