Repair Procedures

Removal

Engine removal is not required for this procedure.

CAUTION:
- Use Fender cover 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.

NOTE:
- 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.

1. Disconnect the terminals(A) from battery and remove the battery.




2. Remove the engine cover.
3. Remove the under cover(A).




4. Drain the engine coolant.
Remove the radiator cap to speed draining.
5. Remove the intake air hose and air cleaner assembly.
(1) Disconnect the breather hose(B) from intake air hose(D).
(2) Remove the intake air hose(D) and air cleaner upper cover(C).




(3) Disconnect the ECM connector(A) and ECM connector(B) (A/T only).
(4) Remove the air cleaner element and air cleaner lower cover(C).




6. Remove the battery tray(A).




7. Remove the upper radiator hose(A) and lower radiator hose(B).




8. Remove the heater hoses(A).
9. Remove the fuel hose(B).




10. Remove the accelerator cable(A) by loosening the lock-nut, then slip the cable end out of the throttle linkage.
11. Disconnect the TPS (Throttle Position Sensor) connector(B) and the MAP sensor connector(C).




12. Remove the engine wire harness connectors and wire harness clamps from cylinder head and the intake manifold.
(1) Disconnect the rear oxygen sensor connector (A).
(2) Disconnect the air conditioner compressor switch connector (B).
(3) Disconnect the knock sensor connector (C).
(4) Disconnect the injector connectors(No.3,4) (D).
(5) Disconnect the injector connectors(No.1,2) (E)




(6) Remove the wire harness bracket(A).
(7) Disconnect the ISA (Idle Speed Actuator) connector (B).




(8) Disconnect the front oxygen sensor connector(A).
(9) Disconnect the CKP(Crankshaft Position Sensor) connector (B).
(10) Disconnect the OCV(Oil Control Valve) connector (C).




(11) Disconnect the ignition coil connector(A).
(12) Disconnect the ignition coil condenser connector(B).
(13) Disconnect the CMP(Camshaft Position Sensor) connector(C).
(14) Disconnect the ground cable(D).
(15) Remove the wire harness bracket(E).




13. Disconnect the hose(A) of the PCSV (Purge Control Solenoid Valve) side.
14. Remove the brake booster vacuum hose(B).




15. Remove the power steering pump and fix the pump to vehicle with a wire. .
16. Remove the ignition coil. .
17. Remove the exhaust manifold.
18. Remove the intake manifold.
19. Remove the timing belt.
20. Remove the cylinder head cover.
21. Remove the camshaft sprocket.
22. Remove the timing chain auto tensioner(A).




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




24. Remove the OCV(Oil Control Valve)(A).




25. Remove the OCV(Oil Control Valve) filter(A).




26. Remove the engine mounting support bracket fixing bolts(A).




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





CAUTION:
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 replace the cylinder head on wooden blocks on a bench.

CAUTION:
Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

Replacement

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 of cylinder head so that it can match the newly press-fitted oversize valve guide.
3. Using the SST (09221-3F100A, 09221-26000), 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.

Valve guide length
Intake : 36.3 - 36.7mm (1.4291 - 1.4449in)
Exhaust : 40.8 - 41.2mm (1.6063 - 1.6220in)




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.
Valve Guide Oversize






Valve Seat Ring
1. Cut away the inner face of the valve seat to reduce the wall thickness.




2. Enlarge the seat ring hole of cylinder head so that matches the specified cylinder head hole inner diameter of new valve seat ring.
3. Heat the cylinder head to about 250°C(480°F) and press-fit an oversize seat ring for the cylinder head hole size.
4. Using lapping compound, lap the valve to the new seat.
Valve Seat Ring Oversize






Disassembly

NOTE:
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 the HLAs(A).




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




(2) Remove the spring retainer.
(3) Remove the valve spring.
(4) Remove the valve.
(5) Using a needle-nose pliers, remove the oil seal.
(6) Using a magnetic finger, remove the spring seat.

Inspection

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)
Flatness of manifold mating surface
Standard : Less than 0.15mm (0.0059in)
Limit : 0.20mm (0.0079in)




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 the valve stems and valve guides.
(1) Using a caliper gauge, measure the inner diameter of valve guide.

Valve guide inner diameter :
6.000 - 6.015mm (0.2362 - 0.2368in)




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

Valve stem outer diameter
Intake : 5.965 - 5.980mm (0.2348 - 0.2354in)
Exhaust : 5.950 - 5.965mm (0.2343 - 0.2348in)




(3) Subtract the valve stem outer diameter measurement from the valve guide inner 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 : 0.10mm (0.0039in)
Exhaust : 0.15mm (0.0059in)

If the clearance is greater than maximum, replace the valve and valve guide.
2. Inspect the valves.
(1) Check the valve is ground to the correct valve face angle.
(2) Check the surface of 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 : 1.1mm (0.0433in)
Exhaust : 1.3mm (0.0512in)
Limit
Intake : 0.8mm (0.0315in)
Exhaust : 1.0mm (0.0394in)




(4) Check the surface of valve stem tip for wear.
If the valve stem tip is worn, replace the valve.
3. Inspect the valve seats.
(1) Check the valve seat for evidence of overheating and improper contact with the valve face.
Replace the seat if necessary.
(2) Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace it, then recondition the seat.
(3) 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 the valve springs.
(1) Using a steel square, measure the out-of-square of valve spring.
(2) Using a vernier calipers, measure the free length of valve spring.

Valve spring
Standard
Free height : 44mm (1.7323in)
Load : 21.6±1.1kg/35.0mm (47.6±2.4lb/1.3780in)
45.1±2.2kg/27.2mm (99.4±4.9lb/1.0709in)
Out of square : Less than 1.5°
Limit
Out of square : 3°




If the loads is not as specified, replace the valve spring.

Camshaft
1. Inspect the cam lobes.
Using a micrometer, measure the cam lobe height.

Cam height
Intake : 43.7492 - 43.9492mm (1.72241 - 1.73028in)
Exhaust : 44.1494 - 44.3494mm (1.73816 - 1.74604in)




If the cam lobe height is less than specified, replace the camshaft.
2. Inspect the 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 and tighten the bolts with specified torque.

CAUTION:
Do not turn the camshaft.

(5) Remove the bearing caps.
(6) Measure the plastigage at its widest point.

Bearing oil clearance
Standard : 0.020 - 0.061mm (0.0008 - 0.0024in)
Limit : 0.1mm ( 0.0039in)




If the oil clearance is greater than specified, 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 the 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 : 0.1 - 0.2mm (0.0039 - 0.0079in)




If the end play is greater than specified, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.
(3) Remove the camshafts.

CVVT(Continuous Variable Valve Timing) Assembly
1. Inspect the CVVT (Continuous Variable Valve Timing) assembly.
(1) Check that the CVVT (Continuous Variable Valve Timing) assembly will not turn.
(2) Apply vinyl tape to all the parts except the one indicated by the arrow in the illustration.




(3) Wrap tape around the tip of the air gun and apply air of approx. 98kpa (1kg/cm2, 14psi) to the port of the camshaft.
Perform this order to release the lock pin for the maximum delay angle locking.)

NOTE:
Wrap around it with a shop rag and the likes, because the oil splashes.

(4) Under the condition of 3), turn the CVVT assembly to the advance angle side with your hand.
A. Depending on the air pressure, the CVVT assembly will turn to the advance side.
B. If air is leaking from the port and air pressure cannot be maintained, the locking pin will not release.




(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.

: Movable smoothly in the range about 20°

(6) Turn the CVVT assembly with your hand and lock it at the maximum delay angle position.

HLA (Hydraulic Lash Adjuster)

With the HLA filled with engine oil, hold A and press B by hand. If B moves, replace the HLA.










Reassembly

NOTE:
- Thoroughly clean all parts to be assembled.
- Before installing the parts, apply fresh engine oil to all sliding and rotating surface.
- Replace oil seals with new ones.

1. Install the valves.
(1) Install the spring seats.
(2) Using the SST (09222 - 22001), push in a new oil seal.

NOTE:
Do not reuse old valve stem oil seals.
Incorrect installation of the seal could result in oil leakage past the valve guides.




(3) Install the valve, valve spring and spring retainer.

NOTE:
Place the 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 the HLA(Hydraulic Lash Adjuster)s.
Check that the HLA rotates smoothly by hand.






Installation

NOTE:
- Thoroughly clean all parts to be assembled.
- Always use a new cylinder head and manifold gasket.
- Always use a new cylinder head bolt.
- 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.

NOTE:
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 the 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 :
29.4N.m (3.0kgf.m, 21.7lb-ft) + 90° -> Release all bolts -> 29.4N.m (3.0kgf.m, 21.7lb-ft) + 90°




4. Install the engine mounting support bracket fixing bolts(A).




5. Install the OCV(Oil Control Valve) filter(A).

Tightening torque :
40.2 - 50.0N.m (4.1 - 5.1kgf.m, 29.7 - 36.9lb-ft)





NOTE:
- Always use a new OCV(Oil Control Valve) filter gasket.
- Keep clean the OCV(Oil Control Valve) filter.

6. Install the OCV(Oil Control Valve)(A).

Tightening torque :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)





CAUTION:
- Do not reuse the OCV(Oil Control Valve) when dropped.
- Keep clean the OCV(Oil Control Valve).
- Do not hold the OCV(Oil Control Valve) sleeve during servicing.
- When the OCV(Oil Control Valve) is installed on the engine, do not move the engine with holding the OCV(Oil Control Valve) yoke.

7. 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) and bearing caps(B).

Tightening torque :
11.8 - 13.7N.m (1.2 - 1.4kgf.m, 8.7 - 10.1lb-ft)




(3) Install the timing chain auto tensioner(A).

Tightening torque :
7.8 - 9.8N.m (0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)




8. Using the SST (09221 - 21000), install the camshaft bearing oil seal.




9. Install the camshaft sprocket.
10. Install the cylinder head cover.
(1) Install the cylinder head cover gasket(A) in the groove of the cylinder head cover(B).





NOTE:
- Before installing the cylinder head cover gasket, thoroughly clean the cylinder head cover and the groove.
- When installing, make sure the cylinder 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.





NOTE:
- 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 bolts(B).
Uniformly tighten the bolts in several passes.
Pre-tighten all bolts by 3.9 - 4.9N.m (0.4 - 0.5kgf.m, 2.9 - 3.6lb-ft) and then tighten by the specified torque.

Tightening torque :
7.8 - 9.8N.m (0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)




11. Install the timing belt.
12. Install the intake manifold.
13. Install the exhaust manifold.
14. Install the ignition coil. .
15. Install the power steering pump. .
16. Install the brake booster hose(B).
17. Connect the hose(A) of the PCSV (Purge Control Solenoid Valve) side.




18. Install the engine wire harness connectors and wire harness clamps to the cylinder head and the intake manifold.
(1) Install the wire harness bracket(E).
(2) Connect the ground cable(D).
(3) Connect the CMP(Camshaft position sensor) connector(C).
(4) Connect the ignition coil condenser connector(B).
(5) Connect the ignition coil connector(A).




(6) Connect the OCV(Oil Control Valve) connector(C).
(7) Connect the CKP(Crankshaft Position Sensor) connector(B).
(8) Connect the front oxygen sensor connector(A).




(9) Connect the ISA(Idle Speed Actuator) connector(B).
(10) Install the wire harness bracket(A).




(11) Connect the injector connectors (No.1,2) (E).
(12) Connect the injector connectors (No.3,4) (D).
(13) Connect the knock sensor connector(C).
(14) Connect the air conditioner compressor switch connector(B).
(15) Connect the rear oxygen sensor connector(A).




19. Connect the TPS (Throttle Position Sensor) connector(B) and the MAP sensor connector(C).
20. Install the accelerator cable(A).




21. Install the fuel hose(B).
22. Install the heater hoses(A).




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




24. Install the battery tray(A).




25. Install the intake air hose and air cleaner assembly.
(1) Install the air cleaner element and air cleaner lower cover(C).

Tightening torque :
7.8 - 9.8N.m (0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)

(2) Connect the ECM connector(A) and ECM connector(B) (A/T only).




(3) Install the intake air hose(D) and air cleaner upper cover(C).
(4) Connect the breather hose(B) to intake air hose(D).




26. Install the under cover(A).




27. Install the engine cover.

Tightening torque :
3.9 - 5.9N.m (0.4 - 0.6kgf.m, 2.9 - 4.3lb-ft)

28. Install the battery and connect the battery terminals(A).




29. Fill with engine coolant.
30. Start the engine and check for leaks.
31. Recheck engine coolant level and oil level.