•
|
Use fender covers to avoid damaging
painted surfaces. |
•
|
To avoid damaging the cylinder head,
wait until the engine coolant temperature drops below normal
temperature before removing
it. |
•
|
When handling a metal gasket, take care
not to fold the gasket or damage the contact surface of the
gasket. |
•
|
To avoid damage, unplug the wiring
connectors carefully while holding the connector
portion. | |
•
|
Mark all wiring and hoses to avoid
misconnection. |
•
|
Inspect the timing belt before removing
the cylinder head. |
•
|
Turn the crankshaft pulley so that the
No. 1 piston is at top dead center. (See page EM -
9) | |
1. |
Disconnect the negative terminal from the
battery.

|
2. |
Remove the engine cover. (See page EM -
8) |
3. |
Drain the engine coolant.
Remove the radiator cap to speed
draining. |
4. |
Remove the intake air hose and air cleaner
assembly.
(1) |
Disconnect the AFS
connector. |
(2) |
Disconnect the breather hose from air
cleaner hose. |
(3) |
Remove the intake air hose and air
cleaner
assembly. | |
5. |
Remove the upper radiator hose(A) and lower
radiator hose(B).

|
6. |
Remove the heater hoses(A).

|
7. |
Remove the engine wire harness connectors and
wire harness clamps from the cylinder head and the intake
manifold.
(1) |
OCV(Oil control Valve)
connector(A). |
(2) |
Oil temperature sensor
connector(B). |
(3) |
ECT(Engine Coolant Temperature) sensor
connector(C). |
(4) |
Ignition coil connector(D).

|
(5) |
TPS(Throttle Position Sensor)
connector(A). |
(6) |
ISA(Idle Speed Actuator)
connector(B).

|
(7) |
CMP(Camshaft Position Sensor)
connector(A). |
(8) |
Four fuel injector
connectors(B). |
(9) |
Knock sensor
connector(C). |
(10) |
Disconnect ground cable(D) from the
intake manifold.

|
(11) |
Front heated oxygen sensor
connector(A).

|
(12) |
PCSV(Purge Control Solenoid Valve)
connector(A).

| |
8. |
Remove the fuel inlet hose(A) from delivery
pipe.

|
9. |
Remove the PCSV hose(A).

|
10. |
Remove the brake booster vacuum
hose(A).

|
11. |
Remove the accelerator cable by loosening the
locknut, then slip the cable end out of the throttle
linkage. |
12. |
Remove the power steering pump. (See ST group
- power steering pump) |
13. |
Remove the power steering pump bracket
bolts(A).

|
14. |
Remove the spark plug cable. (See EE group -
ignition) |
15. |
Remove the PCV hose. (See page EM -
11) |
16. |
Remove the cylinder head cover. (See page EM -
11) |
17. |
Remove the timing belt. (See page EM -
23) |
18. |
Remove the exhaust manifold. (See page EM -
102) |
19. |
Remove the intake manifold. (See page EM -
101) |
20. |
Remove the camshaft sprocket. (See page EM -
26) |
21. |
Remove the timing chain auto
tensioner(A).

|
22. |
Remove the camshaft bearing caps(A) and
camshafts(B).

|
23. |
Remove the OCV(oil control
valve)(A).

|
24. |
Remove the OCV(oil control valve)
filter(A).

|
25. |
Remove the water hose(B) from the water
pipe(A).

|
26. |
Remove the cylinder head bolts, then remove
the cylinder head.
(1) |
Using 8mm and 10mm hexagon wrench,
uniformly loosen and remove the 10 cylinder head bolts, in
several passes, in the sequence shown. Remove the 10 cylinder
head bolts and plate washers.

Head warpage or cracking could
result from removing bolts in an incorrect
order. | |
(2) |
Lift the cylinder head from the dowels
on the cylinder block and place the cylinder head on wooden
blocks on a bench.
Be careful not to damage the
contact surfaces of the cylinder head and cylinder
block. | | |
VALVE GUIDE
1. |
Using the SST(09221-3F100A), withdraw the old
valve guide toward the bottom of cylinder head.

|
2. |
Recondition the valve guide hole so that it
can match the newly press-fitted oversize valve
guide. |
3. |
Using the SST(09221-3F100A/B), press-fit the
valve guide. The valve guide must be press-fitted from the upper
side of the cylinder head. Keep in mind that the intake and exhaust
valve guides are different in length.
Over size
mm(in.)
|
Size mark
|
Oversize valve guide hole
size mm(in.)
|
0.05
(0.002)
|
5
|
11.05
~ 11.068 (0.4350 ~
0.4357)
|
0.25
(0.010)
|
25
|
11.25
~ 11.268 (0.4429 ~
0.4436)
|
0.50
(0.020)
|
50
|
11.50
~ 11.518 (0.4528 ~
0.4535)
|
Valve guide
length
Intake : 46mm (1.8in.)
Exhaust : 54.5mm
(2.15in.)
|

|
4. |
After the valve guide is press-fitted, insert
a new valve and check for proper stem -to-guide
clearance. |
5. |
After the valve guide is replaced, check that
the valve is seated properly. Recondition the valve seats as
necessary. |
•
|
Thoroughly clean all parts to be
assembled. |
•
|
Always use a new head and manifold
gasket. |
•
|
The cylinder head gasket is a metal
gasket. Take care not to bend
it. |
•
|
Rotate the crankshaft, set the No.1
piston at TDC. (See page EM -
9) | |
1. |
Install the cylinder head gasket(A) on the
cylinder block.

Be careful of the installation
direction. | |
2. |
Place the cylinder head carefully in order not
to damage the gasket with the bottom part of the
end. |
3. |
Install cylinder head bolts.
(1) |
Apply a light coat if engine oil on the
threads and under the heads of the cylinder head
bolts. |
(2) |
Using 8mm and 10mm hexagon wrench,
install and tighten the 10 cylinder head bolts and plate
washers, in several passes, in the sequence
shown.
Tightening torque
M10 :
25Nm (250kgf.cm, 18lbf.ft) + (60°
~ 65°) + (60° ~ 65°)
M12 :
30Nm (300kgf.cm, 22lbf.ft) + (60°
~ 65°) + (60° ~ 65°)
|

| |
4. |
Install OCV filter(A).
Tightening
torque
41 ~ 51Nm (410 ~ 510kgf.cm, 30 ~
37.6lbf.ft)
|

Always use a new OCV filter
gasket.
Keep clean the OCV
filter. | |
5. |
Install OCV(A).
Tightening
torque
10 ~ 12Nm(100 ~ 120kgf.cm, 7.3 ~
8.8lbf.ft)
|

•
|
Do not reuse the OCV when
dropped. |
•
|
Do not hold the OCV sleeve during
servicing. |
•
|
When the OCV is installed on the
engine, do not move the engine with holding the OCV
yoke. | | |
6. |
Install the camshafts.
(1) |
Align the camshaft timing chain with the
intake timing chain sprocket and exhaust timing chain sprocket
as shown.

|
(2) |
Install the camshafts(A) and bearing
caps(B).
Tightening torque
14 ~ 15Nm (140 ~ 150kgf.cm, 10 ~
11lbf.ft)
|

|
(3) |
Install the timing chain auto
tensioner(A).
Tightening torque
8 ~ 10Nm (80 ~ 100kgf.cm, 6 ~
7.4lbf.ft)
|

|
(4) |
Remove the auto tensioner stopper
pin(B). | |
7. |
Check and adjust valve clearance. (See page EM
- 11) |
8. |
Using the SST(09221-21000), install the
camshaft bearing oil seal.

|
9. |
Install the camshaft sprocket. (See page EM -
27) |
10. |
Install the timing belt. (See page EM -
27) |
11. |
Install the cylinder head cover.
(1) |
Install the cylinder head cover
gasket(A) in the groove of the cylinder head
cover(B).

• |
Before installing the head
cover gasket, thoroughly clean the head cover
gasket and the
groove. |
• |
When installing, make sure
the head cover gasket is seated securely in the
corners of the recesses with no
gap. | | |
(2) |
Apply liquid gasket to the head cover
gasket at the corners of the recess.

• |
Use liquid gasket, loctite
No. 5999. |
• |
Check that the mating
surfaces are clean and dry before applying liquid
gasket |
• |
After assembly, wait at
least 30 minutes before filling the engine with
oil. | | |
(3) |
Install the cylinder head cover(A) with
the 12bolts(B). Uniformly tighten the bolts in several
passes.
Tightening torque
8 ~ 10Nm (80 ~ 100kgf.cm, 6 ~
7.4lbf.ft)
|

| |
12. |
Install the intake
manifold. |
13. |
Install the exhaust
manifold. |
14. |
Install the PCV. (See page EM -
28) |
15. |
Install the spark plug cable. (See EE group -
ignition) |
16. |
Install the power steering pump bracket
bolts(A).
Tightening
torque
35 ~ 50Nm (350 ~ 500kgf.cm, 26 ~
37lbf.ft)
|

|
17. |
Install the power steering pump. (See ST group
- power steering pump) |
18. |
Install the accelerator
cable. |
19. |
Install the bake booster hose(A).

|
20. |
Install the PCSV hose(A).

|
21. |
Install the fuel inlet hose(A).

|
22. |
Install the engine wire harness connectors and
wire harness clamps to the cylinder head and the intake
manifold.
(1) |
PCSV connector(A).

|
(2) |
Front heated oxygen sensor
connector(A).

|
(3) |
Connect the ground cable to the intake
manifold(D). |
(4) |
Knock sensor
connector(C). |
(5) |
Four fuel injector
connectors(B). |
(6) |
CMP connector(A).

|
(8) |
TPS connector(A).

|
(9) |
Ignition coil
connector(D). |
(10) |
ECT sensor
connector(C). |
(11) |
Oil temperature sensor
connector(B). |
(12) |
OCV connector(A).

| |
23. |
Install the heater hoses(A).

|
24. |
Install the upper radiator hose(A) and lower
radiator hose(B).

|
25. |
Install the intake air hose and air cleaner
assembly. |
26. |
Install the engine cover. (See page EM -
10) |
27. |
Connect the negative terminal to the
battery. |
28. |
Filll with engine
coolant. |
29. |
Start the engine and check for
leaks. |
30. |
Recheck engine coolant level and oil
level. |
Identify MLA(Mechanical Lash Adjuster),
valves, valve springs as they are removed so that each item can be
reinstalled in its original
position. |
1. |
Remove MLAs(A).

|
2. |
Remove valves.
(1) |
Using SST(09222-28000, 09222-28100),
compress the valve spring and remove retainer
lock.

|
(2) |
Remove the spring
retainer. |
(3) |
Remove the valve
spring. |
(5) |
Using needle-nose pliers, remove the oil
seal. |
(6) |
Using a magnetic finger, remove the
spring
seat. | |
CYLINDER HEAD
1. |
Inspect for flatness.
Using a precision straight edge and feeler
gauge, measure the surface the contacting the cylinder block and the
manifolds for warpage.
Flatness of
cylinder head gasket surface
Standard : Less than
0.03mm(0.0012in.)
Limit : 0.05mm (
0.0020in.)
|

|
2. |
Inspect for cracks.
Check the combustion chamber, intake ports,
exhaust ports and cylinder block surface for cracks. If cracked,
replace the cylinder head. |
VALVE AND VALVE SPRING
1. |
Inspect valve stems and valve
guides.
(1) |
Using a caliper gauge, measure the
inside diameter or the valve guide.

|
(2) |
Using a micrometer, measure the diameter
of the valve stem.

|
(3) |
Subtract the valve stem diameter
measurement from the valve guide inside diameter
measurement.
Valve stem-to-guide
clearance
[Standard]
Intake : 0.02 ~ 0.05mm (0.0008 ~
0.0020in.)
Exhaust : 0.035 ~ 0.065mm (0.0014
~ 0.0026in.)
[Limit]
Intake : 0.1mm
(0.0040in.)
Exhaust : 0.13mm
(0.0051in.)
|
If the clearance is greater than
maximum, replace the valve and valve
guide. | |
2. |
Inspect valves.
(1) |
Check the valve is ground to the correct
valve face angle. |
(2) |
Check that the surface of the valve for
wear.
If the valve face is worn, replace the
valve. |
(3) |
Check the valve head margin
thickness.
If the margin thickness is less than
minimum, replace the valve.
Margin
[Standard]
Intake :
1.15mm(0.0453in.)
Exhaust :
1.35mm(0.0531in.)
[Limit]
Intake :
0.8mm(0.0315in.)
Exhaust :
1.0mm(0.040in.)
|

|
(4) |
Check the surface of the valve stem tip
for wear.
If the valve stem tip is worn, replace
the
valve. | |
3. |
Inspect valve seats
Check the valve seat for evidence of
overheating and improper contact with the valve face.
Replace the seat if necessary.
Before reconditioning the seat, check the
valve guide for wear. If the valve guide is worn, replace it, then
recondition the seat. Recondition the valve seat with a valve seat
grinder or cutter. The valve seat contact width should be within
specifications and centered on the valve
face. |
4. |
Inspect valve springs.
(1) |
Using a steel square, measure the
out-of-square of the valve
spring. |
(2) |
Using a vernier calipers, measure the
free length of the valve spring.
Valve
spring
[Standard]
Free height : 48.86mm
(1.9236in.)
Load : 18.8kg/39 mm
(41.45lb/1.535in.)
[Limit]
Free height :
-1.0mm(-0.0394in.)
Out-of-square :
3°
|

If the free length is not as specified,
replace the valve
spring. | |
CAMSHAFT
1. |
Inspect cam lobes.
Using a micrometer, measure the cam lobe
height.
Cam
height
[Standard value]
Intake : 44.618mm
(1.7566in.)
Exhaust : 44.518mm
(1.7527in.)
[Limit]
Intake : 44.518mm
(1.7527in.)
Exhaust : 44.418mm
(1.7487in.)
|

If the cam lobe height is less than minimum,
replace the camshaft. |
2. |
Inspect camshaft journal
clearance.
(1) |
Clean the bearing caps and camshaft
journals. |
(2) |
Place the camshafts on the cylinder
head. |
(3) |
Lay a strip of plastigage across each of
the camshaft journal.

|
(4) |
Install the bearing caps. (See page EM -
50)
Do not turn the
camshaft. | |
(5) |
Remove the bearing
caps. |
(6) |
Measure the plastigage at its widest
point.
Bearing
oil clearance
[Standard value] : 0.02 ~ 0.061mm
(0.0008 ~ 0.0024in.)
[Limit] : 0.1mm
(0.0039in.)
|

If the oil clearance is greater than
maximum, replace the camshaft. If necessary, replace the
bearing caps and cylinder head as a
set. |
(7) |
Completely remove the
plastigage. |
(8) |
Remove the
camshafts. | |
3. |
Inspect camshaft end play.
(1) |
Install the camshafts. (See page EM -
50) |
(2) |
Using a dial indicator, measure the end
play while moving the camshaft back and forth.
Camshaft
end play
[Standard value] : 0.1 ~
0.2mm(0.004 ~ 0.008in.)
|

If the end play is greater than maximum,
replace the camshaft. If necessary, replace the bearing caps
and cylinder head as a set. |
(3) |
Remove the
camshafts. | |
CVVT ASSEMBLY
1. |
Inspect CVVT assembly.
(1) |
Check that the CVVT assembly will not
turn. |
(2) |
Apply vinyl tape to all the parts except
the one indicated by the arrow in the
illustration.

|
(3) |
Wind tape around the tip of the air gun
and apply air of approx. 100kpa(1kgf/cm², 14psi) to the port
of the camshaft.
(Perform this order to release the lock
pin for the maximum delay angle locking.)
When the oil splashes, wipe it off
with a shop rag and the
likes. | |
(4) |
Under the condition of (3), turn the
CVVT assembly to the advance angle side (the arrow marked
direction in the illustration) with your hand.
Depending on the air pressure, the CVVT
assembly will turn to the advance side without applying force
by hand. Also, under the condition that the pressure can be
hardly applied because of the air leakage from the port, there
may be the case that the lock pin could be hardly
released.

|
(5) |
Except the position where the lock pin
meets at the maximum delay angle, let the CVVT assembly turn
back and forth and check the movable range and that there is
no disturbance.
Standard: Movable smoothly in the
range about 20°
| |
(6) |
Turn the CVVT assembly with your hand
and lock it at the maximum delay angle
position. | |
Thoroughly clean all parts to be
assembled.
Before installing the parts, apply fresh
engine oil to all sliding and rotating surfaces.
Replace oil seals with new
ones. |
1. |
Install valves.
(1) |
Install the spring
seats. |
(2) |
Using SST(09222-22001), push in a new
oil seal.
Do not reuse old valve stem
seals.
Incorrect installation of the seal
could result in oil leakage past the valve
guides. |

|
(3) |
Install the valve, valve spring and
spring retainer.
Place valve springs so that the
side coated with enamel faces toward the valve spring
retainer and then installs the
retainer. | |
(4) |
Using the SST(09222-28000, 09222-28100),
compress the spring and install the retainer locks. After
installing the valves, ensure that the retainer locks are
correctly in place before releasing the valve spring
compressor.

|
(5) |
Lightly tap the end of each valve stem
two or three times with the wooden handle of a hammer to
ensure proper seating of the valve and retainer
lock.

| |
2. |
Install MLAs.
Check that the MLA rotates smoothly by
hand.

| |