Part 3
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 topward.
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 topward.
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.
20. Install the LH/RH exhaust manifolds (A) by tightening the nuts as following method.
Tightening torque :
49.0 - 53.9N.m (5.0 - 5.5kgf.m, 36.2 - 39.8lb-ft)
NOTE:
The "TOP"mark of the gasket must be face the exhaust manifold.
NOTE:
Tighten the exhaust manifold nuts as following method.
[RH]
[LH]
21. Install the LH/RH exhaust manifold heat protectors (A).
Tightening torque :
8.8 - 10.8 N.m ( 0.9 - 1.1kgf.m, 6.5 - 8.0lb-ft)
22. Install the engine coolant temperature sensor (ECTS) wiring assembly and bracket (A).
Tightening torque
Wiring bracket bolts :
9.8 - 11.8Nm (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
Engine coolant temperature sensor :
19.6 - 39.2Nm (2.0 - 4.0kgf.m, 14.5 - 28.9lb-ft)
23. Install the oil pressure switch (OPS) wiring assembly and bracket (A).
Tightening torque
Wiring bracket bolts :
9.8 - 11.8Nm (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
Oil pressure switch :
14.7 - 21.6Nm ( 1.5 - 2.2kgf.m, 10.8 - 15.9lb-ft)
24. Use the SST (09231-2J500, 09231-H1100), install the oil seals (B) and the gaskets (A), fuel pump adapter gaskets (C).
25. Install the LH/RH cylinder head covers.
(1) The sealant locations on cylinder head and timing chain upper case must be free of engine oil and etc.
(2) Before assembling the cylinder head cover, the liquid sealant LT5900H or equivalent should be applied on the gap between cylinder head and timing chain upper case.
The part must be assembled within 5 minutes after sealant was applied.
(3) Install the LH/RH cylinder head covers (A).
The part must be assembled within 5 minutes after sealant was applied.
Tightening torque
1st step : 4.9 - 5.9N.m (0.5 - 0.6kgf.m, 3.6 - 4.3lb-ft)
2nd step : 9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
NOTE:
Tighten the cylinder head cover bolts as following method.
[RH]
[LH]
26. Install the LH/RH fuel pumps (A).
Tightening torque :
12.7 - 14.7 N.m (1.3 - 1.5 kgf.m, 9.4 - 10.8 lb-ft)
27. Install the LH/RH ignition coils (A).
Tightening torque :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
28. Reconnect the water hose (A).
29. Install the knock sensors (A) and wiring assembly brackets (B).
Tightening torque
Knock sensor :
14.7 - 24.5 N.m (1.5 - 2.5 kgf.m, 10.8 - 18.1 lb-ft)
LH bracket bolts :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)
RH bracket & hanger bolts :
18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft)
