2.
Remove the air duct (A).
Use fender covers to avoid damaging painted surfaces.
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
Mark all wiring and hoses to avoid misconnection.
Turn the crankshaft pulley so that the No.1 piston is at top dead center.
Disconnect the negative terminal from the battery.
Remove the air duct (A).
Remove the air cleaner assembly.
Disconnect the breather hose (A).
Disconnect the ECM connectors (B).
Disconnect the AFS connector (C) and then remove the air cleaner assembly (D).
Remove the under cover(A).
Remove the RH front wheel and the side cover (A).
Drain the engine coolant.
Remove the radiator cap to speed draining.
Remove the radiator upper hose(A).
Drain the engine oil.
Remove the lower oil pan(A).
Insert the blade of SST(09215-3C000) between the upper oil pan and lower oil pan, and cut off applied sealer and removed lower oil pan.
Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the direction of arrow.
After tapping the SST with a plastic hammer along the direction of arrow around more than 2/3 edge of the oil pan, remove it from the ladder frame.
Do not use the SST as a prybar. Hold the tool in position (on the gasket line) and tap in with a light hammer.
Be careful not to damage the contact surfaces of Upper oil pan and lower oil pan.
Install the jack to the edge of upper oil pan.
Place a rubber bolck between oil pan and jack.
Just loosen the transaxle mounting bolts(A) without removing the transaxle mounting(B).
Remove the engine coolant reservoir tank (A).
Disconnect the ground cable (B) and then remove the engine mounting supprot bracket (C).
Loosen the A/C pipe bracket mounting bolt (A).
Remove the engine mounting bracket (A) through the lower position of A/C pipe line.
Disconnect the wiring connectors and then remove the surge tank. (Refer to intake and exhaust system in this group)
Cover the inlet of intake manifold with a clean woven stuff or vinyl cover to prevent foreign materials from entering.
Disconnect the RH ignition coil connectors (A) and the injector connectors (B).
Remove the LH/RH ignition coils.
Remove the exhaust OCV cap (A), and then remove the LH, RH cylinder head covers.
Cover the cylinder head with a clean woven stuff or vinyl cover to prevent foreign materials from entering.
To release the tension, turn the drive belt tensioner counterclockwise then remove the drive belt (A).
Lift up the engine assembly by using the jack for get a space to work
Remove the power steering pump(A).
Remove the air conditioner compressor(A).
Remove the alternator(A).
Remove the drive belt idler(A).
Remove the drive belt auto tensioner(A).
Remove water pump pulley(A).
Set No.1 cylinder to TDC/compression.
Turn the crankshaft pulley and align its groove with the timing mark "T" of the timing chain cover.
Do not rotate engine counterclockwise.
Check that the mark (A) of the camshaft timing sprockets are in straight line on the cylinder head surface as shown in the illustration.
If not, turn the crankshaft one revolution (360°).
Do not rotate engine counterclockwise.
Remove the crankshaft pulley(A).
There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley.
Install the SST (09231-3C300) to hold the ring gear after removing the starter.
Install the SST (09231-3D100) to hold the ring gear after removing the dust cover.
Remove the front muffler. (Refer to Intake And Exhaust system)
Remove the dust cover (A) on the bottom of the upper oil pan and unfasten the two transaxle mounting bolts (B).
Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth.
Fasten the two transaxle mounting bolts in the original mounted holes.
Install the SST (09231-3D100) using the two mounting bolts. Tighten the bolts and nuts of the holder securely.
Remove the timing chain cover(A).
Disconnect the water vent hose located at back of timing chain cover before removing.
Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover.
Before removing the timing chain, mark the RH/LH timing chain with an identification based on the location of the sprocket because the identification mark on the chain for TDC (Top Dead Center) can be erased.
Remove the oil pump chain cover (A).
Remove the oil pump chain tensioner assembly (A).
Remove the RH timing chain guide(A).
Install a set pin after compressing the RH timing chain tensioner.
Remove the RH timing chain auto tensioner (A) and the RH timing chain tensioner arm(B).
Remove the RH timing chain guide (A) and the RH timing chain (B).
Remove the oil pump chain sprocket(A) and oil pump chain(B).
Remove the crankshaft sprocket(A) (O/P & RH camshaft drive).
Install a set pin after compressing the LH timing chain tensioner.
Remove the LH timing chain auto tensioner (A) and LH timing chain tensioner arm(B).
Remove the LH timing chain guide(A) and the LH timing chain (B).
Remove the crankshaft sprocket(A) (LH camshaft drive).
Remove the tensioner adapter assembly(A).
Check the camshaft sprocket and crankshaft sprocket for abnormal wear, cracks, or damage. Replace as necessary.
Inspect the tensioner arm and chain guide for abnormal wear, cracks, or damage. Replace as necessary.
Check that the tensioner piston moves smoothly when the ratchet pawl is released with thin rod.
Install the jack to the upper oil pan.
Place a rubber block between oil pan and jack.
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.
Install the tensioner adapter assembly (A).
Install the crankshaft sprocket(A) (LH camshaft drive).
Install the LH timing chain guide(A) and the LH timing chain (B).
Tightening torque
19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.2 ~ 18.1lb-ft)
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.
The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at installing timing chain.
Install the LH timing chain tensioner arm(B) and the chain tensioner(A).
Tightening torque
Tensioner (A) : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Tensioner arm (B): 18.8 ~ 21.6N.m (1.9 ~ 2.2kgf.m, 13.7 ~ 15.9lb-ft)
Install the crankshaft sprocket(A) (O/P ＆ RH camshaft drive).
Install the oil pump sprocket(A) and the oil pump chain(B).
Tightening torque
18.6 ~ 21.6N.m (1.9 ~ 2.2kgf.m, 13.7 ~ 15.9lb-ft)
Install the RH timing chain guide(A) and the RH timing chain (B).
Tightening torque
19.6 ~ 24.5N.m (2.0 ~ 2.5kgf.m, 14.2 ~ 18.1lb-ft)
To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure.
Crankshaft sprocket → Intake CVVT sprocket → Exhaust CVVT sprocket.
The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at installing timing chain.
Install the RH timing chain tensioner arm(B) and the RH timing chain auto tensioner(A).
Tightening torque
Tensioner (A): 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Tensioner arm (B): 18.6 ~ 21.6N.m (1.9 ~ 2.2kgf.m, 13.7 ~ 15.9lb-ft)
Install the oil pump chain guide(A).
Tightening torque
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Install the oil pump chain tensioner assembly(A).
Tightening torque
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Pull out the pins of hydraulic tensioner (LH ＆ RH).
Install the oil pump chain cover(A).
Tightening torque
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
After rotating the crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm the timing mark.
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.
Install the timing chain cover.
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.
Before assembling the timing chain cover, the liquid sealant TB 1217H 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.)
After applying liquid sealant TB1217H on timing chain cover.
The part must be assembled within 5 minutes after sealant was applied.
Selant should be applied without discontinuity.
Bead width : 2.5mm(0.1in.)
Fill the T-joint area (6EA *) with sealant.
Apply sealant all around the dowel pin hole (2EA).
Install the new gasket(A) to the timing chain cover.
During timing cover installation, care not to take off applied sealant on the timing cover by contact with other parts.
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) :
18.6 ~ 21.6N.m (1.9 ~ 2.2kgf.m, 13.7 ~ 15.9lb-ft)
C(4) :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.7lb-ft)
D(2) :
58.8 ~ 68.8N.m (6.0 ~ 7.0kgf.m, 43.4 ~ 50.6lb-ft)
F(2) :
24.5 ~ 26.5N.m (2.5 ~ 2.7kgf.m, 18.1 ~ 19.5lb-ft)
G(4) :
21.5 ~ 23.5N.m (2.2 ~ 2.4kgf.m, 15.91 ~ 17.4lb-ft)
H(1) :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.7lb-ft)
I(1) :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.7lb-ft)
J(1) :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.7lb-ft)
K(4) :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.7lb-ft)
L(1):
21.6 ~ 26.5N.m (2.2 ~ 2.7kgf.m, 15.9 ~ 19.5lb-ft)
- New bolt
Connect the water vent hose.
Running the engine or performing a pressure test should not be performed within 30 minutes of assembly.
Using SST(09231-3C100), install timing chain cover oil seal.
Install the crankshaft pulley(A).
Tightening torque
284.2 ~ 303.8N.m (29.0 ~ 31.0kgf.m, 209.8 ~ 224.2lb-ft)
There are two methods to hold the ring gear when installing or removing the crankshaft damper pulley.
Install the SST (09231-3C300) to hold the ring gear after removing the starter.
Install the SST (09231-3D100) to hold the ring gear after removing the dust cover.
Remove the front muffler. (Refer to Intake And Exhaust system)
Remove the dust cover (A) on the bottom of the upper oil pan and unfasten the two transaxle mounting bolts (B).
Adjust the length of the holder nuts (A) so that the front plate of the holder (B) puts in the ring gear (C) teeth.
Fasten the two transaxle mounting bolts in the original mounted holes.
Install the SST (09231-3D100) using the two mounting bolts. Tighten the bolts and nuts of the holder securely.
Install the drive belt auto tensioner(A).
Tightening torque
Bolt(B) :
81.4 ~ 85.3N.m (8.3 ~ 8.7kgf.m, 60.0 ~ 62.9lb-ft)
Bolt(C) :
17.7 ~ 21.6N.m (1.8 ~ 2.2kgf.m, 13.0 ~ 15.9lb-ft)
Install the drive belt idler(A).
Tightening torque
52.9 ~ 57.9N.m (5.4 ~ 5.9kgf.m, 39.1 ~ 42.7lb-ft)
Install the water pump pulley(A).
Tightening torque
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
Install the power steering pump(A). (Refer to ST group)
Install the air conditioner compressor(A). (Refer to HA group)
Install the alternator(A).
Tightening torque
26.5 ~ 33.3N.m (2.7 ~ 3.4kgf.m, 19.5 ~ 24.6lb-ft)
Install the drive belt(A).
Crankshaft pulley → A/C pulley → idler pulley → alternator pulley → water pump pulley → P/S pump pulley→ tensioner pulley.
Rotate auto tensioner arm in the counterclockwise moving auto tensioner pulley bolt with wrench.
After putting belt on auto tensioner pulley, release the auto tensioner pulley slowly.
Install the LH/RH cylinder head covers.
Install the cylinder head cover under the exhaust OCV cap is removed.
To prevent engine oil leakage, surely install the exhaust OCV cap after installing the cylinder head cover.
The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling cylinder head cover.
After applying sealant(TB1217H), it should be assembled within 5 minutes.
Bead width : 2.5mm (0.1in.)
Running the engine or performing a pressure test should not be performed within 30 minutes of assembly.
Install the cylinder head cover bolts as following method.
Tightening torque
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Do not reuse cylinder head cover gasket.
Install the exhaust OCV cap (A).
Tightening torque
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Install the ignition coils.
Connect the RH ignition coil connectors (A) and the injector connectors (B).
Install the surge tank (A) and then connect the wiring connectors. (Refer to intake and exhaust system in this group)
Tightening torque
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Install the engine mounting bracket (A) through the lower position of A/C pipe line.
Tightening torque
49.0 ~ 63.7N.m (5.0 ~ 6.5kgf.m, 36.2 ~ 47.0lb-ft)
Install the A/C pipe bracket mounting bolt (A).
Tightening torque
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Install the engine coolant reservoir tank (A).
Tightening torque
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Install the engine mounting support bracket (C) and then connect the ground cable (B).
Tightening torque
63.7 ~ 83.4N.m (6.5 ~ 8.5kgf.m, 47.0 ~ 61.5lb-ft)
Install the transaxle mounting bolts(A).
Tightening torque
49.0 ~ 63.7N.m (5.0 ~ 6.5kgf.m, 36.2 ~ 47.0lb-ft)
Remove the jack from the upper oil pan.
Install the lower oil pan.
Using a gasket scraper, remove all the old gasket material from the gasket surfaces.
Before assembling the oil pan, the liquid sealant TB 1217H 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.).
But marked area(*) to be 5.0mm(0.2in.)
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.
Install the oil pan(A).
Uniformly tighten the bolts in several passes.
Tightening torque
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Install the radiator upper hose(A).
Install the side cover(A) and the RH front wheel.
Tightening torque
Cover (A): 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Wheel nuts : 88.3 ~ 107.9N.m (9.0 ~ 11.0kgf.m, 65.1 ~ 79.6lb-ft)
Install the under cover(A).
Tightening torque
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Install the air cleaner assembly.
Install the air cleaner assembly (D) and then connect the AFS connector (C).
Tightening torque
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
Connect the ECM connectors (B).
Connect the breather hose (A).
Install the air duct.
Connect the negative terminal to the battery.
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 and let it cool down. 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.
