Repair Procedures: Installation

WARNING: This page is about a different variant/trim than selected.

NOTE:

Thoroughly clean all parts to be assembled.
Always use new cylinder head gasket and manifold gaskets.
Always use new cylinder head bolts. Cylinder head bolts are torque-to-yield bolts designed to be permanently elongated beyond the state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.
The cylinder head gasket is a metal gasket. Take care not to bend it.
Rotate the crankshaft to set the No. 1 piston at TDC (Top dead center) on compression stroke.

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

Remove hardening sealant, oil, dust, moisture and harmful foreign materials from the cylinder block and the cylinder head.
Apply liquid gasket on the edge of the cylinder block.
Install the cylinder head gasket with the dowel pins of the cylinder block.

Apply liquid gasket on the edge of the cylinder head gasket.

Information

Apply liquid gasket on the edge of the cylinder block and cylinder head gasket.

Sealant:

Threebond 1217H or equivalent

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NOTE: Assemble the cylinder head gasket and the cylinder head within 5 minutes after applying sealant.

Place the cylinder head (A) carefully to protect damage to the head gasket (B) during installation.

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Install the cylinder head bolts with washers.
Install and tighten the 10 cylinder head bolts, in several passes, in the sequence as shown.

Tightening torque

1st step:

32.4 - 36.3 N.m (3.3 - 3.7 kgf.m, 23.9 - 26.8 lb.ft)

2nd step: 90-95°

3rd step: 90-95°

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Fig 1: Cylinder Head Bolts Tightening Sequence
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NOTE:
- Always use new cylinder head bolts. Cylinder head bolts are torque-to-yield bolts designed to be permanently elongated beyond the state of elasticity when torqued, so if the bolts are removed and reused, it may cause the bolts to break or fail to maintain clamping force.
- Do not apply engine oil on the bolt threads to achieve correct torque.
- Remove the extruded sealant within 5 minutes after installing cylinder head bolts.
- The engine running or pressure test should not be performed within 30 minutes after installing cylinder head bolts.
- Be careful not to change the installing position of the preassembled washer bolts and non-preassembled washer bolts.
- When installing the washer of the non-preassembled washer bolts, the round and chamfer of washers should be faced up.
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Install the rear engine hanger (A).
Tightening torque:

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

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Install the exhaust oil control valve (OCV) (A).
Tightening torque:

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

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Install the intake oil control valve (OCV) (A).
Tightening torque:

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

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NOTE:
- Do not reuse the OCV when dropped.
- Keep the OCV filter clean.
- Do not hold the OCV sleeve (A) during servicing.
- When the OCV is installed on the engine, do not move the engine with holding the OCV yoke.
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Install the oil control adapter (A) with a new gasket (B).
Tightening torque:

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

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Install the hydraulic lash adjuster (HLA) (A) and the swing arm (B).

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When installing HLA, it should be held upright so that engine oil in HLA may not spill and assured that dust does not adhere to HLA.

HLA should be inserted carefully to the cylinder head not to spill engine oil.

If engine oil has spilled out of the lash adjuster, HLA bleeding should be performed according to the below procedure.

HLA bleeding procedure

Stroke the lash adjuster in engine oil by pushing its cap 4 to 5 times while pushing the ball down slightly using a hard steel wire. Be careful not to give the ball a hard push because the ball weighs just several grams.

If installing with engine oil spilling out of the lash adjuster and air in it, it might make an abnormal noise.

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Install the cam carrier.

Using a gasket scraper, remove all the old packing material from the gasket surfaces.
The sealant locations on the cam carrier and the cylinder head must be free of harmful foreign materials, oil, dust and moisture. Spray cleaner on the surface and wipe with a clean duster.

After applying liquid sealant on the bottom surface of the cam carrier, assemble the cam carrier. Continuous bead of sealant should be applied to prevent any path from oil leakage.

Bead width : 2.5 - 3.5 mm (0.10 - 0.14 in.)

Sealant : Threebond 1217H or equivalent

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Place the cam carrier (A) on the cylinder head. The dowel pins on the cam carrier and holes on the cylinder head should be used as a reference in order to assemble the cam carrier in exact position.

Fasten the cam carrier bolts.

Tightening torque:

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

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NOTE:

Assemble the cam carrier within 5 minutes after applying sealant.
Assemble the camshaft bearing cap within 5 minutes after assembling the cam carrier.
The engine running or pressure test should not be performed within 30 minutes after assembling the cam carrier.

Install the camshafts.

Place the intake and exhaust camshafts (A) on the cam carrier.

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Install the camshaft bearing caps (A).

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Tighten the bolts, in several passes, in the sequence as shown.

Tightening torque

M6 bolts:

11.8 - 13.7 N.m (1.2 - 1.4 kgf.m, 8.7 - 10.1 lb.ft)

M8 bolts:

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

Fig 2: Camshaft Bearing Caps Bolts Tightening Sequence

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NOTE: Be careful not to change the position and direction of bearing caps.

Install the intake CVVT assembly (A) and exhaust CVVT assembly (B).
Tightening torque:

64.7 - 76.5 N.m (6.6 - 7.8 kgf.m, 47.7 - 56.4 lb.ft)

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Information

When removing the CVVT assembly bolt, hold the camshaft with a wrench to prevent the camshaft from rotating.

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Install the other parts reverse order of removal.
Add all the necessary fluids and check for leaks. Connect KDS. Check for codes, note, and clear. Recheck.
NOTE:
- Refill engine with engine oil.
- Refill a radiator and a reservoir tank with engine coolant.
- Clean battery posts and cable terminals and assemble.
- 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 line.
- 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.