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.
- 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 battery terminals (A).




2. Remove the air intake hose and air cleaner assembly.
(1) Disconnect the breather hose (A).
(2) Remove the intake air hose and the air cleaner assembly (B).




3. Loosen the radiator drain plug (A) and drain engine coolant. Remove the radiator cap to speed draining.




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




5. Disconnect the engine wiring harness connectors, clamps and hoses.
(1) Disconnect the A/C compressor switch connector (A).
(2) Disconnect the knock sensor connector (B).
(3) Disconnect the TDC sensor connector (C).
(4) Disconnect the fuel injector (No. 1) connector (D).
(5) Disconnect the fuel injector (No. 2, 3, 4) connector (E).
(6) Disconnect the MAP sensor connector (F).




(7) Disconnect the engine ground line (A).




(8) Disconnect the PCSV connector (A).
(9) Disconnect the TPS connector (B).
(10) Disconnect the ISCA connector (C).




(11) Disconnect the front heated oxygen sensor connector (A).
(12) Disconnect the rear heated oxygen sensor connector (B).
(13) Disconnect the oil pressure switch connector (C).
(14) Disconnect the OPS connector (D).
(15) Disconnect the CKPS connector (E).
(16) Disconnect the OTS connector (F).
(17) Disconnect the ECTS connector (D).
(18) Disconnect the ignition coil connector (E).
(19) Disconnect the inhibitor switch connector (F).




(20) Disconnect the brake booster vacuum hose (A).
(21) Disconnect the heater hoses (B).
(22) Disconnect the fuel inlet hose (C).
(23) Disconnect the PCSV hose (D).




6. Remove the cylinder head cover.
(1) Disconnect the spark plug cables and do not pull on the spark plug by force.

NOTE:
Pulling on or bending the cables may damage the conductor inside.

(2) Disconnect the positive crankcase ventilation (P.C.V) hose (A).
(3) Disconnect the accelerator cable (B) and the auto-cruise cable (C) from the cylinder head cover.




7. Remove the timing belt.
8. Remove the exhaust manifold and intake manifold.
9. Remove camshaft sprocket.
(1) Hold the hexagonal head wrench (A) portion of the camshaft with a wrench (B), and remove the bolt and camshaft sprocket (C).





CAUTION:
Be careful not to damage the cylinder head and valve lifter with the wrench.

10. Remove the timing chain auto tensioner (A) after installing the auto tensioner stopper pin (B).




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




12. Remove the OCV(oil control valve) (A).




13. Remove the OCV(oil control valve) filter (A).




14. Disconnect the water pipe (A) and water hose (B).




15. Remove the cylinder head bolts, then remove the cylinder head.
(1) Using 8mm and 10mm hexagon 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 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.

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 cylinder head gasket (A) on the cylinder block.





NOTE:
Be careful of the installation direction.

2. Place the cylinder head gently in order not to damage the gasket with the bottom part of the end.
3. 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 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
M10 :
22.6 - 26.5Nm (2.3 - 2.7kgf.m, 16.6 - 19.5lb-ft) + (60° ~ 65°) + (60° ~ 65°)
M12 :
27.5 - 31.4Nm (2.8 - 3.2kgf.m, 20.3 - 23.1lb-ft) + (60° ~ 65°) + (60° ~ 65°)





4. Install OCV filter (A).

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






NOTE:
Always use a new OCV filter gasket.
Keep clean the OCV filter.

5. Install OCV (A).

Tightening torque
9.8 - 11.8Nm(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 (B) during servicing.
- When the OCV is installed on the engine, do not rotate the engine while holding the OCV yoke.

6. 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 camshafts (A) and bearing caps (B).

Tightening torque
13.7 - 14.7Nm (1.4 - 1.5kgf.m, 10.1 - 10.8lb-ft)





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

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





(4) Remove the auto tensioner stopper pin (B).
7. Check and adjust valve clearance.
8. Using the SST (09221-21000), install the camshaft bearing oil seal.




9. Install the camshaft sprocket and tighten the bolt to the specified torque.
(1) Temporarily install the camshaft sprocket bolt.
(2) Hold the hexagonal head wrench (A) portion of the camshaft with a wrench (B), and tighten the camshaft sprocket (C) bolt.

Tightening torque
Camshaft sprocket bolt :
98.1 - 117.7Nm (10.0 - 12.0kgf.m, 72.3 - 86.8lb-ft)





10. Install the timing belt.
11. 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 head cover gasket, thoroughly clean the head cover gasket and the groove.
- When installing, make sure the 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 the 12bolts(B). Uniformly tighten the bolts in several passes.

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





(4) Connect the accelerator cable (B) and the auto-cruise cable (C) from the cylinder head cover.
(5) Connect the positive crankcase ventilation (P.C.V) hose (A).




(6) Connect the spark plug cables.

NOTE:
Pulling on or bending the cables may damage the inside conductor.




12. Install the intake manifold and exhaust manifold.
13. Connect the engine wiring harness connectors, clamps and hoses.
(1) Connect the brake booster vacuum hose (A).
(2) Connect the heater hoses (B).
(3) Connect the fuel inlet hose (C).
(4) Connect the PCSV hose (D).




(5) Connect the front heated oxygen sensor connector (A).
(6) Connect the rear heated oxygen sensor connector (B).
(7) Connect the oil pressure switch connector (C).
(8) Connect the CKPS connector (D).
(9) Connect the OCV connector (E).
(10) Connect the OTS connector (F).
(11) Connect the ECTS connector (D).
(12) Connect the ignition coil connector (E).
(13) Connect the inhibitor switch connector (F).




(14) Connect the PCSV connector (A).
(15) Connect the TPS connector (B).
(16) Connect the ISCA connector (C).




(17) Connect the engine ground line (A).

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





(18) Connect the A/C compressor switch connector (A).
(19) Connect the knock sensor connector (B).
(20) Connect the TDC sensor connector (C).
(21) Connect the fuel injector (No. 1) connector (D).
(22) Connect the fuel injector (No. 2,3,4) connector (E).
(23) Connect the MAP sensor connector (F).




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




15. Install the air intake hose and air cleaner assembly.
16. Connect the battery terminals.
17. Fill with engine coolant.
18. Start the engine and check for leaks.
19. Recheck engine coolant level and oil level.