Installation
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.
A. The sealant locations on cylinder head and cylinder block must be free of engine oil and ETC.
B. Apply sealant on cylinder block top face before assembling cylinder head gaskets.
The part must be assembled within 5 minutes after sealant was applied.
NOTE:
Refer to below illustration to apply the sealant.
Bead width :
2.0 - 3.0 mm (0.078 - 0.118 in.)
Sealant locations :
1.0 - 1.5mm (0.039 - 0.059 in.) from block surface
Recommended sealant :Liquid sealant TB1217H
C. 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.
D. Install the cylinder head.
NOTE:
Remove the extruded sealant after assembling cylinder heads.
2. Install cylinder head bolts.
(1) Do not apply engine oil on the threads and under the heads of 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
Head bolt: 39.2N.m (4.0kgf.m, 28.9lb-ft)+ 120° + 90°
Bolt (A):18.6 - 23.5Nm (1.9 - 2.4kgf.m, 13.7 - 17.4lb-ft)
3. Install the CVVT assembly.
Tightening torque :
64.7 - 76.5N.m (6.6 - 7.8kgf.m, 47.7 - 56.4lb-ft)
CAUTION:
- Install camshaft-inlet to dowel pin of CVVT assembly.
At this time, attend not to be installed to oil hole of camshaft-inlet.
- Hold the hexagonal head wrench portion of the camshaft with a vise, and install the bolt and CVVT assembly.
- Do not rotate CVVT assembly when camshaft is installed to dowel pin of CVVT assembly.
4. Install the LH/RH camshaft assembly (A).
CAUTION:
- Apply a light coat of engine oil on camshaft journals.
- Assemble the key groove of camshaft rear side to the same level of head top surface.
- Be careful the right, left bank, intake, exhaust side before assembling.
Intake Camshaft
As for camshaft identification, refer to the table below.
Exhaust Camshaft
As for camshaft identification, refer to the table below.
5. Install the LH/RH camshaft bearing cap (A) and thrust bearing cap (B).
Tightening torque
1st step : 5.8N.m (0.6kgf.m, 4.3lb-ft)
2nd step : 9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
CAUTION:
Be sure to install the thrust bearing cap bolts and the bearing cap bolts in the correct place.
NOTE:
Be careful the right, left bank, intake, exhaust side before assembling.
A : L(LH),R(RH)
B : I(Intake), None(Exhaust)
C : Journal number
D : Front mark
CAUTION:
Rotate the crankshaft not to contact the valves to the pistons by making the pistons below 10mm(0.3937in.) from the top of cylinder block.
6. Install the LH/RH exhaust camshaft OCV (A).
Tightening torque :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
7. Install the LH/RH exhaust manifold (A) with a new gasket.
Tightening torque :
39.2 - 44.1N.m (4.0 - 4.5kgf.m, 28.9 - 32.5lb-ft)
8. Install the LH/RH exhaust manifold heat protector (A).
Tightening torque :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
9. Install the LH/RH exhaust manifold stay bolt (A).
Tightening torque :
34.3 - 41.2N.m (3.5 - 4.2kgf.m, 25.3 - 30.4lb-ft)
10. Install the intake the manifold (B) with a new gasket, and connect the water vent hose (A).
CAUTION:
- Be sure to drain the engine coolant before removing the intake manifold.
- If any coolant drained from the cylinder head vent hole has entered the intake port ; this can potentially lead to engine trouble.
Tightening torque
Step 1: 3.9 - 5.9N.m (0.4 - 0.6kgf.m, 2.9 - 4.3lb-ft)
Step 2:
Nut-18.62 - 23.52N.m (1.9 - 2.4kgf.m, 13.74 - 17.36lb-ft)
Bolt -26.5 - 31.4 N.m (2.7 - 3.2 kgf.m, 19.5 - 23.1lb-ft)
Step 3: Repeat 2nd step twice or more.
a - h : 1st step order
1 - 8 : 2nd step order
NOTE:
Confirm the manifold gasket identification mark (LH, RH) and be careful of the installation direction.
11. Install the water temperature control assembly (A) with a new gasket.
Tightening torque :
19.6 - 23.5Nm (2.0 - 2.4kgf.m, 14.5 - 17.4lb-ft)
CAUTION:
When tightening the bolt (C), use a ground bolt.
12. Install the timing chain.
NOTE:
- Refill engine oil.
- Clean the battery posts and cable terminals with sandpaper. Assemble and then apply grease to prevent corrosion.
- Inspect for fuel leakage.
- After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for approximately two seconds and fuel line pressurizes.
- Repeat this operation two or three times, then check for fuel leakage at any point in the fuel lines.
- Refill radiator and reservoir tank with engine coolant.
- Bleed air from the cooling system.
- Start engine and let it run until it warms up. (Until the radiator fan operates 3 or 4 times.)
- Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed from the cooling system.
- Put radiator cap on tightly, then run the engine again and check for leaks.