Reassembly
REASSEMBLY
1. The key(A) of crankshaft should be aligned with the timing mark(B) of timing chain cover. As a result of this, the piston of No.1 cylinder is placed at the top dead center on compression stroke.
2. Install tensioner adapter assembly(A).
3. Install crankshaft sprocket(A)(LH camshaft drive).
4. Install LH timing chain guide(A).
Tightening torque
19.60 - 24.50Nm(2.0 - 2.5kgf.m, 14.17 - 18.08lb-ft)
5. Install LH timing chain.
To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure.
Crankshaft sprocket(A) -> Timing chain guide(B) -> Exhaust camshaft sprocket(C) -> Intake camshaft sprocket(D).
The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at installing timing chain.
6. Install LH timing chain tensioner arm(B).
Tightening torque
18.62 - 21.56Nm(1.9 - 2.2kgf.m, 13.74 - 15.91lb-ft)
7. Install chain tensioner(A).
Tightening torque
9.80 - 11.76Nm(1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
8. Install LH cam-to-cam guide(A).
Tightening torque
9.80 - 11.76Nm(1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
9. Install crankshaft sprocket(A)(O/P & RH camshaft drive).
10. Install oil pump chain(B) and oil pump sprocket(A).
Tightening torque
18.62 - 21.56Nm(1.9 - 2.2kgf.m, 13.74 - 15.91lb-ft)
11. Install RH timing chain guide(A).
Tightening torque
19.60 - 24.50Nm(2.0 - 2.5kgf.m, 14.17 - 18.08lb-ft)
12. Install RH timing chain.
To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure.
Crankshaft sprocket(A) -> Intake camshaft sprocket(B) -> Exhaust camshaft sprocket(C).
The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at installing timing chain.
13. Install RH timing chain tensioner arm(B).
14. Install RH timing chain auto tensioner(A).
Tightening torque
9.80 - 11.76Nm(1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
15. Install RH cam-to-cam guide(A).
Tightening torque
9.80 - 11.76Nm(1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
16. Install oil pump chain guide(A).
Tightening torque
9.80 - 11.76Nm(1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
17. Install oil pump chain tensioner assembly(A).
Tightening torque
9.80 - 11.76Nm(1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
18. Pull out the pins of hydraulic tensioner (LH & RH).
19. Install oil pump chain cover(A).
Tightening torque
9.80 - 11.76Nm(1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
20. After rotating crankshaft 2 revolutions in regular direction(clockwise viewed from front), confirm the timing mark.
NOTE:
Always turn the crankshaft clockwise.
21. Install timing chain cover.
A. The sealant locations on chain cover and on counter parts (cylinder head, cylinder block, and lower oil pan) must be free of engine oil and ETC.
B. Before assembling the timing chain cover, the liquid sealant TB1217H should be applied on the gap between cylinder head and cylinder block
The part must be assembled within 5 minutes after sealant was applied.
Bead width : 2.5mm(0.1in.)
C. After applying liquid sealant TB1217H on timing chain cover.
The part must be assembled within 5 minutes after sealant was applied.
Sealant should be applied without discontinuity.
Sealant should also be applied all around the two holes of the dowel pins.
Bead width : 2.5mm(0.1in.)
D. Install the new gasket(A) to the timing chain cover.
E. The dowel pins on the cylinder block and holes on the timing chain cover should be used as a reference in order to assemble the timing chain cover to be in exact position.
Tightening torque
B(17): 18.62 - 21.56Nm(1.9 - 2.2kgf.m, 13.74 - 15.91lb-ft)
C(4): 9.80 - 11.76Nm(1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
D(1): 58.80 - 68.80Nm(6.0 - 7.0kgf.m, 43.40 - 50.63lb-ft)
E(1): 58.80 - 68.80Nm(6.0 - 7.0kgf.m, 43.40 - 50.63lb-ft)
F(2): 24.50 - 26.46Nm(2.5 - 2.7kgf.m, 18.08 - 19.53lb-ft)
G(4): 21.56 - 23.52Nm(2.2 - 2.4kgf.m, 15.91 - 17.36lb-ft)
H(1): 9.80 - 11.76Nm(1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
I(1): 9.80 - 11.76Nm(1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
J(1): 9.80 - 11.76Nm(1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
K(4): 9.80 - 11.76Nm(1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
L(1): 21.56 - 26.46Nm(2.2 - 2.7kgf.m, 15.91 - 19.53lb-ft) - New bolt
F. The firing and/or blow out test should not be performed within 30 minutes after the timing chain cover was assembled.
22. Using SST(09231-3C100), install timing chain cover oil seal.
23. Install lower oil pan.
A. Using a gasket scraper, remove all the old packing material from the gasket surfaces.
B. Before assembling the oil pan, the liquid sealant TB1217H should be applied on oil pan.
The part must be assembled within 5 minutes after the sealant was applied.
Bead width : 2.5mm(0.1in.).
CAUTION:
- Make clean the sealing face before assembling two parts.
- Remove harmful foreign matters on the sealing face before applying sealant.
- When applying sealant gasket, sealant must not be protruded into the inside of oil pan.
- To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.
C. Install oil pan(A).
Uniformly tighten the bolts in several passes.
Tightening torque
9.80 - 11.76Nm(1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
24. Using SST(09231-3C300) install crankshaft damper pulley(A).
Tightening torque
284.2 - 303.8Nm(29.0 - 31.0kgf.m, 209.76 - 224.22lb-ft)
25. Install 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(TB1217H), it should be assembled within 5 minutes.Bead width : 2.5mm(0.1in.)
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 cover bolts as following method.
Tightening torque
9.80 - 11.76Nm(1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
CAUTION:
Do not reuse cylinder head cover gasket.
E. Install ignition coil
F. Connect RH ignition coil connector(A), condenser connector(B) and install wiring bracket(C).
G. Install connector bracket from LH cylinder head cover.