Repair Procedures: Installation

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 THREE BOND 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: 2.5 mm (0.1 in.)
  
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3. Apply liquid sealant THREE BOND 1217H on timing chain cover. The part must be assembled within 5 minutes after sealant was applied. Sealant should be applied without discontinuity.
  
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  NOTE:
  - Fill the T-joint area (6EA *) with sealant.
  - Apply sealant all around the dowel pin hole (2EA).
4. Install the new gasket (A) to the timing chain cover.
  Always use a new gasket.
  
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  NOTE: During timing cover installation, be careful not to take off applied sealant on the timing cover by contacting 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 the exact position.
  Tightening torque
  
  A (19EA):
  
  18.6 ~ 21.6 N.m (1.9 ~ 2.2 kgf.m, 13.7 ~ 15.9 lb-ft)
  
  B (2EA):
  
  24.5 ~ 26.5 N.m (2.5 ~ 2.7 kgf.m, 18.1 ~ 19.5 lb-ft)
  
  C (2EA):
  
  58.8 ~ 68.8 N.m (6.0 ~ 7.0 kgf.m, 43.4 ~ 50.6 lb-ft)
  
  D (3EA):
  
  9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
  
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6. Install the water vent hose to the timing chain cover.
7. The firing and/or blow out test should not be performed within 30 minutes after the timing chain cover was assembled.
Install the water pump.
(Refer to Cooling System - "WATER PUMP ")
Install the crankshaft damper pulley.
(Refer to Timing System - "CRANKSHAFT DAMPER PULLEY ")
Install the oil filter body.
(Refer to OIL FILTER BODY Lubrication System )
Install the drive belt auto tensioner.
(Refer to Timing System - "DRIVE BELT TENSIONER ")
Install the idler.
(Refer to Timing System - "IDLER ")
Install the drive belt.
(Refer to Timing System - "DRIVE BELT ")
Install the LH/RH cylinder head cover.
(Refer to Cylinder Head Assembly - "CYLINDER HEAD COVER ")
Install the intake manifold.
(Refer to Intake And Exhaust System - "INTAKE MANIFOLD ")
Install the surge tank.
(Refer to Intake And Exhaust System - "SURGE TANK ")
Install the air cleaner assembly.
(Refer to Intake And Exhaust System - "AIR CLEANER ")
Refill the coolant.
(Refer to Cooling System - "COOLANT ")
Install the lower oil pan.
(Refer to Lubrication System - "OIL PAN ")

NOTE:

Refill 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 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.
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 that the fuel line is pressurized.
- Repeat this operation two or three times, then check for fuel leakage at any point in the fuel lines.