Part 2 of 2
ReassemblyNOTE:
Thoroughly clean all parts to be assembled.
Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
Replace oil seals with new ones.
1. Install valves.
(1) Using SST(09222-4A000), push in a new oil seal.
NOTE:
Do not reuse old valve stem seals.
Incorrect installation of the seal could result in oil leakage past the valve guides.
(2) Install the valve, valve spring and spring retainer.
NOTE:
Place valve springs so that the side coated with enamel faces toward the valve spring retainer and then installs the retainer.
(3) Using the SST(09222-3K000, 09222-3K100), compress the spring and install the retainer locks. After installing the valves, ensure that the retainer locks are correctly in place before releasing the valve spring compressor.
(4) Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to ensure proper seating of the valve and retainer lock.
2. Install MLAs.
Check that the MLA rotates smoothly by hand.
NOTE:
MLA can be reinstalled in its original position.
Installation
NOTE:
- 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.
1. Install OCV filter.
CAUTION:
Keep the OCV filter clean.
2. Install the cylinder head gasket(A) on the cylinder block.
NOTE:
- Be careful of the installation direction.
- Apply liquid gasket (Loctite 5900H) on the mark (B).
- After applying sealant, assemble the cylinder head in five minutes.
3. Place the cylinder head carefully in order not to damage the gasket with the bottom part of the end.
4. Install cylinder head bolts.
A. Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.
B. Using hexagon wrench, install and tighten the 10 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°)
NOTE:
Always use new cylinder head bolt.
5. Install the intake OCV (A).
Tightening torque :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
6. Install the exhaust OCV (A).
Tightening torque :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
CAUTION:
- Do not reuse the OCV when dropped.
- Keep the OCV filter clean.
- Do not hold the OCV sleeve during servicing.
- When the OCV is installed on the engine, do not move the engine with holding the OCV yoke.
7. Install the camshafts.
NOTE:
Apply a light coat of engine oil on camshaft journals.
A. Install the exhaust camshaft lower bearing (A).
B. Install the camshafts (A).
C. Install the exhaust camshaft upper bearing (A).
D. Install camshaft bearing caps 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, 7.9 - 9.4lb-ft)
M8 : 27.5 - 31.4N.m(2.8 - 3.2kgf.m, 20.3 - 23.1lb-ft)
8. Install the water temperature control assembly (B) and then connect the oil cooler hoses (A).
Tightening torque :
Bolts : 14.7 - 19.6N.m (1.5 - 2.0 kgf.m, 10.8 - 14.5 lb-ft)
Nut : 18.6 - 23.5N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft)
CAUTION:
- Assemble water temp control assembly and water inlet pipe to water pump assembly before bolt for assembling of water inlet pipe to be tightened.
- Always use a new O-ring.
9. Install the water inlet pipe mounting bolt (A).
Tightening torque :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
10. Install the timing chain.
11. Check and adjust valve clearance.
12. Install the cylinder head cover.
A. The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling cylinder head cover.
B. After applying sealant, it should be assembled within 5 minutes.
Bead width :2.5mm(0.1in.)
Sealant :LOCTITE 5900H
C. Running the engine or performing a pressure test should not be performed within 30 minutes of assembly
D. Install the cylinder head cover bolts in the following sequence.
Tightening torque :
Step 1 : 3.9 - 5.9N.m(0.4 - 0.6kgf.m, 2.9 - 4.3lb-ft)
Step 2 : 7.8 - 9.8N.m(0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)
CAUTION:
Do not reuse cylinder head cover gasket.
13. Install the intake & exhaust manifold.
14. Connect the throttle body coolant hoses (A).
15. Connect the fuel hose (A), the brake booster vacuum hose (B) and heater hoses (C).
16. Connect the wiring connectors and harness clamps.
(1) OCV connector (A)
(2) VIS connector (A)
(3) Oil pressure switch (B)
(4) Knock sensor connector (C)
(5) A/C compressor switch connector (D)
(6) Alternator connector (E)
(7) Injector connectors (A)
(8) Ignition coil connectors (B)
(9) Intake CMPS connector (C)
(10) Exhaust CMPS connector (D)
(11) Exhaust OCV connector (E)
(12) VCM connector (A)
(13) ETC connector (A)
(14) MAP & IATS connector (B)
(15) PCSV connector (A)
(16) ECT sensor connector (B)
(17) Condenser connector (C)
(18) CKP sensor connector (D)
(19) Oxygen sensor connector (E)
17. Connect the radiator upper hose (A) and low hose (B).
18. Install the under cover (A).
Tightening torque:
19.6 - 24.5 N.m (2.0 - 2.5 kgf.m, 14.5 - 18.1 lb-ft)
19. Install the battery (D) and connect the battery positive terminal.
Tightening torque:
(+) terminal : 7.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 5.8 - 8.7 lb-ft)
Bracket bolt : 9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)
20. Install the air cleaner assembly (C) and then connect the air intake hose (B) and breather hose (A).
Tightening torque
Hose clamp bolt:
2.9 - 4.9 N.m (0.3 - 0.5 kgf.m, 2.2 - 3.6 lb-ft)
Air cleaner assembly bolts:
7.8 - 11.8 N.m (0.8 - 1.2 kgf.m, 5.8 - 8.7 lb-ft)
21. Install the air duct (C).
22. Install the engine cover (B).
23. Connect the battery negative terminal (A).
Tightening torque:
(-) terminal : 4.0 - 6.0 N.m (0.4 - 0.6 kgf.m, 3.0 - 4.4 lb-ft)
NOTE:
- Refill engine oil.
- Clean the battery posts and cable terminals with sandpaper. Assemble 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, 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.