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.
- Turn the crankshaft pulley so that the No. 1 piston is at top dead center.

1. Remove the timing chain.

2. Remove the camshaft bearing caps(A) with the order below.




3. Remove the injector connectors(A) and the harness bracket(B).




4. Remove the delivery pipe(A).




5. Remove the exhaust manifold assembly.
6. Remove the intake manifold module assembly.
7. Disconnect the camshaft position sensor(CMP) connector(A) and remove the purge control solenoid valve(PCSV) bracket(B) and the module hanger bracket(C).




8. Remove the water temperature control assembly and the oil control valve(OCV).
9. Remove the cylinder head bolts, then remove the cylinder head.
(1) 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 cylinder block and put the cylinder head on wooden blocks.

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 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 assembly.
(1) Before installing, remove the hardened sealant from the cylinder block and cylinder head surface.
(2) Before installing the cylinder head gasket, apply sealant on the upper surface of the cylinder block and reassemble the gasket within five minutes.





NOTE:
Refer to the illustration for applying sealant.

Width :2.0 - 3.0mm(0.0787 - 0.1181in.)
Position :1.0 - 1.5mm(0.0394 - 0.0591in.)
Specification :TB 1217H or LOCTITE 5900H





(3) After installing the cylinder head gasket on the cylinder block, apply sealant on the upper surface of the cylinder head gasket and reassemble in five minutes.
2. Place the cylinder head carefully not to damage the gasket.
3. Install the cylinder head bolts with washers.
(1) Tighten the 10 cylinder head bolts, in several passes, in the sequence shown.

Tightening torque :
1st step - 17.7 - 21.6 N.m (1.8 - 2.2 kgf.m, 13.0 - 15.9 lb-ft)
2nd step - 90°~95°
3rd step - 100°~105°






CAUTION:
Always use new cylinder head bolts.

4. Install the oil control valve(OCV)(A).

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





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

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





6. Connect the camshaft position sensor(CMP) connector(A) and install the purge control solenoid valve(PCSV) bracket(B) and the module hanger bracket(C).




7. Install the intake manifold module assembly.
8. Install the exhaust manifold assembly.
9. Install the delivery pipe assembly(A).

Tightening torque :
19.6 - 24.5N.m (2.0 - 2.5kgf.m, 14.4 - 18.0lb-ft)





10. Install the injector connector(A) and harness bracket(B).




11. Install the camshafts.
(1) Before installing, apply engine oil on journals.

CAUTION:
Do not make oil flow down to the front side of the cylinder head.

(2) After installing, check the valve clearance.
12. Install the camshaft bearing caps with the order below.

Tightening torque :
M6 bolts - 11.8 - 13.7N.m (1.2 - 1.4kgf.m, 8.7 - 10.1lb-ft)
M8 bolts - 18.6 - 22.6N.m (1.9 - 2.3kgf.m, 13.7 - 16.6lb-ft)





13. Install the intake and exhaust manifold.

14. Install the timing chain.