Repair Procedures

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.

1. Disconnect the battery terminals (A).
2. Remove the engine cover (B).
3. Disconnect the ECM connector (C).
4. Disconnect the breather hose and then, remove the air duct (D) and air cleaner assembly (E).

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





5. Remove the under covers (A).

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





6. Loosen the drain plug (A), and then drain the engine coolant.




7. Remove the radiator upper hose (A) and lower hose (B).
8. Remove the heater hoses (C).
9. Disconnect the brake booster vacuum hose (D).




10. Disconnect the wiring connectors and harness clamps from the engine.
(1) Disconnect the ETC connector (A) and knock sensor connector (B).
(2) Disconnect the PCSV connector (C).
(3) Disconnect the ECT connector (D).
(4) Disconnect the condenser connector (E).
(5) Disconnect the CKP sensor connector (F).
(6) Disconnect the oxygen sensor connector (G).




(7) Disconnect the VCM connector (A) and MAP sensor connector (B). (SULEV type only)




(8) Disconnect the power steering fluid pressure switch connector (A).
(9) Disconnect the MAP sensor connector (B).
(10) Disconnect the OPS connector (C).
(11) Disconnect the alternator connector (D) and 'B' terminal cable from the alternator.
(12) Disconnect the A/C switch connector from the compressor.
(13) Disconnect the VIS connector.




(14) Disconnect the intake OCV connector (A).




(15) Disconnect the CMP sensor connector (A) and fuel hose (B).




(16) Disconnect the injector connectors (A) and ignition coil connectors (B).




11. Remove timing chain.
12. Remove the intake and exhaust manifold.
13. Remove the water temperature control assembly (A).




14. Remove the intake CVVT assembly (A) and exhaust CVVT sprocket or camshaft sprocket (B).

[Single CVVT]





[Dual CVVT]





NOTE:
When removing the sprocket bolt or CVVT assembly bolt, fix the camshaft by wrench at position A.




15. Remove the camshaft.
(1) Remove the front camshaft bearing cap (A).




(2) Remove the exhaust camshaft upper bearing (A). (Dual CVVT only)




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




(4) Remove the camshafts (A).




(5) Remove the exhaust lower bearing (A). (Dual CVVT only)




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




17. Remove the exhaust OCV (A). (Dual CVVT only)
18. 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.

19. Remove the cylinder head gasket.

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 the OCV filter.





CAUTION:
Keep the OCV filter clean.

2. Install the cylinder head gasket (A) on the cylinder block.

NOTE:
- Be careful of the installation direction.
- Apply liquid gasket (Loctite 5900H) on the edge of cylinder head gasket upside and downside. (At the position 'B')
- After applying sealant, assemble the cylinder head in five minutes.




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.
A. Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.
B. Using the SST(09221-4A000), tighten the 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°)


CAUTION:
Always use new cylinder head bolt.




5. Install the intake OCV (A).

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





6. Install the exhaust OCV (A). (Dual CVVT only)

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






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




7. Install the camshafts.

NOTE:
Apply a light coat of engine oil on camshaft journals.

(1) Install the exhaust camshaft lower bearing (A). (Dual CVVT only)




(2) Install the camshafts (A).




(3) Install the exhaust camshaft upper bearing (A) to the front bearing cap (A). (Dual CVVT only)




8. Install camshaft bearing caps in their proper locations.
Tightening order.
Group A -> Group B -> Group C.

Tightening torque :
M6 : 10.8 - 12.7N.m(1.1 - 1.3kgf.m, 7.9 - 9.3lb-ft)
M8 : 27.4 - 31.4N.m(2.8 - 3.2kgf.m, 20.2 - 23.1lb-ft)





9. Install the intake CVVT assembly (A) and exhaust CVVT sprocket or camshaft sprocket (B).

[Single CVVT]





[Dual CVVT]





NOTE:
When installing the sprocket bolt or CVVT assembly bolt, fix the camshaft by wrench at position A.




10. Install the water temperature control assembly (A).

Tightening torque :
Bolt : 14.7 - 19.6N.m(1.5 - 2.0kgf.m, 10.8 - 14.5lb-ft)
Nut : 18.6 - 23.5N.m(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.

11. Install the timing chain.
12. Install the intake and exhaust manifold.
13. Check and adjust the valve clearance.
14. Install cylinder head cover.
(1) The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling cylinder head cover.
(2) After applying sealant, it should be assembled within 5 minutes.

Bead width :2.5mm (0.1in.)





(3) Install the cylinder head cover bolts as following method.

Tightening torque :
1st step : 3.9 - 5.9N.m(0.4 - 0.6kgf.m, 2.9 - 4.3lb-ft)
2nd step : 7.8 - 9.8N.m(0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)






CAUTION:
- Do not reuse cylinder head cover gasket.
- The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was assembled.

15. Install the other parts in the reverse order of removal.

NOTE:
- Refill engine oil.
- Clean the battery posts and cable terminals with sandpaper assemble them, 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, and 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. 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.