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 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 TB 1217H 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 TB1217H
(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 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 :
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) :
32.4 - 36.3N.m(3.3 - 3.7kgf.m, 23.9 - 26.8lb-ft)
[RH]
[LH]
3. Install the CVVT assembly.
Tightening torque :
73.5 - 83.4N.m(7.5 - 8.5kgf.m, 54.2 - 61.5lb-ft)
A. Install camshaft to dowel pin of CVVT assembly.At this time, attend not to be installed to oil hole of camshaft.
B. Hold the hexagonal head wrench portion of the camshaft with a vise, and install the bolt and CVVT assembly.
C. Do not rotate CVVT assembly when camshaft is installed to dowel pin of CVVT assembly.
4. Install the roller finger follower and the hydraulic lash adjuster assembly (A).
5. Install the LH/RH camshaft assembly (A).
A. Apply a light coat of engine oil on camshaft journals.
B. Assemble the timing mark of CVVT to the same level of cylinder head top surface.
C. Be careful the right, left bank, intake, exhaust side before assembling.
D. 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 timing chain to the camshaft sprocket.
NOTE:
To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure.
Crankshaft sprocket -> Timing chain guide -> Exhaust camshaft sprocket -> Intake camshaft sprocket. (LH Bank)
Crankshaft sprocket -> Timing chain guide -> Intake camshaft sprocket -> Exhaust camshaft sprocket. (RH Bank)
The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at installing timing chain.
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.
- 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.
8. Press the LH timing chain tensioner piston using the vise (over 150N force) for as the mark (A).
9. Install the LH timing chain guide bolt (B) and then the LH timing chain tensioner (A).
Tightening torque :
Timing chain guide bolts :
21.6 - 25.5Nm (2.2 - 2.6kgf.m, 15.9 - 18.8lb-ft)
Timing chain tensioner bolts :
78.5 - 88.3N.m(8.0 - 9.0kgf.m, 57.9 - 65.1lb-ft)
NOTE:
Check the tensioner direction before assembly.
10. Press the RH timing chain tensioner using the vise for as the mark (A).
11. Install the RH timing chain guide bolt (B) and then the RH timing chain tensioner (A).
Tightening torque :
Timing chain guide bolts :
21.6 - 25.5Nm (2.2 - 2.6kgf.m, 15.9 - 18.8lb-ft)
Timing chain tensioner bolts :
78.5 - 88.3N.m(8.0 - 9.0kgf.m, 57.9 - 65.1lb-ft)
NOTE:
Check the tensioner direction before assembly.
12. Install the cam to cam guide (A).
Tightening torque :
9.8 - 11.8Nm (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
13. 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.
14. 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)
15. 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)
16. Install the alternator (A).
Tightening torque :
29.4 - 41.2N.m (3.0 - 4.2kgf.m, 21.7 - 30.4lb-ft)
17. Install the oil control valve (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 during servicing.
- When the OCV is installed on the engine, do not move the engine while holding the OCV yoke.
18. Use the SST (09231-2J500, 09231-H1100) install the timing chain upper cover oil seal (A).
19. 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 TB1217H or LT5900H should be applied on upper cover.
The part must be assembled within 5 minutes after the sealant was applied.
Bead width :2.5mm(0.1in)
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.