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 and remove the battery.
2. Remove the engine cover (A).




3. Remove the air duct (A).




4. Disconnect the breather hose (A), ECM connector (B) and remove the air cleaner assembly (C).




5. Remove the under cover (A).




6. Remove the drain plug and drain the engine coolant.
7. Remove the radiator upper hose (A) and lower hose (B).




8. Remove the heater hoses (A).




9. Disconnect the intake OCV connector (A), power steering switch connector (B), VIS connector (C), OPS connector (D), knock sensor connector (E), alternator connector (F) and A/C switch connector (G).




10. Disconnect the exhaust OCV connector (A) and remove the wiring from the cylinder head cover.




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




12. Remove the PCV hose (A).




13. Remove the ignition coils (A).




14. Remove the cylinder head cover (A).




15. Disconnect the ETC connector (A) and MAP sensor connector (B).




16. Disconnect the intake CMP sensor connector (A), fuel hose (B), brake booster vacuum hose (C) and PCSV hose (D).
Disconnect the VCM connector (E). (SULEV only)




17. Disconnect the PCSV connector (A), ECTS connector (B), condenser connector (C), CKP sensor connector (D), exhaust CMP sensor connector (E) and brake booster vacuum hose (F).
Disconnect the HO2S (Bank 1 / Sensor 1) connector (G), HO2S (Bank 1 / Sensor 2) connector (H) (SULEV only).




18. Remove the water temp control assembly (A).




19. Remove the timing chain.
20. Remove the intake & exhaust manifold.
21. Remove the intake & exhaust CVVT assembly.




22. 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).




23. Remove the intake OCV (A).




24. Remove the exhaust OCV (A).




25. 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.





CAUTION:
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.

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

26. 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 OCV filter.





CAUTION:
Keep clean the OCV filter.

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 mark (B).
- After applying sealant, assemble the cylinder head in fire 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 triple square 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°)






NOTE:
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).

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 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.

7. Install the camshafts.

NOTE:
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)





8. Install the water temp 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 - 2.4 kgf.m,13.7 - 17.4 lb-ft)






CAUTION:
- Assemble water temp control assembly and water inlet pipe to water pump assembly before nuts for assembling of water inlet pipe to be tightened.
- Always use a new O-ring.

9. Install the timing chain.
10. Check and adjust valve clearance.
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. The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was assembled.
D. Install the cylinder head cover bolts as following method.

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)






CAUTION:
Do not reuse cylinder head cover gasket.

12. Install the intake & exhaust manifold.
13. Connect the PCSV connector (A), ECTS connector (B), condenser connector (C), CKP sensor connector (D), exhaust CMP sensor connector (E) and brake booster vacuum hose (F).
Disconnect the HO2S (Bank 1 / Sensor 1) connector (E), HO2S (Bank 1 / Sensor 2) connector (F). (SULEV only)




14. Connect the brake booster vacuum hose (D), PCSV hose (C) fuel hose (B) and intake CMP sensor connector (A).
Connect the VCM connector (E). (SULEV only)




15. Connect the ETC connector (A) and MAP sensor connector (B).




16. Install the cylinder head cover (A).




17. Install the ignition coils (A).




18. Connect the injector connectors (A) and ignition coil connectors (B).




19. Install the PCV hose (A).




20. Connect the exhaust OCV connector (A).




21. Connect the intake OCV connector (A), power steering switch connector (B), VIS connector (C), OPS connector (D), knock sensor connector (E), alternator connector (F) and A/C switch connector (G).




22. Install the heater hoses (A).




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




24. Install the under cover.




25. Connect the breather hose (A), ECM connector (B) and install the air cleaner assembly (C).




26. Install the air duct (A).




27. Install the engine cover (A).




28. Install the negative terminal to the battery.
29. Fill with engine coolant.
30. Start the engine and check for leaks.
31. Recheck engine coolant level and oil level.