ENGINE UNIT REASSEMBLY

PROCEDURE

  1. INSTALL ENGINE WATER PUMP ASSEMBLY

    Click here

  2. INSTALL OIL PUMP ASSEMBLY

    Click here

  3. INSTALL NO. 1 OIL PAN BAFFLE PLATE

    1. Install the No. 1 oil pan baffle plate.

  4. INSTALL OIL PAN SUB-ASSEMBLY

    Click here

  5. INSTALL OIL FILTER UNION

    1. Install the oil filter union.

      8.0 N*m

      82 kgf*cm

      71 in.*lbf

  6. INSTALL OIL FILTER SUB-ASSEMBLY

    Click here

  7. INSTALL NO. 2 OIL PAN SUB-ASSEMBLY

    Click here

  8. INSTALL OIL PAN DRAIN PLUG

    1. Install the oil pan drain plug and a new gasket to the oil pan sub-assembly.

      42 N*m

      428 kgf*cm

      31 ft.*lbf

  9. INSTALL CYLINDER HEAD GASKET

    Click here

  10. INSTALL CYLINDER HEAD SUB-ASSEMBLY

    Click here

  11. INSTALL ENGINE WATER HOUSING COVER

    Click here

  12. INSTALL ENGINE OIL PRESSURE SWITCH ASSEMBLY

    Click here

  13. INSTALL KNOCK CONTROL SENSOR

    Click here

  14. INSTALL ENGINE COOLANT TEMPERATURE SENSOR

    Click here

  15. INSTALL CAM POSITION SENSOR (for Intake Side)

    Click here

  16. INSTALL CAM POSITION SENSOR (for Exhaust Side)

    Click here

  17. INSTALL REAR CYLINDER BLOCK COVER

    1. Clean the contact surfaces of the cylinder block sub-assembly and confirm that no oil, moisture, or other foreign matter is on the surfaces.

    2. Using a lint free piece of cloth or paper, clean the contact surfaces of the crankshaft and let them dry.

    3. A319015C01

      *1

      Rear Cylinder Block Cover

      *a

      Guide Sleeve

      Align the guide sleeve with the crankshaft and install a new rear cylinder block cover to the crankshaft.

      Note:

      Do not apply engine oil to the seal ring contact surfaces.

      Tip:

      A new rear cylinder block cover comes with a seal ring and guide sleeve.

    4. Evenly push the rear cylinder block cover until it contacts the cylinder block, then remove the guide sleeve.

    5. A325802

      Install the rear cylinder block cover with the 8 bolts.

      8.0 N*m

      82 kgf*cm

      71 in.*lbf

  18. INSTALL NO. 1 FLYWHEEL SPACER

    1. Install the No. 1 flywheel spacer.

  19. INSTALL FLYWHEEL SUB-ASSEMBLY

    Tip:

    The flywheel sub-assembly bolts are tightened in 4 progressive steps.

    1. Step 1:

      1. A325800N01

        Temporarily install the flywheel sub-assembly with the 6 bolts in several steps in the sequence shown in the illustration.

        8.0 N*m

        82 kgf*cm

        71 in.*lbf

    2. Step 2:

      1. A319013N01

        Turn the crankshaft clockwise and install SST as shown in the illustration.

        0109-2

        0109-2B

      2. Confirm that the crankshaft is locked and cannot be turned.

    3. Step 3:

      1. Uniformly tighten the 6 bolts in the order shown in step 1.

        30 N*m

        306 kgf*cm

        22 ft.*lbf

    4. A319006C01

      *a

      Paint Mark

      Step 4:

      1. Mark each flywheel sub-assembly bolt head with paint as shown in the illustration.

      2. Tighten the flywheel sub-assembly bolts by 90° in the order shown in step 1.

  20. INSTALL SPEED SENSOR

    Click here

  21. INSTALL ENGINE SPEED SENSOR PROTECTOR

    Click here

  22. INSTALL TIMING BELT

    Click here

  23. INSTALL CRANKSHAFT TIMING PULLEY

    1. Install the crankshaft timing pulley to crankshaft pulley hub.

  24. TEMPORARILY TIGHTEN CRANKSHAFT PULLEY HUB

    1. A319016C01

      *a

      Key

      *b

      Key Groove

      Align the key of the crankshaft pulley hub with the key groove of the crankshaft, and fit the crankshaft pulley hub to the crankshaft.

    2. A325797

      Temporarily install the crankshaft pulley hub with bolt.

      A319017C01

      *a

      Mark
      Note:

      Make sure the mark of the crankshaft pulley hub is horizontal as shown in the illustration.

  25. INSTALL NO. 2 CAMSHAFT

    Click here

  26. INSTALL CAMSHAFT

    Click here

  27. INSTALL CAMSHAFT TIMING GEAR ASSEMBLY

    Click here

  28. INSTALL CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    Click here

  29. INSPECT VALVE CLEARANCE

    Click here

  30. ADJUST VALVE CLEARANCE

    Click here

  31. INSTALL NO. 1 TIMING BELT IDLER SUB-ASSEMBLY

    1. Install the No. 1 timing belt idler sub-assembly with the bolt.

      20 N*m

      204 kgf*cm

      15 ft.*lbf

  32. TEMPORARILY TIGHTEN TIMING BELT TENSIONER ASSEMBLY

    1. A319018C01

      *a

      Hexagonal Hole of Timing Belt Tensioner Assembly

      Temporarily install the timing belt tensioner assembly with the bolt.

      Tip:

      Position the hexagonal hole of the timing belt tensioner assembly as shown in the illustration so that the timing belt tensioner assembly can be installed easily.

  33. ADJUST TIMING BELT

    1. Check the timing belt is positioned as shown in the illustration.

      A327651C01

      *a

      Timing Mark

      -

      -
    2. A319019C01

      *a

      Hexagonal Hole of Timing Belt Tensioner Assembly

      *b

      Match Mark

      Insert a hexagon wrench into the hexagonal hole of the timing belt tensioner assembly and turn the timing belt tensioner assembly counterclockwise to align the match mark as shown in the illustration.

      Note:

      Do not turn the timing belt tensioner assembly further than the match mark, or the timing belt tension may become excessive.

  34. FULLY TIGHTEN TIMING BELT TENSIONER ASSEMBLY

    1. Fully tighten the timing belt tensioner assembly with the bolt.

      20 N*m

      204 kgf*cm

      15 ft.*lbf

  35. FULLY TIGHTEN CRANKSHAFT PULLEY HUB

    1. A325797

      Fully tighten the crankshaft pulley hub with the bolt.

      50 N*m

      510 kgf*cm

      37 ft.*lbf

    2. A319009C01

      *a

      Paint Mark

      Mark crankshaft pulley hub bolt head with paint as shown in the illustration.

    3. Tighten the crankshaft pulley hub bolt 180°.

  36. INSTALL FUEL DELIVERY PIPE

    Click here

  37. INSTALL NO. 1 WATER BY-PASS PIPE

    1. Install the No. 1 water by-pass pipe with the bolt.

      8.0 N*m

      82 kgf*cm

      71 in.*lbf

  38. INSTALL ENGINE OIL LEVEL DIPSTICK GUIDE

    Click here

  39. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Intake Side)

    Click here

  40. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY (for Exhaust Side)

    Click here

  41. INSTALL CYLINDER BLOCK COVER

    1. Install a new cylinder block cover gasket.

    2. Install the cylinder block cover with the 4 bolts.

      8.0 N*m

      82 kgf*cm

      71 in.*lbf

  42. INSTALL CRANKSHAFT PULLEY HUB OIL SEAL

    1. Clean the cylinder block housing and confirm that no oil, moisture, or other foreign matter is on the surfaces.

    2. Using SST, install a new crankshaft pulley hub oil seal.

      0109-3

      0109-3A

      A319020C01

      *1

      Crankshaft Pulley Hub

      *2

      Crankshaft Pulley Hub Oil Seal

      1. Using a screwdriver, install SST (A) with the 3 bolts (SST (B)) to the crankshaft pulley hub.

      2. Install a new crankshaft pulley hub oil seal and SST (C) with the bolt (SST (D)).

      3. Tighten the bolt (SST (D)) until SST (C) contacts the cylinder block.

        Note:

        After installing the crankshaft pulley hub oil seal, wait for 30 seconds before removing SST.

  43. INSTALL CRANKSHAFT PULLEY

    1. Install the crankshaft pulley with the 3 bolts.

      30 N*m

      306 kgf*cm

      22 ft.*lbf

  44. INSTALL STUD BOLT

    Tip:

    Perform this procedure only when replacement of the stud bolt is necessary.

    1. A319025C01

      *a

      Type A

      *b

      Type B

      Using an E10 "TORX" socket wrench, install the 2 stud bolts to the cylinder head sub-assembly.

      Torque

      7.0 N*m (71 kgf*cm, 62 in.*lbf)

  45. INSTALL CYLINDER HEAD COVER GASKET

    1. A319007

      Confirm that the 17 seal washer inserts are installed to the cylinder head cover sub-assembly.

    2. A325789C01

      *1

      Cylinder Head Cover Gasket

      Install 2 new cylinder head cover gaskets.

  46. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY

    1. A319008C02

      *a

      Type A

      Install the cylinder head cover sub-assembly with the 17 bolts in several steps in the order shown in the illustration.

      8.0 N*m

      82 kgf*cm

      71 in.*lbf

      Tip:

      Using a 10 mm deep socket, tighten the bolt (type A).

  47. INSTALL OIL FILLER CAP SUB-ASSEMBLY

    1. Install the oil filler cap sub-assembly to the cylinder head cover sub-assembly.

  48. INSTALL SPARK PLUG

    Click here