2 of 2
The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at installing timing chain.
14. Install the RH timing chain tensioner arm(B).
Tightening torque
18.62 - 21.56N.m (1.9 - 2.2kgf.m, 13.74 - 15.91lb-ft)
15. Install the RH timing chain auto tensioner(A).
Tightening torque
9.80 - 11.76N.m (1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
16. Install the RH cam-to-cam guide(A).
Tightening torque
9.80 - 11.76N.m (1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
17. Install the oil pump chain guide(A).
Tightening torque
9.80 - 11.76N.m (1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
18. Install the oil pump chain tensioner assembly(A).
Tightening torque
9.80 - 11.76N.m (1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
19. Pull out the pins of hydraulic tensioner (LH & RH).
20. Install the oil pump chain cover(A).
Tightening torque
9.80 - 11.76N.m (1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
21. After rotating the crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm the timing mark.
NOTE:
Always turn the crankshaft clockwise.
22. Install the timing chain cover.
(1) The sealant locations on chain cover and on counter parts (cylinder head, cylinder block, and lower oil pan) must be free of engine oil and etc.
(2) Before assembling the timing chain cover, the liquid sealant TB 1217H should be applied on the gap between cylinder head and cylinder block.
The part must be assembled within 5 minutes after sealant was applied.
Bead width :2.5mm(0.1in.)
(3) After applying liquid sealant TB1217H on timing chain cover.
The part must be assembled within 5 minutes after sealant was applied.
Sealant should be applied without discontinuity.
Bead width :2.5mm(0.1in.)
(4) Install the new gasket(A) to the timing chain cover.
NOTE:
During timing cover installation, care not to take off applied sealant on the timing cover by contact with other parts.
(5) The dowel pins on the cylinder block and holes on the timing chain cover should be used as a reference in order to assemble the timing chain cover to be in exact position.
Tightening torque
B(17) :
18.62 - 21.56N.m (1.9 - 2.2kgf.m, 13.74 - 15.91lb-ft)
C(4) :
9.80 - 11.76N.m (1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
D(1) :
58.80 - 68.80N.m (6.0 - 7.0kgf.m, 43.40 - 50.63lb-ft)
E(1) :
58.80 - 68.80N.m (6.0 - 7.0kgf.m, 43.40 - 50.63lb-ft)
F(2) :
24.50 - 26.46N.m (2.5 - 2.7kgf.m, 18.08 - 19.53lb-ft)
G(4) :
21.56 - 23.52N.m (2.2 - 2.4kgf.m, 15.91 - 17.36lb-ft)
H(1) :
9.80 - 11.76N.m (1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
I(1) :
9.80 - 11.76N.m (1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
J(1) :
9.80 - 11.76N.m (1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
K(4) :
9.80 - 11.76N.m (1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
L(1):
21.56 - 26.46N.m (2.2 - 2.7kgf.m, 15.91 - 19.53lb-ft)
- New bolt
(6) The firing and/or blow out test should not be performed within 30 minutes after the timing chain cover was assembled.
23. Install the water pump pulley(A).
Tightening torque
7.84 - 9.80N.m (0.8 - 1.0kgf.m, 5.78 - 7.23lb-ft)
24. Install the drive belt auto tensioner(A).
Tightening torque
Bolt(B) :
81.39 - 85.32N.m (8.3 - 8.7kgf.m, 60.03 - 62.93lb-ft)
Bolt(C) :
17.64 - 21.56N.m (1.8 - 2.2kgf.m, 13.02 - 15.91lb-ft)
25. Install the drive belt idler(A).
Tightening torque
52.92 - 57.82N.m (5.4 - 5.9kgf.m, 39.06 - 42.67lb-ft)
26. Install the alternator(A).
Tightening torque
26.48 - 33.34N.m (2.7 - 3.4kgf.m, 19.53 - 24.59lb-ft)
27. Install the air conditioner compressor(A).
28. Install the power steering pump(A).
29. Lower the engine assembly by using the jack.
30. Using SST(09231-3C100), install timing chain cover oil seal.
31. Using SST(09231-3C300) install the crankshaft damper pulley(A).
Tightening torque
284.2 - 303.8N.m (29.0 - 31.0kgf.m, 209.76 - 224.22lb-ft)
32. Install the drive belt(A).
Crankshaft pulley -> A/C pulley -> idler pulley -> alternator pulley -> water pump pulley -> P/S pump pulley-> tensioner pulley.
Rotate auto tensioner arm in the counterclockwise moving auto tensioner pulley bolt with wrench.
After putting belt on auto tensioner pulley, release the auto tensioner pulley slowly.
33. Install the 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(TB1217H), it should be assembled within 5 minutes.
Bead width :2.5mm (0.1in.)
(3) The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was assembled.
(4) Install the cylinder head cover bolts as following method.
Tightening torque
9.80 - 11.76N.m (1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
CAUTION:
Do not reuse cylinder head cover gasket.
(5) Install the ignition coil.
(6) Connect the RH ignition coil connector(A), the condenser connector(B) and install the wiring bracket(C).
(7) Install the connector bracket(A) from the LH cylinder head cover.
34. Install the surge tank.
(1) Install the surge tank(A).
Tightening torque
9.80 - 11.76N.m (1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
(2) Install the connector bracket(A) on the surge tank.
Tightening torque
6.86 - 10.78N.m (0.7 - 1.1kgf.m, 5.06 - 7.96lb-ft)
(3) Install the surge tank stay.
Tightening torque
27.44 - 31.36N.m (2.8 - 3.2kgf.m, 20.25 - 23.14lb-ft)
(4) Connect the brake vacuum hose.
(5) Connect the PCV hose(C).
(6) Connect the water hoses(B) to the ETC.
(7) Install the ETC bracket(A).
Tightening torque
15.68 - 25.48N.m (1.6 - 2.6kgf.m, 11.57 - 18.80lb-ft)
(8) Connect the PCSV connector(A), the MAP sensor connector(B) and the PCSV hose(C).
(9) Connect the ETC connector(A) and the knock sensor connector(B).
(10) Connect the RH injector connector (A) and the ignition coil connector(B).
(11) Connect the RH oxygen sensor connector(A).
35. Install the no.1 engine mounting (A) through the lower position of A/C pipe line.
Tightening torque
49.03 - 63.74N.m (5.0 - 6.5kgf.m, 36.17 - 47.01lb-ft)
36. Install the A/C pipe bracket mounting bolt (A).
37. Install the engine coolant reservoir tank (A).
38. Install the engine mounting bracket (B).
Tightening torque
63.74 - 83.36N.m (6.5 - 8.5kgf.m, 47.01 - 61.48lb-ft)
39. Install the transaxle mounting bolts(A).
Tightening torque
49.03 - 63.74N.m (5.0 - 6.5kgf.m, 36.17 - 47.01lb-ft)
40. Remove the jack from the upper oil pan.
41. Install the lower oil pan.
(1) Using a gasket scraper, remove all the old packing material from the gasket surfaces.
(2) Before assembling the oil pan, the liquid sealant TB 1217H should be applied on oil pan.
The part must be assembled within 5 minutes after the sealant was applied.
Bead width :2.5mm(0.1in.).
But marked area(*) to be 5.0mm(0.2in.)
CAUTION:
- Make clean the sealing face before assembling two parts.
- Remove harmful foreign matters on the sealing face before applying sealant.
- When applying sealant gasket, sealant must not be protruded into the inside of oil pan.
- To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.
(3) Install the oil pan(A).
Uniformly tighten the bolts in several passes.
Tightening torque
9.80 - 11.76N.m (1.0 - 1.2kgf.m, 7.23 - 8.68lb-ft)
42. Install the upper radiator hose(A).
43. Install the side cover(A).
44. Install the under cover(A).
45. Install the front wheels.
46. Install the intake air hose and air cleaner assembly.
(1) Install the intake air hose(C) and air cleaner(D).
(2) Connect the ECM connector.
(3) Connect the breather hose(B) from air cleaner hose.
(4) Connect the AFS connector(A).
47. Install the air duct.
48. Install the engine cover.
49. Connect the negative terminal from the battery.
NOTE:
- Refill engine with engine oil.
- 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.