Part 2 of 2
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 LT5900H or equivalent 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 exhaust manifold (A) by tightening 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 following method.
[RH]
[LH] - With engine assembly removal
[LH] - Without engine assembly removal
21. 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)
22. Install the engine coolant temperature sensor (ECTS) wiring assembly and bracket (A).
Tightening torque :
Wiring bracket bolts :
9.8 - 11.8Nm (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
Engine coolant temperature sensor :
19.6 - 39.2Nm (2.0 - 4.0kgf.m, 14.5 - 28.9lb-ft)
23. Install the oil pressure switch (OPS) 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)
24. Use the SST (09231-2J500, 09231-H1100), install the oil seal (B) and the gasket (A).
25. 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 LT5900H or equivalent 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]
26. Install the ignition coils (A).
Tightening torque :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
27. Reconnect the water hose (A).
28. Install the knock sensors (A) and wiring assembly bracket (B).
Tightening torque :
64.7 - 76.5N.m (6.6 - 7.8kgf.m, 47.7 - 56.4lb-ft)
29. Install the intake manifold module (A) by tightening 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 following method.
30. Reconnect the positive crankcase ventilation (PCV) hose (A) to the intake manifold module.
31. Install the oxygen sensor (HO2S) connector bracket (A).
32. Install the oil level gauge (A).
Tightening torque :
9.8 - 11.8Nm (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
33. Install the engine wiring harness to the cylinder head.
(1) Reconnect the engine coolant temperature sensor (ECTS) connector (A) and the CVVT oil control valve (OCV) connectors (B).
(2) Reconnect the alternator connector (A).
(3) Reconnect the ETC module connector (A).
(4) Reconnect the purge control solenoid valve (PCSV) connector (A) and the injector connectors (B).
(5) Reconnect the ignition coil connectors (A) and the wiring harness protector (B).
(6) Reconnect the knock sensor connectors (A), the camshaft position sensor (CMPS) connectors (B), the oxygen sensor (HO2S) connector (C), the condenser connector (D) and the ground line (E).
(7) Reconnect the variable intake system (VIS) solenoid valve connector (A) and the wiring harness protector (B).
(8) Reconnect the knock sensor connectors (A), the camshaft position sensor (CMPS) connectors (B), the crankshaft position sensor (CKPS) connector (C), the oxygen sensor (HO2S) connector (D), the condenser connector (E) and the ground line (F).
(9) Reconnect the injector connectors (A).
(10) Reconnect the ignition coil connectors (A) and the wiring harness protector (B).
(11) Reconnect the oil pressure switch (OPS) connector (A), the CVVT oil control valve (OCV) connectors (B) and the air conditioner compressor switch connector (C).
34. Install the drive belt tensioner (A).
Tightening torque :
19.6 - 23.5N.m (2.0 - 2.4kgf.m, 14.5 - 17.4lb-ft)
35. Turn the tensioner (B) clockwise and loosen, then install the drive belt (A).
36. Install the radiator & cooling fan assembly.
37. Connect the heater hoses (A),
38. Connect the fuel hose (A), the purge control solenoid valve (PCSV) hose (B) and the brake booster vacuum hose (C).
39. Connect the radiator upper hose (A) and lower hose (B).
40. Install the air cleaner assembly.
(1) Install the resonator (F), the intake air hose (E) and air cleaner assembly (D).
(2) Reconnect the breather hose (B).
(3) Reconnect the air flow sensor (AFS) connector (C).
(4) Install the air duct (A).
41. Install the engine room cover (A), the engine cover (B) and the radiator grill upper cover (C).
42. Connect the battery negative terminal (A).
NOTE:
- Refill engine oil.
- Clean the battery posts and cable terminals with sandpaper assemble them, 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, and 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.