Removal and Installation
REMOVAL
Engine removal is not required for this procedure.
CAUTION:
- 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.
NOTE:
- 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 negative terminal from the battery.
2. Remove engine cover(A).
3. Remove air duct.
4. Remove the intake air hose and air cleaner assembly.
(1) Disconnect the AFS(B) connector.
(2) Disconnect the breather hose(D) and vacuum hose(E) from air cleaner hose(C).
(3) Disconnect the PCM connector and cover(F).
(4) Remove the intake air hose and air cleaner(A).
5. Remove front wheels.
6. Remove under cover(A).
7. Drain the engine coolant.
Remove the radiator cap to speed draining.
8. Remove the upper and lower radiator hose(A).
9. Remove the heater hoses(A).
10. Disconnect A/C switch(A), alternator connector(B), and oil pressure switch(C).
11. Disconnect OCV connector(A) and OTS connector(B) and P/S switch connector(C).
12. Disconnect injector connectors(A).
13. Disconnect the engine wire harness connectors.
(1) Remove the ETC connector(B), CMP connector(C) and knock sensor connector(D).
14. Disconnect ignition coil connectors(A).
15. Disconnect PCSV connector(A), WTS connector(B), condenser connector(C), and CKP sensor connector(D).
16. Remove delivery pipe(A), brake vacuum hose(B), and PCSV hose(C).
17. Remove water temperature control assembly(A).
18. Remove intake manifold.
19. Remove exhaust manifold.
20. Remove timing chain.
21. Remove CVVT assembly and camshaft sprocket(A).
22. Remove camshaft.
(1) Remove front camshaft bearing cap(A).
(2) Remove camshaft bearing cap(A), in the sequence shown.
(3) Remove camshafts(A).
23. Remove OCV(A) and OTS(B).
24. Remove the cylinder head bolts, then remove the cylinder head.
(1) Using triple square 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.
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 place 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.
INSTALLATION
NOTE:
- 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 OCV filter.
NOTE:
Keep clean the OCV filter.
2. Install the cylinder head gasket(A) on the cylinder block.
NOTE:
Be careful of the installation direction.
3. Place the cylinder head carefully in order not to damage the gasket with the bottom part of the end.
4. 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 triple square hexagon wrench, install and tighten the 10 cylinder head bolts and plate washers, in several passes, in the sequence shown.
Tightening torque
34.3Nm (3.5kgf.m, 25.3lb-ft) + 90° + 90°
NOTE:
Always use new cylinder head bolt.
5. Install OCV(A) and OTS (B).
Tightening torque
OCV : 9.8 - 11.76Nm(1.0 - 1.2kgf.m, 7.23 - 8.67lb-ft)
OTS : 19.6 - 23.52Nm(2.0 - 2.4kgf.m, 14.46 - 17.35lb-ft)
CAUTION:
- Do not reuse the OCV when dropped.
- Keep clean the OCV.
- 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 CVVT and camshaft sprocket.
Tightening torque
53.9 - 63.7Nm(5.5 - 6.5 kgf.m, 39.7 - 47.0lb-ft)
NOTE:
Hold the hexagonal head wrench portion of the camshaft with a vise, and install the bolt and CVVT assembly.
7. Install camshafts (A).
NOTE:
Apply a light coat of engine oil on camshaft journals.
8. Install camshaft bearing caps in their proper locations.
Tightening order.
Group A -> Group B -> Group C.
Tightening torque
M6 : 10.78 - 12.74Nm(1.1 - 1.3kgf.m, 7.95 - 9.39lb-ft)
M8 : 27.44 - 31.36Nm(2.8 - 3.2kgf.m, 20.24 - 23.14 lb-ft)
9. Install timing chain.
10. Check and adjust valve clearance.
11. Install the exhaust manifold.
12. Install the intake manifold.
13. Install water temp control assembly (A).
Tightening torque
Bolt : 14.7 - 19.6Nm(1.5 - 2.0kgf.m, 10.84 - 14.5lb-ft)
Nut : 18.6 - 23.5Nm(1.9 - 2.4kgf.m, 13.7 - 17.4lb-ft)
NOTE:
- Assemble water temp control assembly and water inlet pipe to water pump assembly before nuts for assembling of water inlet pipe to be tightened.
- Insert after wetting O-ring or inner surface of thermostat housing.
- Always use a new O-ring.
14. Install delivery pipe (A), brake hose(B), and PCSV hose (C).
15. Install the PCSV connector (A), WTS connector (B), condenser connector (C), and CKP sensor connector (D).
16. Install ignition coil connector (A).
17. Install the engine wire harness connectors.
(1) Install the ETC connector(B), CMP connector(C), knock sensor connector(D).
18. Install the injector connectors (A).
19. Install the OCV connector(A), OTS connector(B), P/S switch connector(C).
20. Install the A/C switch(A), alternator connect(B), and oil pressure switch(C).
21. Install heater hoses(A).
22. Install the upper radiator hose and lower radiator hose(A).
23. Install under cover.
24. Install the intake air hose and air cleaner assembly.
(1) Install the AFS(B) connector.
(2) Install the breather hose(D) and vacuum hose(E) from air cleaner hose(C).
(3) Install the PCM connector and cover(F).
(4) Install the intake air hose and air cleaner(A).
25. Install the engine cover.
26. Install the negative terminal to the battery.
27. Fill with engine coolant.
28. Start the engine and check for leaks.
29. Recheck engine coolant level and oil level.