13501272

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).

note

●

Apply a light coat of engine oil on camshaft journals.

●

Assemble the timing mark of CVVT to the same level of cylinder head top surface.

●

Be careful the right, left bank, intake, exhaust side before assembling.

●

Turn the crankshaft to set the No.1 piston at TDC position.

6.

Install the timing chain to the camshaft sprocket.

note

●

Make sure the crankshaft is at TDC position.

●

Align the chain installation mark (A) of the crankshaft sprocket and the timing mark (A) of the chain link, and then install the chain.

note

In case of marking the timing chain links corresponding to the chain installation marks on the sprocket with an identification for on-vehicle repair (for cylinder head assembly, timing chain tensioner, CVVT, camshaft, HLA or etc.), align all of the chain installation mark of the sprocket and the timing marked chain links for reassembly.

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)

When reassembling the timing chain, make sure all of the chain installation mark of the sprocket and the timing marked chain links are aligned.

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.

8.

Install the cam to cam guide (A).

Tightening torque :

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

9.

Install the LH timing chain guide bolt (B) and then the LH timing chain tensioner (A).

(1)

Install the timing chain tensioner & plug bolt in the hole on the cylinder head by hand.

(2)

Tighten the plug bolt with the specified torque while pressing the timing chain on the LH intake CVVT.

Tightening torque :

Timing chain guide bolt :

21.6 ~ 25.5Nm (2.2 ~ 2.6kgf.m, 15.9 ~ 18.8lb-ft)

Timing chain tensioner plug bolt :

78.5 ~ 88.3N.m(8.0 ~ 9.0kgf.m, 57.9 ~ 65.1lb-ft)

note

1.

Do not reuse the timing chain tensioner.

2.

Make sure the timing chain tensioner is at compressed transport position state.

3.

Install the timing chain tensioner with the oil hole facing the plug bolt.

10.

Install the RH timing chain guide bolt (B) and then the RH timing chain tensioner (A).

(1)

Install the timing chain tensioner & plug bolt in the hole on the cylinder head by hand.

(2)

Tighten the plug bolt with the specified torque while pressing the timing chain on the RH intake CVVT.

Tightening torque :

Timing chain guide bolt :

21.6 ~ 25.5Nm (2.2 ~ 2.6kgf.m, 15.9 ~ 18.8lb-ft)

Timing chain tensioner plug bolt :

78.5 ~ 88.3N.m(8.0 ~ 9.0kgf.m, 57.9 ~ 65.1lb-ft)

note

1.

Do not reuse the timing chain tensioner.

2.

Make sure the timing chain tensioner is at compressed transport position state.

3.

Install the timing chain tensioner with the oil hole facing the plug bolt.

11.

Set tension of the timing chain tensioner.

(1)

LH Bank

A.

Press the timing chain on the LH intake CVVT by hand with the timing mark “L” on the LH intake and exhaust CVVT and the LH cylinder head upper surface aligned.

B.

To set tension of the timing chain tensioner, push the timing chain tensioner arm outward with a force about 150N (15.3kgf, 33.7lbf).

C.

To check the tension of the timing chain tensioner, push the timing chain tensioner arm outward strongly. The distance between the cylinder head surface and end of tensioner plunger should be about 20mm (0.79inch).

(2)

RH Bank

A.

To align the timing mark “R” on the RH intake and exhaust CVVT and the RH cylinder head upper surface, turn the exhaust CVVT about 20˚ counterclockwise while pressing the timing chain on the intake CVVT by hand with all of the chain installation mark of the sprocket and the timing marked chain links aligned.

B.

To set tension of the timing chain tensioner, push the timing chain tensioner arm outward with a force about 150N (15.3kgf, 33.7lbf).

C.

To check the tension of the timing chain tensioner, push the timing chain tensioner arm outward strongly. The distance between the tensioner body and end of tensioner plunger should be about 3.5mm (0.14inch).

(3)

After setting tension of the LH, RH timing chain tensioner, check timing again.

A.

Make sure the chain installation mark of the sprocket and the timing marked chain links are aligned.

B.

Rotate the crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm the timing marks on the LH, RH intake and exhaust CVVT and the RH cylinder head upper surfaces are aligned.

12.

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.

13.

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)

14.

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)

15.

Install the alternator (A).

Tightening torque :

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

16.

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

●

When the OCV is installed on the engine, do not move the engine while holding the OCV yoke.

17.

Use the SST (09231-2J500, 09231-H1100) install the timing chain upper cover oil seal (A).

18.

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 : Ø2.5 ± 0.5mm(0.1 ± 0.002in)

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.

19.

Install the timing chain upper cover (A).

Tightening torque :

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

20.

Install the water temperature sensor wiring assembly and bracket (A).

Tightening torque :

Wiring bracket bolts :

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

Water temperature sensor :

19.6 ~ 39.2Nm (2.0 ~ 4.0kgf.m, 14.5 ~ 28.9lb-ft)

21.

Install the oil pressure switch wiring assembly and bracket (A).

Tightening torque :

Wiring bracket bolts :

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

Oil pressure switch :

14.7 ~ 21.6Nm ( 1.5 ~ 2.2kgf.m, 10.8 ~ 15.9lb-ft)

22.

Use the SST (09231-2J500, 09231-H1100), install the oil seal (B) and the gasket (A).

23.

Install the cylinder head cover.

(1)

The sealant locations on cylinder head and timing chain upper case must be free of engine oil and ETC.

(2)

Before assembling the cylinder head cover, the liquid sealant TB 1217H or LT5900H should be applied on the gap between cylinder head and timing chain upper case.

The part must be assembled within 5 minutes after sealant was applied.

(3)

Install the cylinder head cover (A).

The part must be assembled within 5 minutes after sealant was applied.

Tightening torque :

1st step : 4.9 ~ 5.9N.m (0.5 ~ 0.6kgf.m, 3.6 ~ 4.3lb-ft)

2nd step : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

note

Tighten the cylinder head cover bolts as following method.

[RH]

[LH]

24.

Install the ignition coils (A).

Tightening torque :

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

25.

Install the knock sensors (A).

Tightening torque :

14.7 ~ 24.5N.m, 1.5 ~ 2.5kgf.m, 10.9 ~ 18.1lb-ft)

26.

Install the intake manifold module (A) tighten the nuts as following method.

Tightening torque :

1st step :

4.9 ~ 7.8N.m ( 0.5 ~ 0.8kgf.m, 3.6 ~ 5.8lb-ft)

2nd step :

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

note

Tighten the intake manifold nuts as followig method.

27.

Reconnect the PCV hose (A), the PCSV hose (B) and the water hoses (C) to the intake manifold module and the throttle body.

28.

Install the exhaust manifold (A) tighten the nuts as following method.

Tightening torque :

49.0 ~ 53.9N.m (5.0 ~ 5.5kgf.m, 36.2 ~ 39.8lb-ft)

note

The “TOP”mark of the gasket must be face the exhaust manifold.

note

Tighten the exhaust manifold nuts as followig method.

[LH]

[RH]

29.

Install the exhaust manifold heat protector (A).

Tightening torque :

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

30.

Reconnect the oxygen sensor connector (A) and Install the oxygen sensor connector bracket (B).

31.

Install the oil level gauge (A).

Tightening torque :

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

32.

Install the engine wiring harness to the cylinder head.

(1)

Reconnect the water temperature sensor connector (A) and the CVVT oil control valve connectors (B).

(2)

Reconnect the ETC module connector (A).

(3)

Reconnect the PCSV connector (A) and the injector connectors (B).

(4)

Reconnect the ignition coil connectors (A) and the wiring harness protector (B).

(5)

Reconnect the knock sensor connectors (A), the camshaft position sensor connectors (B), the oxygen sensor connector (C) and the condenser connector (D).

(6)

Reconnect the variable intake system solenoid valve connector (A) and the wiring harness protector (B).

(7)

Reconnect the knock sensor connectors (A), the camshaft position sensor connectors (B), the crankshaft position sensor connector (C), the oxygen sensor connector (D) and the condenser connector (E).

(8)

Reconnect the injector connectors (A).

(9)

Reconnect the ignition coil connectors (A) and the wiring harness protector (B).

(10)

Reconnect the oil pressure switch connector (A), the CVVT oil control valve connectors (B) and the air conditioner compressor switch connector (C).

33.

Install the drive belt tensioner (A).

Tightening torque :

19.6 ~ 23.5N.m (2.0 ~ 2.4kgf.m, 14.5 ~ 17.4lb-ft)

34.

Turn the tensioner (B) clockwise and loosen, then install the drive belt (A).

35.

Install the cooling fan clutch (A).

Tightening torque :

58.8N.m (6.0kgf.m, 43.4lb-ft)

note

Install the cooling fan clutch (A) after fixing the cooling fan pulley (B) by inserting a pin (C) into the hole of it.

36.

Install the cooling fan (A).

Tightening torque :

8.8 ~ 13.7Nm (0.9 ~ 1.4kgf.m, 6.5 ~ 10.1lb-ft)

37.

Reconnect the heater hoses (A), the fuel hose (B) and the purge control solenoid valve (PCSV) hose (C).

38.

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

39.

Install the air duct (A) and the air cleaner assembly (B).

Tightening torque :

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

40.

Install the engine cover (A).

41.

Reconnect the negative terminal to the battery.

note

●

Refill engine oil.

●

Clean the battery posts and cable terminals with sandpaper assemble them, 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.