Repair Procedures: Installation

Tightening torque: 

18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft)

Fig 3: Identifying Timing Chain Guide

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Tightening torque: 

18.6 ~ 22.6 N.m (1.9 ~ 2.3 kgf.m, 13.7 ~ 16.6 lb-ft)

Fig 4: Identifying Timing Chain Tensioner Arm

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Crankshaft sprocket (A) → Timing chain guide (B) → Intake CVVT sprocket (C) → Exhaust CVVT sprocket (D)

1. Install the timing chain with no slack between the crankshaft sprocket and the intake CVVT sprocket.
   Fig 5: Identifying Crankshaft Sprocket

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   NOTE: The timing marks of each sprocket should be matched with timing marks (color link) of timing chain when installing the timing chain.
2. Install the timing chain on the exhaust CVVT sprocket with no slack while turning the CVVT assembly clockwise.

Fig 6: Identifying Timing Marks

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Tightening torque: 

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

Fig 7: Identifying Timing Chain Auto Tensioner

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1. Using a gasket scraper, remove all the old packing material from the gasket surfaces.
2. The sealant locations on the chain cover and the counter parts (cam carrier, cylinder head, cylinder block, and lower crankcase) must be free of harmful foreign materials, oil, dust and moisture. Spraying cleaner on the surface and wiping with a clean duster.
3. Before assembling the timing chain cover, liquid sealant should be applied on the gap between cam carrier, cylinder head and cylinder block.

   Bead width:  3.0 ~ 5.0 mm (0.11 ~ 0.20 in.)

   Sealant:  Threebond 1217H or equivalent

   Fig 9: Identifying Sealant Locations

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4. After applying liquid sealant on the timing chain cover, assemble the cover within 5 minutes after sealant was applied. Continuous bead of sealant should be applied to prevent any path from oil leakage.

   Bead width 

   Whole section: 2.5 ~ 3.5 mm (0.10 ~ 0.14 in.)

   Section A: 4.5 ~ 5.5 mm (0.18 ~ 0.22 in.)

   Section B: 8.0 ~ 9.0 mm (0.32 ~ 0.35 in.)

   Sealant:  Threebond 1217H or equivalent

   Fig 10: Identifying Liquid Sealant Apply Area

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5. Install the timing chain cover. 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 in exact position.

   Tightening torque 

   Bolts (A, B):

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

   Bolt (C):

   19.6 ~ 23.5 N.m (2.0 ~ 2.4 kgf.m, 14.5 ~ 17.4 lb-ft)

   Bolts (D, E):

   39.2 ~ 49.0 N.m (4.0 ~ 5.0 kgf.m, 28.9 ~ 36.2 lb-ft)

   Bolt (F):

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

   Fig 11: Identifying Timing Chain Cover Bolt Tightening Sequence

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   CAUTION: Do not reuse the seal bolts (C, F).
   CAUTION: The engine running or pressure test should not be performed within 30 minutes after the timing chain cover was assembled.

1. Apply engine oil on the edge of new oil seal.
   CAUTION: Remove any debris from the lip portion of the oil seal.
2. Install the front oil seal (A) using SST (09231-2E000, 09231-H1100).
   Fig 12: Identifying Front Oil Seal

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Tightening torque: 

196.1 ~ 205.9 N.m (20.0 ~ 21.0 kgf.m, 144.7 ~ 151.9 lb-ft)

Fig 13: Identifying Crankshaft Damper Pulley

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Tightening torque: 

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

Fig 19: Identifying Water Pump Pulley

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Tightening torque: 

34.3 ~ 39.2 N.m (3.5 ~ 4.0 kgf.m, 25.3 ~ 28.9 lb-ft)

Fig 20: Identifying Front Engine Hanger

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1. Preassemble the alternator (A) temporarily.
   Fig 21: Identifying Alternator

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2. Install the drive belt (B).
3. Adjust the tension by turning the tension adjusting bolt (A) clockwise. (Refer to "ALTERNATOR ")

   Belt tension 

   New belt:

   637.4 ~ 735.5 N (65 ~ 75 kgf, 143.3 ~ 165.3 lbf)

   Used belt:

   441.3 ~ 539.4 N (45 ~ 55 kgf, 99.2 ~ 121.3 lbf)

   Fig 22: Engine Drive Belt Routing

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4. Tighten the alternator mounting bolts with the specified torque.

   Tightening torque 

   M10 bolt:

   29.4 ~ 41.2 N.m (3.0 ~ 4.2 kgf.m, 21.7 ~ 30.4 lb-ft)

   M8 bolt:

   21.6 ~ 32.4 N.m (2.2 ~ 3.3 kgf.m, 15.9 ~ 23.9 lb-ft)

1. Install the engine mounting support bracket (B).

   Tightening torque 

   Nut (C):

   63.7 ~ 83.4 N.m (6.5 ~ 8.5 kgf.m, 47.0 ~ 61.5 lb-ft)

   Bolt (D) and Nuts (E):

   49.0 ~ 63.7 N.m (5.0 ~ 6.5 kgf.m, 36.2 ~ 47.0 lb-ft)

2. Connect the engine ground line (A).
   Fig 23: Connecting Engine Ground Line

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3. Remove the jack from the lower crankcase.

1. The hardening sealant located on the cylinder head cover and the gap between the timing chain cover and the cam carrier should be removed before assembling cylinder head cover.
2. Apply engine oil on the lip portion of the oil seal on the cover and outer surface of the spark plug pipes.
3. After applying sealant on the gap between the timing chain cover and the cam carrier, it should be assembled within 5 minutes.

   Bead width:  2.0 ~ 3.0 mm (0.08 ~ 0.12 in.)

   Sealant:  Threebond 1217H or equivalent

   Fig 24: Identifying Sealant Apply Area

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4. Install the cylinder head cover (A) by tightening the bolts, in several passes, in the sequence as shown.

   Tightening torque 

   1st step: 3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)

   2nd step: 7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)

   Fig 25: Identifying Cylinder Head Cover

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   CAUTION:

   • Do not reuse cylinder head cover gasket.
   • Before installing the cylinder head cover, make sure the cylinder head cover gasket is not separated from the cylinder head cover gasket groove.
   • The engine running or pressure test should not be performed within 30 minutes after the cylinder head cover was assembled.

Tightening torque: 

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

Fig 27: Identifying Ignition Coils

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1. The intake OCV (Oil control valve) connector (A)
   Fig 30: Identifying Intake OCV Connector

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2. The exhaust OCV (Oil control valve) connector (A)
   Fig 31: Identifying Exhaust OCV Connector

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3. The alternator connector (A)
   Fig 32: Identifying Alternator Connector

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4. The ignition coil connectors (A)
   Fig 33: Identifying Ignition Coil Connectors

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5. The intake CMPS (Camshaft position sensor) connector (A)
6. The exhaust CMPS (Camshaft position sensor) connector (B)
   Fig 34: Identifying CMPS Connectors

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