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.
Install the cylinder head gasket (A) on the cylinder block.
Be careful of the installation direction.
Apply liquid gasket (Loctite 5900H or equivalent) on the edge of cylinder head gasket upside and downside. (At the position 'B')
After applying sealant, assemble the cylinder head in five minutes.
Place the cylinder head carefully in order not to damage the gasket with the bottom part of the end.
Install cylinder head bolts.
Do not apply engine oil on the the cylinder head bolts.
Using the SST(09221-4A000), tighten the cylinder head bolts and plate washers, in several passes, in the sequence shown.
Tightening torque :
32.4~36.3Nm (3.3~3.7kgf.m, 23.9~26.8lb-ft) + 90~95° + 90~95°
Always use new cylinder head bolt.
Install the intake CMPS (Camshaft position sensor) (A).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Install the exhaust CMPS (Camshaft position sensor) (A) and the engine hanger and cam position sensor cover (B).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Install the intake OCV (Oil control valve) (A).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Install the exhaust OCV (Oil control valve) (A).
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Do not reuse the OCV when dropped.
Keep the OCV filter clean.
Do not hold the OCV sleeve (A) during servicing.
When the OCV is installed on the engine, do not move the engine with holding the OCV yoke.
Install the camshafts.
Apply a light coat of engine oil on camshaft journals.
Install the exhaust camshaft lower bearing (A).
Install the camshafts (A).
Install the exhaust camshaft upper bearing (A) to the front bearing cap.
Install camshaft bearing caps (A) in their proper locations.
Tightening order
Group A → Group B → Group C.
Tightening torque :
Step 1
M6 : 5.9N.m (0.6kgf.m, 4.3lb-ft)
M8 : 14.7N.m (1.5kgf.m, 10.8lb-ft)
Step 2
M6 : 10.8 ~ 12.7N.m (1.1 ~ 1.3kgf.m, 8.0 ~ 9.4lb-ft)
M8 : 27.5 ~ 31.4N.m (2.8 ~ 3.2kgf.m, 20.3 ~ 23.1lb-ft)
Be careful not to change the position and direction of bearing caps.
Install the intake CVVT assembly (A) and exhaust CVVT assembly (B).
Tightening torque :
53.9 ~ 63.7N.m (5.5 ~ 6.5kgf.m, 39.7 ~ 47.0lb-ft)
When installing the CVVT assembly bolt, prevent the camshaft from rotating by using a wrench at position A.
Install the intake and exhaust manifold. (Refer to Intake and exhaust system in this group)
Install the timing chain. (Refer to Timing system in this group)
Check and adjust the valve clearance. (Refer to General information in this group)
Install the water temperature control assembly (A) with the water inlet pipe (B).
Tightening torque :
Bolts : 14.7 ~ 19.6N.m (1.5 ~ 2.0kgf.m, 10.8 ~ 14.5lb-ft)
Nut : 18.6 ~ 23.5N.m (1.9 ~ 2.4kgf.m, 13.7 ~ 17.4lb-ft)
Tightening torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)
Assemble water temp control assembly and water inlet pipe to water pump assembly before nuts for assembling of water inlet pipe to be tightened.
Insert after wetting O-ring or inner surface of thermostat housing.
Always use a new O-ring.
Install 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 (Loctite 5900H or equivalent), it should be assembled within 5 minutes.
Bead width : 2.5mm (0.10in.)
Install the cylinder head cover (A) by tightening the bolts as following method.
Tightening torque :
1st step : 3.9 ~ 5.9N.m(0.4 ~ 0.6kgf.m, 2.9 ~ 4.3lb-ft)
2nd step : 7.8 ~ 9.8N.m(0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
Do not reuse cylinder head cover gasket.
The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was assembled.
Connect the oil cooler coolant hoses (A). (2.4L only)
Connect the throttle body coolant hoses (A). (if equipped)
Connect the fuel hose (A), the brake booster vacuum hose (B), the PCSV (Purge control solenoid valve) hose (C).
Connect the heater hose (A).
When installing the heater hoses, install as shown in illustrations.
Connect the wiring connectors and harness clamps, and install the wiring and protectors to the cylinder head and intake manifold.
The intake OCV (Oil control valve) connector (A)
The power steering oil pressure switch connector (A) (HPS only) and the exhaust OCV (Oil control valve) connector (B)
The VIS (Variable intake system) connector (A), the OPS (Oil pressure switch) connector (B), the knock sensor connector (C), the A/C compressor switch connector (D) and the alternator connector (E)
The injector connectors (A) and the ignition coil connectors (B).
The ETC (Electronic throttle control) connector (A) and the MAPS (Manifold absolute pressure sensor) & IATS (Intake air temperature sensor) connector (B)
The exhaust CMPS (Camshaft position sensor) connector (A)
The ECTS (Engine coolant temperature sensor) connector (A), the condenser connector (B), the CKPS (Crankshaft position sensor) connector (C), the front oxygen sensor connector (D)
The intake CMPS (Camshaft position sensor) connector (A) and the PCSV (Purge control solenoid valve) connector (B)
Connect the radiator upper hose (A) and lower hose (B).
Install the radiator hoses as shown illustrations.
Install the under cover. (Refer to Timing system in this group)
Remove the RH front wheel. (Refer to SS group)
Install the air cleaner assembly.
Install the air cleaner assembly (E) and then connect the air intake hose (D).
Tightening torque
Hose clamp bolt :
2.9 ~ 4.9N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6lb-ft)
Air cleaner assembly bolts :
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
Connect the breather hose (A), the brake booster vacuum hose (B) and the intensifier hose (C).
Install the air intake hose while the plate of the hose clamp must be in line with the stopper of the hose.
Install the air intake hose while the center of the mark of hose must be in line with the throttle body rib.
Install the air duct (B).
Connect the battery negative terminal (A).
Tightening torque:
Without battery sensor :
7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb-ft)
With battery sensor :
4.0 ~ 6.0N.m (0.4 ~ 0.6kgf.m, 3.0 ~ 4.4lb-ft)
Install the engine cover.
Perform the following :
Adjust a shift cable.
Refill engine with engine oil.
Refill a transaxle with fluid.
Refill a radiator and a reservoir tank with engine coolant.
Clean battery posts and cable terminals and assemble.
Inspect for fuel leakage.
After assemble 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 line.
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.
