•
|
Use fender covers to avoid damaging
painted surfaces. |
•
|
To avoid damaging the cylinder head,
wait until the engine coolant temperature drops below normal
temperature (20°C [68°F]) 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. |
•
|
Turn the crankshaft pulley so that the
No. 1 piston is at top dead
center. | |
1. |
Disconnect the battery negative terminal (A).
|
2. |
Remove the engine cover
(B). |
3. |
Remove the air duct (C).

|
4. |
Disconnect the breather hose (A), air intake
hose (B) and then remove the air cleaner assembly (C).
|
5. |
Disconnect the battery positive terminal and
then remove the battery (D).

|
6. |
Remove the under cover (A).

|
7. |
Loosen the drain plug (A), and drain the
coolant.
Remove the radiator cap to speed
draining.

Never remove the radiator cap when the
engine is hot. Serious scalding could be caused by hot fluid
under high pressure escaping from the
radiator. | |
8. |
Remove the radiator upper hose (A) and lower
hose (B).

|
9. |
Disconnect the wiring connectors, harness
clamps from the engine.
(1) |
OCV connector (A)

|
(3) |
Oil pressure switch
(B) |
(4) |
Knock sensor connector
(C) |
(5) |
A/C compressor switch connector
(D) |
(6) |
Alternator connector (E)

|
(7) |
Injector connectors
(A) |
(8) |
Ignition coil connectors (B)
|
(9) |
Intake CMPS connector (C)
|
(10) |
Exhaust CMPS connector
(D) |
(11) |
Exhaust OCV connector (E)

|
(12) |
VCM connector (A)

|
(14) |
MAP & IATS connector
(B)

|
(16) |
ECT sensor connector (B)
|
(17) |
Condenser connector (C)
|
(18) |
CKP sensor connector (D)
|
(19) |
Oxygen sensor connector (E)

| |
10. |
Disconnect the fuel hose (A), brake booster
vacuum hose (B) and heater hoses (C).

|
11. |
Disconnect the throttle body coolant hoses
(A).

|
12. |
Remove the water inlet pipe mounting bolt
(A).

|
13. |
Disconnect the oil cooler hoses (A) and then
remove the water temperature control assembly (B).

|
14. |
Remove the timing chain. (Refer to Timing
system in this group) |
15. |
Remove the intake & exhaust manifold.
(Refer to Intake and exhaust system in this group)
|
16. |
Remove the intake & exhaust CVVT
assembly.

|
17. |
Remove the cam shaft.
A. |
Remove the front cam shaft bearing cap
(A).

|
B. |
Remove the exhaust cam shaft upper
bearing (A).

|
C. |
Remove camshaft bearing cap (A), in the
sequence shown.

|
D. |
Remove the cam shaft (A).

|
E. |
Remove the exhaust cam shaft lower
bearing (A).

| |
18. |
Use a torx wrench, remove the intake OCV
(A).

|
19. |
Remove the exhaust OCV.

|
20. |
Remove the cylinder head bolts, then remove
the cylinder head.
A. |
Using triple square wrench, uniformly
loosen and remove the 10 cylinder head bolts, in several
passes, in the sequence shown.

Head warpage or cracking could
result from removing bolts in an incorrect
order. | |
B. |
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. | | |
21. |
Remove the cylinder head
gasket. |
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(09222-3K000, 09222-3K100),
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
valve stem
seal. | |
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
0.05mm(0.002in.)
|

|
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 of the valve guide.
Valve
guid I.D.
Intake / Exhaust : 5.500 ~ 5.512mm
(0.216 ~ 0.217in.)
|

|
(2) |
Using a micrometer, measure the diameter
of the valve stem.
Valve
stem O.D.
Intake : 5.465 ~ 5.480mm (0.2151 ~
0.2157in.)
Exhaust : 5.458 ~ 5.470mm (0.2149
~ 0.2153in.)
|

|
(3) |
Subtract the valve stem diameter
measurement from the valve guide inside diameter
measurement.
Valve
stem-to-guide clearance
[Standard]
Intake : 0.020 ~ 0.047mm (0.0008 ~
0.0018in.)
Exhaust : 0.030 ~ 0.054mm (0.0012
~ 0.0021in.)
[Limit]
Intake : 0.07mm
(0.0027in.)
Exhaust : 0.09mm
(0.0035in.)
|
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 :
1.02mm(0.0401in.)
Exhaust :
1.09mm(0.0429in.)
|

|
(4) |
Check the valve length.
Valve
length
[Standard]
Intake : 113.18mm
(4.456in.)
Exhaust : 105.84mm
(4.167in.)
[Limit]
Intake : 112.93mm
(4.446in.)
Exhaust : 105.59mm
(4.157in.)
| |
(5) |
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 : 47.44mm
(1.8677in.)
Out-of-square :
1.5°
|

If the free length is not as specified,
replace the valve
spring. | |
MLA
1. |
Inspect MLA.
Using a micrometer, measure the MLA outside
diameter.
MLA
O.D.
Intake/Exhaust : 31.964 ~
31.980mm(1.2584 ~ 1.2590in.)
| |
2. |
Using a caliper gauge, measure MLA tappet bore
inner diameter of cylinder head.
Tappet bore
I.D.
Intake/Exhaust : 32.000 ~
32.025mm(1.2598 ~ 1.2608in.)
| |
3. |
Subtract MLA outside diameter measurement from
tappet bore inside diameter measurement.
MLA to tappet
bore clearance
[Standard]
Intake/Exhaust : 0.020 ~ 0.061mm(0.0008
~ 0.0024in.)
[Limit]
Intake/Exhaust :
0.07mm(0.0027in.)
| |
Camshaft
1. |
Inspect cam lobes.
Using a micrometer, measure the cam lobe
height.
Cam
height
[Standard value]
Intake : 44.10 ~ 44.30mm (1.7362 ~
1.7440in.)
Exhaust : 44.90 ~ 45.10mm (1.7677 ~
1.7756in.)
|

If the cam lobe height is less than standard,
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.
Do not turn the
camshaft. | |
(5) |
Remove the bearing
caps. |
(6) |
Measure the plastigage at its widest
point.
Bearing
oil clearance
[Standard value]
Intake
No.1 journal : 0.022 ~ 0.057mm
(0.0008 ~ 0.0022in.)
No.2,3,4,5, journal : 0.045 ~
0.082mm (0.0018 ~ 0.0032in.)
Exhaust
No.1 journal : 0 ~ 0.032mm (0 ~
0.0012in.)
No.2,3,4,5, journal : 0.045 ~
0.082mm (0.0017 ~ 0.0032in.)
[Limit]
:
Intake
No.1 journal : 0.09mm
(0.0035in.)
No.2,3,4,5 journal : 0.12mm
(0.0047in.)
Exhaust : 0.12mm
(0.0047in.)
|

If the oil clearance is greater than
maximum, replace the camshaft. If necessary, replace cylinder
head. |
(7) |
Completely remove the
plastigage. |
(8) |
Remove the
camshafts. | |
3. |
Inspect camshaft end play.
(1) |
Install the
camshafts. |
(2) |
Using a dial indicator, measure the end
play while moving the camshaft back and forth.
Camshaft
end play
[Standard value] : 0.04 ~
0.16mm(0.0015 ~ 0.0062in.)
[Limit] : 0.20mm
(0.0078in.)
|

If the end play is greater than maximum,
replace the camshaft. If necessary, replace cylinder
head. |
(3) |
Remove the
camshafts. | |
Exhaust Cam Shaft Bearing
1. |
Check the cylinder head bore
mark.
Location Of Cylinder
Head Bore Mark

Discrimination Of Cylinder Head
Class
|
Mark
|
Exhaust No.1 Inside
Diameter Of Cylinder Head Bore
|
a
|
A
|
40.000
~ 40.008 mm (1.5748 ~ 1.5751
in.)
|
b
|
B
|
40.008
~ 4.016 mm (1.5751 ~ 1.5754
in.)
|
c
|
C
|
40.016
~ 40.024 mm (1.5754 ~ 1.5757
in.)
|
|
2. |
Select class of camshaft bearing same as class
of cylinder head as shown on the table below.
Place Of Exhaust Cam
Shaft Bearing Identification Mark

Discrimination Of Exhaust Camshaft Bearing
Cylinder Head Bore
Class
|
Bearing Class For
Installing (Color)
|
Thickness Of
Bearing
|
a
(A)
|
C
(Green)
|
1.996~2.000mm (0.0785~0.0787in.)
|
b
(B)
|
B
(None color)
|
2.000~2.004mm (0.0787~0.0788in.)
|
c
(C)
|
A
(Black)
|
2.004~2.008mm (0.0788~0.0790in.)
|
Oil clearance
: 0 ~ 0.032mm (0 ~
0.0012in.)
| |
CVVT Assembly
1. |
Inspect CVVT assembly.
(1) |
Check that the CVVT assembly will not
turn. |
(2) |
Apply vinyl tape to the retard hole
except the one indicated by the arrow in the
illustration.
Verify the hold to tape and the hold to
put air in.
[Intake]

[Exhaust]

|
(3) |
Wind tape around the tip of the air gun
and apply air of approx. 150kpa(1.5kgf/cm², 21psi) to the port
of the camshaft.
(Perform this in order to release the
lock pin.)
When the oil splashes, wipe it off
with a shop rag and the
likes. | |
(4) |
With air applied, as in step (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) |
Turn the CVVT assembly back and forth
and check the movable range and that there is no
disturbance.
Standard:
Should move smoothly in a range
from about
22.5° (Intake) / 20.0°
(Exhaust)
| |
(6) |
Turn the CVVT assembly with your hand
and lock it at the maximum delay angle position (counter
clockwise). | |
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) |
Using SST(09222-4A000), 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. |

|
(2) |
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. | |
(3) |
Using the SST(09222-3K000, 09222-3K100),
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.

|
(4) |
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.

MLA can be reinstalled in its original
position. | |
•
|
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.
| |
1. |
Install the cylinder head gasket(A) on the
cylinder block.
•
|
Be careful of the installation
direction. |
•
|
Apply liquid gasket (Loctite
5900H) on the mark (B). |
•
|
After applying sealant, assemble
the cylinder head in five
minutes. | |

|
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.
A. |
Apply a light coat if engine oil on the
threads and under the heads of the cylinder head
bolts. |
B. |
Using hexagon wrench, install and
tighten the 10 cylinder head bolts and plate washers, in
several passes, in the sequence shown.
Tightening torque :
32.4~36.3Nm (3.3~3.7kgf.m,
23.9~26.8lb-ft) + (90~95°) +
(90~95°)
|

Always use new cylinder head
bolt. | | |
4. |
Install the intake OCV (A).
Tightening
torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~
8.7lb-ft)
|

|
5. |
Install the exhaust OCV (A).
Tightening
torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~
8.7lb-ft)
|

•
|
Do not reuse the OCV when
dropped. |
•
|
Keep the OCV filter
clean. |
•
|
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.
Apply a light coat of engine oil on
camshaft journals. |
A. |
Install the exhaust camshaft lower
bearing (A).

|
B. |
Install the camshafts (A).

|
C. |
Install the exhaust camshaft upper
bearing (A).

|
D. |
Install camshaft bearing caps in their
proper locations.
Tightening order.
Group A → Group B → Group
C.
Tightening torque
Step 1
M6 : 5.9N.m( 0.6kgf.m, 4.3lb-ft)
M8 : 14.7N.m( 1.5kgf.m, 10.8lb-ft)
Step 2
M6 : 10.8 ~ 12.7N.m(1.1 ~
1.3kgf.m, 7.9 ~ 9.4lb-ft)
M8 : 27.5 ~ 31.4N.m(2.8 ~
3.2kgf.m, 20.3 ~ 23.1lb-ft)
|

| |
7. |
Install the water temperature control assembly
(B) and then connect the oil cooler hoses (A).
Tightening
torque :
Bolts : 14.7 ~ 19.6N.m (1.5 ~ 2.0 kgf.m,
10.8 ~ 14.5 lb-ft)
Nut : 18.6 ~ 23.5N.m (1.9 ~ 2.4 kgf.m,
13.7 ~ 17.4 lb-ft)
|

•
|
Assemble water temp control
assembly and water inlet pipe to water pump assembly
before bolt for assembling of water inlet pipe to be
tightened. |
•
|
Always use a new
O-ring. | | |
8. |
Install the water inlet pipe mounting bolt
(A).
Tightening
torque :
9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~
8.7lb-ft)
|

|
9. |
Install the timing chain. (Refer to Timing
system in this group) |
10. |
Check and adjust valve clearance. (Refer to
General information in this group) |
11. |
Install the cylinder head cover.
A. |
The hardening sealant located on the
upper area between timing chain cover and cylinder head should
be removed before assembling cylinder head
cover. |
B. |
After applying sealant, it should be
assembled within 5 minutes.
Bead
width :
2.5mm(0.1in.)
Sealant
: LOCTITE
5900H
|

|
C. |
Running the engine or performing a
pressure test should not be performed within 30 minutes of
assembly |
D. |
Install the cylinder head cover bolts in
the following sequence.
Tightening torque :
Step 1 : 3.9 ~ 5.9N.m(0.4 ~
0.6kgf.m, 2.9 ~ 4.3lb-ft)
Step 2 : 7.8 ~ 9.8N.m(0.8 ~
1.0kgf.m, 5.8 ~ 7.2lb-ft)
|

Do not reuse cylinder head cover
gasket. | | |
12. |
Install the intake & exhaust manifold.
(Refer to Intake and exhaust system in this
group) |
13. |
Connect the throttle body coolant hoses
(A).

|
14. |
Connect the fuel hose (A), the brake booster
vacuum hose (B) and heater hoses (C).

|
15. |
Connect the wiring connectors and harness
clamps.
(1) |
OCV connector (A)

|
(3) |
Oil pressure switch
(B) |
(4) |
Knock sensor connector
(C) |
(5) |
A/C compressor switch connector
(D) |
(6) |
Alternator connector (E)

|
(7) |
Injector connectors
(A) |
(8) |
Ignition coil connectors (B)
|
(9) |
Intake CMPS connector (C)
|
(10) |
Exhaust CMPS connector
(D) |
(11) |
Exhaust OCV connector (E)

|
(12) |
VCM connector (A)

|
(14) |
MAP & IATS connector
(B)

|
(16) |
ECT sensor connector (B)
|
(17) |
Condenser connector (C)
|
(18) |
CKP sensor connector (D)
|
(19) |
Oxygen sensor connector (E)

| |
16. |
Connect the radiator upper hose (A) and low
hose (B).

|
17. |
Install the under cover (A).
Tightening
torque:
19.6 ~ 24.5 N.m (2.0 ~ 2.5 kgf.m, 14.5 ~
18.1 lb-ft)
|

|
18. |
Install the battery (D) and connect the
battery positive terminal.
Tightening
torque:
(+) terminal : 7.8 ~ 11.8 N.m (0.8 ~ 1.2
kgf.m, 5.8 ~ 8.7 lb-ft)
Bracket bolt : 9.8 ~ 11.8 N.m (1.0 ~ 1.2
kgf.m, 7.2 ~ 8.7 lb-ft)
| |
19. |
Install the air cleaner assembly (C) and then
connect the air intake hose (B) and breather hose (A).
Tightening
torque
Hose clamp bolt:
2.9 ~ 4.9 N.m (0.3 ~ 0.5 kgf.m, 2.2 ~
3.6 lb-ft)
Air cleaner assembly bolts:
7.8 ~ 11.8 N.m (0.8 ~ 1.2 kgf.m, 5.8 ~
8.7 lb-ft)
|

|
20. |
Install the air duct
(C). |
21. |
Install the engine cover
(B). |
22. |
Connect the battery negative terminal (A).
Tightening
torque:
(-) terminal : 4.0 ~ 6.0 N.m (0.4 ~ 0.6
kgf.m, 3.0 ~ 4.4 lb-ft)
|

•
|
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 fuel line pressurizes.
|
-
|
Repeat this operation two or three
times, then check for fuel leakage at any point in the
fuel lines. |
•
|
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. | | | |