•
|
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 EMA -
13). | |
1. |
Disconnect the negative terminal from the
battery.

|
2. |
Remove the engine
cover. |
3. |
Drain the engine coolant. (See page EMA -
72)
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) |
TPS(Throttle Position Sensor)
connector(A). |
(2) |
ISA(Idle Speed Actuator)
connector(B). |
(3) |
PCSV(Purge Control Solenoid Valve)
connector(C). |
(4) |
Injector
connector(E). |
(5) |
Knock sensor
connectors(F). |
(6) |
CMP(Camshaft Position Sensor)
connector(G).

|
(7) |
ECT(Engine Coolant Temperature) sensor
connector(A). |
(8) |
Ignition coil
connector(B). |
(9) |
Crankshaft position sensor
connector(C). |
(10) |
Oxygen sensor connector(D).

|
(11) |
Three fuel injector
connectors(A).

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

|
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 PCV hose(A).

|
13. |
Remove the intake manifold. (See page EMA -
88) |
14. |
Remove the power steering pump. (See ST group
- power steering pump). |
15. |
Remove the exhaust manifold. (See page EMA -
89) |
16. |
Remove the timing belt. (See page EMA -
13) |
17. |
Remove the spark plug cable. (See EE group -
ignition) |
18. |
Remove the cylinder head
covers(A).

|
19. |
Remove the camshaft
sprocket. |
20. |
Remove the camshaft bearing
caps(A).


|
21. |
Remove the camshafts(A).


|
22. |
Remove the timing belt rear
cover(A).

|
23. |
Remove the water temperature control
assembly(A) and water pipe.

|
24. |
Remove the cylinder head bolts, then remove
the cylinder heads.
(1) |
Uniformly loosen and remove the 8
cylinder head bolts on each cylinder head in several passes
and in the sequence shown, then repeat for the other side, as
shown. Remove the 16 cylinder head bolts and plate
washer.

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 : 39mm (1.535in.)
Exhaust : 43mm
(1.693in.)
|

|
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 EMA -
13). | |
1. |
Install the cylinder head gaskets on the
cylinder block.

Be careful of the installation
direction. | |
2. |
Place the cylinder head quietly in order not
to damage the gasket with the bottom part of the
end. |
3. |
Install cylinder head bolts.
Tightening
torque
25Nm (250kgf.cm, 18lbf.ft) + 60° +
45°
|
(1) |
Apply a light coat if engine oil on the
threads and under the heads of the cylinder head
bolts. |
(2) |
Install the plate washer to the cylinder
head bolt. |
(3) |
Install and uniformly tighten the
cylinder head bolts on each cylinder head in several passes
and in the sequence shown, then repeat for the other side, as
shown.

If only one of the cylinder head bolts
dose not meet the torque specification, replace the cylinder
head bolt.
Torque : 25Nm (250kgf.cm,
18lbf.ft)
|

|
(4) |
Retighten the cylinder head bolts by 60°
in the numerical order shown. |
(5) |
Retighten the cylinder head bolts by 45°
in the numerical order
shown. | |
4. |
Install the water pipe and water temperature
control assembly(A).
Tightening
torque
Water temperature control
15 ~ 20Nm (150 ~ 200kgf.cm, 11 ~
14lbf.ft)
|

|
5. |
Install the timing belt rear
cover(A).
Tightening
torque
Timing belt rear cover
10 ~ 12Nm (100 ~ 120kgf.cm, 7 ~
9lbf.ft)
|

|
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 camshaft(A).

|
(3) |
Install the camshaft bearing
caps(A).
Tightening torque
M6(38mm) : 10 ~ 12Nm (100 ~
120kgf.cm, 7 ~ 9lbf.ft)
M6(50mm) : 14 ~ 16Nm (140 ~
160kgf.cm, 10 ~ 12lbf.ft)
|

• |
Apply new engine oil to the
thrust portion and journal of the
camshafts. |
• |
Apply a light coat of engine
oil on the threads and under the heads of the
bearing cap
bolts. | | | |
7. |
Using the SST (09214-21000), install the
camshaft bearing oil seal.

|
8. |
Install the camshaft sprocket.
(1) |
Temporarily install the camshaft
sprocket bolts. |
(2) |
Hold the hexagonal head wrench portion
of the camshaft with a wrench, and tighten the camshaft
sprocket bolts.
Tightening torque
Camshaft sprocket
bolt
90 ~ 110Nm (900 ~ 1100kgf.cm, 65
~80lbf.ft)
| | |
9. |
Install semi-circular
packing. |
10. |
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.5699. |
• |
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 covers(A) with
the 16bolts. Uniformly tighten the bolts in several
passes.
Tightening torque
8 ~ 10Nm (80 ~ 100kgf.cm, 6 ~
7.4lbf.ft)
|


| |
11. |
Install the spark plug cable. (See EE group -
ignition) |
12. |
Install the timing belt. (See page EMA -
17). |
13. |
Install the exhaust manifold. (See page EMA -
91) |
14. |
Install the power steering pump. (See ST group
- power steering pump) |
15. |
Install the intake manifold. (See page EMA-
90) |
16. |
Install the PCV hose(A).

|
17. |
Install the accelerator
cable. |
18. |
Install the brake booster vacuum
hose(A).

|
19. |
Install the PCSV
hose. |
20. |
Install the fuel inlet hose(A).

|
21. |
Install the engine wire harness connectors and
wire harness clamps to the cylinder head and the intake
manifold.
(1) |
Three fuel injector
connectors(A).

|
(2) |
Oxygen sensor
connector(D). |
(3) |
Crankshaft position sensor
connector(C). |
(4) |
Ignition coil
connector(B). |
(5) |
ECT sensor connector(A).

|
(6) |
CMP(Camshaft position sensor)
connector(G). |
(7) |
Knock sensor
connector(F). |
(8) |
Injector
connector(E). |
(9) |
PCSV(Purge Control Solenoid Valve)
connector(C). |
(11) |
TPS connector(A).

| |
22. |
Install the heater hoses(A).

|
23. |
Install the upper radiator hose(A) and lower
radiator hose(B).

|
24. |
Install the intake air hose and air cleaner
assembly.
(1) |
Install the intake air hose and air
cleaner assembly. |
(2) |
Connect the breather hose from air
cleaner hose. |
(3) |
Connect the AFS
connector. | |
25. |
Install the engine
cover. |
26. |
Connect the negative terminal to the
battery.

|
27. |
Filll with engine
coolant. |
28. |
Start the engine and check for
leaks. |
29. |
Recheck engine coolant level and oil
level. |
Identify HLA(Hydraulic Lash Adjuster), valves,
valve springs as they are removed so that each item can be
reinstalled in its original
position. |
1. |
Remove HLAs(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. | |
Cleaning
1. |
Clean top surfaces of pistons and cylinder
block.
(1) |
Turn the crankshaft, and bring each
piston to top dead center(TDC).
Using a gasket scraper, remove all the
carbon from the piston top
surface. |
(2) |
Using a gasket scraper, remove all the
gasket material from the cylinder block
surface. |
(3) |
Using compressed air, blow carbon and
oil from the bolt
holes. | |
2. |
Remove gasket material.
Using a gasket scraper, remove all the gasket
material from the cylinder block contact surface.
Be careful not to scratch the cylinder
block contact
surface. | |
3. |
Clean combustion cambers.
Using a wire brush, remove all the carbon from
the combustion cambers.
Be careful not to scratch the cylinder
block contact
surface. | |
4. |
Clean cylinder heads.
Using a soft brush and solvent. throrghly
clean the cylinder head. |
5. |
Clean valves.
(1) |
Using a gasket scraper, chip off any
carbon from the valve head. |
(2) |
Using a wire brush throroghly clean the
valve. | |
CYLINDER HEAD
1. |
Inspect for flatness.
Using a precision straight edge and feeler
gauge, measure the surface the contacting the cylinder block for
warpage.
Flatness of
cylinder head gasket surface
Standard : Less than 0.03mm(0.0012
in.)
Limit : 0.05 mm ( 0.0020
in.)
|

|
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.
Valve guide inside.

|
(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 : 0.030 ~ 0.065mm (0.0012
~ 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 : 1.0mm
(0.0394in.)
Exhaust : 1.3mm
(0.0512in.)
[Limit]
Intake : 0.5mm
(0.0197in.)
Exhaust : 0.8mm
(0.0315in.)
|

|
(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 : 42.5mm
(1.6732in.)
Load : 21kg/35mm
(48.4kg/1.378mm)
[Limit]
Free height : -1.0mm ( -0.0394
in.)
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 : 43.95 ~44.15mm (1.7303 ~
1.7382in.)
Exhaust : 43.95 ~ 44.15mm (1.7303 ~
1.7382in.)
|

If the cam lobe height is less than minimum,
replace the camshaft. |
2. |
Inspect cam journals.
Using a micrometer, measure the journal
diameter.
Journal
diameter
Standard value
25.964 ~ 25.980mm (1.0222 ~
1.0228in.)
|
If the journal diameter is not as specified,
check the oil clearance. |
3. |
Inspect camshaft bearings.
Check that bearing for flaking and scoring. If
the bearings are damaged, replace the bearing caps and cylinder head
as a set. |
4. |
Inspect camshaft journal oil
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 EMA
- 37)
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. | |
5. |
Inspect camshaft end play.
(1) |
Install the camshafts. (See page EMA -
37). |
(2) |
Using a dial indicator, measure the end
play while moving the camshaft back and forth.
Camshaft
end play
Standard value : 0.1 ~ 0.15mm
(0.004 ~ 0.0059in.)
|

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. | |
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 HLAs.
Check that the HLA rotates smoothly by
hand.

| |