13451021

note

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Thoroughly clean all parts to be assembled.

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Always use a new head and manifold gasket.

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

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

Install the cylinder head gasket (A) on the cylinder block.

note

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Be careful of the installation direction.

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Apply liquid gasket (Loctite 5900H or equivalent) on the edge of cylinder head gasket upside and downside. (At the position 'B')

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After applying sealant, assemble the cylinder head in five minutes.

Install cylinder head bolts.

(1)

Do not apply engine oil on the the cylinder head bolts.

(2)

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°

caution

Always use new cylinder head bolt.

Install the injector & rail module (A). (Refer to FL group)

Pre-tighten the bolts and then tighten the bolts with the specified torque in the sequence shown.

Tightening torque :

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

Install the exhaust CMPS (Camshaft position sensor) (A) and the engine hanger (B).

Tightening torque :

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

Engine hanger bolt: 27.5 ~ 31.4N.m (2.8 ~ 3.2kgf.m, 20.3 ~ 23.1lb-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)

caution

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Do not reuse the OCV when dropped.

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Keep the OCV filter clean.

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Do not hold the OCV sleeve (A) during servicing.

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

Install the camshafts.

note

Apply a light coat of engine oil on camshaft journals.

(1)

Install the exhaust camshaft lower bearing (A).

(2)

Install the camshafts (A).

(3)

Install the exhaust camshaft upper bearing (A) to the front bearing cap.

(4)

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)

10.

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)

note

When installing the CVVT assembly bolt, prevent the camshaft from rotating by using a wrench at position A.

15.

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)

note

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Assemble water temp control assembly and water inlet pipe to water pump assembly before nuts for assembling of water inlet pipe to be tightened.

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Insert after wetting O-ring or inner surface of thermostat housing.

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Always use a new O-ring.

16.

Install cylinder head cover.

(1)

The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling cylinder head cover.

(2)

After applying sealant (Loctite 5900H or equivalent), it should be assembled within 5 minutes.

Bead width : 2.5mm (0.10in.)

(3)

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)

caution

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Do not reuse cylinder head cover gasket.

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The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was assembled.

20.

Install the high pressure fuel pump (A) and the roller tappet (B). (Refer to FL group)

Tightening torque :

12.7 ~ 14.7N.m (1.3 ~ 1.5kgf.m, 9.4 ~ 10.8lb-ft)

caution

Before installing the high pressure fuel pump, position the roller tappet in the lowest position (BDC) by rotating the crankshaft. Otherwise the installation bolts may be broken because of tension of the pump spring.

note

Do not use already used bolt again.

note

When tightening the installation bolts of the high pressure fuel pump, tighten the bolts in small increments (0.5 turns) after tightening them by hand.

caution

Note that internal damage may occur when the component is dropped. In this case, use it after inspecting.

note

Apply engine oil to the O-ring (A) of the high pressure fuel pump, the roller tappet (B), and the protrusion (C). Also apply engine oil to the groove where the protrusion is installed.

21.

Install the high pressure pipe (A). (Refer to FL group)

Tightening torque :

Bolt : 7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

Nuts : 26.5 ~ 32.4N.m (2.7 ~ 3.3kgf.m, 19.5 ~ 23.9lb-ft)

note

Do not reuse the high pressure pipe.

24.

Connect the wiring connectors and harness clamps, and install the wiring protectors to the cylinder head, intake manifold and exhaust manifold.

(1)

Connect the exhaust OCV (Oil control valve) connector (A).

(2)

Connect the VIS (Variable intake system) connector (A), the OPS (Oil pressure switch) connector (B), the injector extension connector (C), the knock sensor connector (D), the alternator connector (E) and the A/C compressor switch connector (F).

(3)

Connect the ignition coil connectors (A), the fuel pump connector (B) and the intake OCV (Oil control valve) connector (C).

(4)

Connect the ETC (Electronic throttle control) connector (A) and MAPS (Manifold absolute pressure sensor) & IATS (Intake air temperature sensor) connector (B).

(5)

Connect the ECTS (Engine coolant temperature sensor) connector (A), the exhaust CMPS (Camshaft position sensor) connector (B), the condenser connector (C), the CKPS (Crankshaft position sensor) connector (D) and the oxygen sensor connector (E).

(6)

Connect the intake CMPS (Camshaft position sensor) connector (A) and the PCSV (Purge control solenoid valve) connector (B).

26.

Install the under covers (A,B).

Tightening torque:

7.8 ~ 11.8N.m (0.8 ~ 1.2kgf.m, 5.8 ~ 8.7lb-ft)

note

When installing the cover (B), install the cover with the mounting bracket.

28.

Install the air cleaner assembly.

(1)

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)

(2)

Connect the breather hose (A), the brake booster vacuum hose (B) and the intensifier hose (C).

note

• 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 bolt.

note

Perform the following :

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Adjust a shift cable.

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Refill engine with engine oil.

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Refill a transaxle with fluid.

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Refill a radiator and a reservoir tank with engine coolant.

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Clean battery posts and cable terminals and assemble.

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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.

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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