13126009

Installation

note

●

Thoroughly clean all parts to be assembled.

●

Always use a new cylinder head and manifold gasket.

●

Always use a new cylinder head bolt.

●

The cylinder head gasket is a metal gasket. Take care not to bend it.

●

Rotate the crankshaft, set the No.1 piston at TDC.

Install the cylinder head assembly.

(1)

Before installing, remove the hardened sealant from the cylinder block and cylinder head surface.

(2)

Before installing the cylinder head gasket, apply sealant on the upper surface of the cylinder block and reassemble the gasket within five minutes.

note

Refer to the illustration for applying sealant.

Width: 2.0 ~ 3.0mm (0.0787~0.1181in.)

Position: 1.0 ~ 1.5mm (0.0394~0.0591in.)

Specification: Three bond 1217H

(3)

After installing the cylinder head gasket on the cylinder block, apply sealant on the upper surface of the cylinder head gasket and reassemble in five minutes.

Place the cylinder head carefully not to damage the gasket.

Install the cylinder head bolts with washers.

(1)

Tighten the 10 cylinder head bolts, in several passes, in the sequence shown.

Tightening torque :

17.7~21.6Nm (1.8~2.2kgf.m, 13.0~15.9lb-ft) + 90~95° + 100~105°

caution

Always use new cylinder head bolts.

Install the oil control valve(OCV) (A).

Tightening torque :

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

Tighten the mounting bolts for the water temperature control assembly (A) after installing the heater pipe (B).

Tightening torque :

M6 bolts : 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

M8 bolts : 18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)

Connect the camshaft position sensor (CMP) connector (A) and install the purge control solenoid valve (PCSV) bracket (B) and the module hanger bracket (C).

Install the intake manifold module assembly.

Install the exhaust manifold assembly.

Install the delivery pipe assembly (A).

10.

Install the injector connector (A) and harness bracket (B).

11.

Install the camshafts.

(1)

Before installing, apply engine oil on journals.

caution

Do not make oil flow down to the front side of the cylinder head.

(2)

After installing, check the valve clearance.

12.

Install the camshaft bearing caps with the order below.

Tightening torque :

M6 bolts - 11.8 ~ 13.7N.m (1.2 ~ 1.4kgf.m, 8.7 ~ 10.1lb-ft)

M8 bolts - 18.6 ~ 22.6N.m (1.9 ~ 2.3kgf.m, 13.7 ~ 16.6lb-ft)

13.

Align the timing marks of the camshaft sprocket with the upper sureface of the cylinder head to make No.1 cylinder be positioned at TDC.

(1)

Check the dowel pin of the crankshaft for facing upside of the engine at this monent.

(2)

Install the timing chain guide (A).

14.

After installation of the chain guide (A), reassemble the timing chain (B).

Tightening torque :

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

(1)

When installing a timing chain, align the timing marks on the sprockets with paint marks of the chain.

Order : Crankshaft sprocket → Timing chain guide → Intake camshaft sprocket → Exhaust camshaft sprocket.

15.

Install the chain tensioner arm (A).

Tightening torque :

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

16.

Fix the hydraulic tensioner (A) with a pin (B) before installing the tensioner (A) and remove the pin (B) after installing the tensioner (A).

Tightening torque :

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

note

Recheck the top dead center (TDC) marks on the crankshaft and camshaft.

17.

Install the timing chain cover(A).

(1)

Before installing, remove the hardened sealant from the cylinder block and ladder frame surface.

(2)

Apply the liquid gasket (THREE BOND 1217H) on the mating surface of the cylinder head assembly and the cylinder block.

Width: 3.0 ~ 5.0mm (0.1181~0.1969in.)

(3)

Apply the liquid gasket (THREE BOND 1282B or THREE BOND 1216E) on the water pump contact parts of the timing chain cover (A) and THREE BOND 1217H or LOCTITE 5900H on the rest parts (B). Reassemble the cover within 5 minutes.

Width: 3.5 ~ 4.5mm (0.1378~0.1772in.)

(4)

Align the dowel pin of the cylinder block and the holes of the oil pump.

Tightening torque :

12mm bolts - 18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)

10mm bolts - 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

caution

After the installation, do not crank engine or apply pressure on the cover for half an hour.

18.

Using the SST(09455-21200), reassemble the timing chain oil seal (A).

19.

Install the crankshaft pulley (A).

Tightening torque :

127.5 ~ 137.3 N.m (13.0 ~ 14.0 kgf.m, 94.0 ~ 101.3 lb-ft)

note

When installing the pulley, remove the starter and fix the SST(09231-2B100).

note

When installing the pulley, the groove on the pulley should be positioned outside.

20.

Install side cover.

Tightening torque :

8.8 ~ 10.8 N.m (0.9 ~ 1.1 kgf.m, 6.5 ~ 8.0 lb-ft)

21.

Install front right wheel and tire.

22.

Before installing the cylinder head cover, remove oil, dust or hardened sealant from the timing chain cover and the cylinder head upper surface.

23.

After applying the liquid gasket, THREE BOND 1217H or LOCTITE 5900H on the cylinder head cover, reassemble the cover within five minutes.

Width : 2.0 ~ 2.5mm (0.0787 ~ 0.0984in.)

24.

Install the cylinder head cover (A) with a new gasket (B).

caution

Do not reuse the disassembled gasket.

25.

Tighten the cylinder head cover bolts with the order and steps.

Tightening torque :

1st step - 3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)

2nd step - 7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)

26.

Install the ignition coils (A).

Tightening torque :

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

27.

Install the positive crankcase ventilation (PCV) hose (A) and PCSV hose (B).

28.

Connect the ignition coil connector (A) and the breather hose (B).

29.

Install the drive belt idler (A).

Tightening torque :

42.2 ~ 53.9 N.m (4.3 ~ 5.5 kgf.m, 31.1 ~ 39.8 lb-ft)

30.

Install the water pump (A) with a gasket.

Tighten bolts with the order below.

Tightening torque :

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

31.

Install the water pump pulley (A).

Tightening torque :

9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

caution

Tighten the bolts diagonally.

32.

Install the engine support bracket (A).

Tightening torque :

29.4 ~ 41.2 N.m (3.0 ~ 4.2 kgf.m, 21.7 ~ 30.4 lb-ft)

33.

Install the alternator bracket (A).

Tightening torque :

19.6 ~ 26.5 N.m (2.0 ~ 2.7 kgf.m, 14.5 ~ 19.5 lb-ft)

34.

Supporting the engine with a jack, install the engine mounting bracket (A) and the ground line(B).

Tightening torque :

Bolt(C) - 58.8 ~ 83.4 N.m (6.0 ~ 8.5 kgf.m, 43.4 ~ 61.5 lb-ft)

Bolt, nuts(D,E) - 49.0 ~ 58.8 N.m (5.0 ~ 6.0 kgf.m, 36.2 ~ 43.4 lb-ft)

Bolt(F) - 9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)

35.

Install the alternator (A).

Tightening torque :

12mm bolts - 19.6 ~ 26.5 N.m (2.0 ~ 2.7 kgf.m, 14.5 ~ 19.5 lb-ft)

10mm bolts - 29.4 ~ 41.2 N.m (3.0 ~ 4.2 kgf.m, 21.7 ~ 30.4 lb-ft)

36.

Install the drive belt (A).

37.

Adjust tension by tightening the alternator tension adjust bolt (A). (Refer to Charging system in EE Group).

Tension

New belt: 882.6 ~ 980.7N (90 ~ 100kg, 198.4 ~ 220.5lb)

Used belt: 637.4 ~ 735.5N (65 ~ 75kg, 143.3 ~ 165.3lb)

38.

Connect the connectors on the cylinder head and install the clamps.

(1)

Connect the front (A) and the rear (B) oxygen sensor connector.

(2)

Connect the ignition coil condenser connector (C) and the purge control solenoid valve(PCSV) conector (D).

(3)

Connect the engine coolant temperature sensor (ECTS) connector (E).

(4)

Connect the electronic throttle control (ETC) connector (A).

(5)

Connect the vapor hose (B) and the throttle body coolant hoses (C).

39.

Install the fuel hose (A).

40.

Connect the heater hose (A) and the brake booster hose (B).

41.

Connect the radiator upper hose (A) and lower hose (B).

42.

Install the battery tray (A) and connect front connector (B).

43.

Install the air cleaner assembly.

Tightening torque :

7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)

(1)

Connect the air cleaner hose (A) and bleeder hose (B).

(2)

Connect the opwer control module (PCM) connectors (C).

44.

Install the air duct (A).

Tightening torque :

7.8 ~ 9.8Nm (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)

45.

Install the under cover (A).

Tightening torque :

8.8 ~ 10.8N.m (0.9 ~ 1.1kgf.m, 6.5 ~ 8.0lb-ft)

46.

Install the battery (B) and connect the terminals (A).

47.

Refill engine coolant and engine oil.

48.

Start engine and check for leakage.

49.

Recheck the level of engine oil and coolant.