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.

Replacement

Valve Guide
1. Using the SST(09221-3F100A), withdraw the old valve guide toward the bottom of cylinder head.




2. Recondition the valve guide hole so that it can match the newly press-fitted oversize valve guide.
3. Using the SST(09221-3F100A/B), press-fit the valve guide. The valve guide must be press-fitted from the upper side of the cylinder head. Keep in mind that the intake and exhaust valve guides are different in length.






Valve guide length
Intake : 46mm (1.8in.)
Exhaust : 54.5mm (2.15in.)





NOTE:
Before the valve guide is press-fitted using the SST (09221-3F100A/B), remove the valve spring seat to install the valve guide correctly.

4. After the valve guide is press-fitted, insert a new valve and check for proper stem -to-guide clearance.
5. After the valve guide is replaced, check that the valve is seated properly. Recondition the valve seats as necessary.

Disassembly

NOTE:
Identify MLA(Mechanical Lash Adjuster), valves, valve springs as they are removed so that each item can be reinstalled in its original position.

1. Remove MLAs (A).




2. Remove valves.
(1) Using SST(09222-28000, 09222-28100), compress the valve spring and remove retainer lock.




(2) Remove the spring retainer.
(3) Remove the valve spring.
(4) Remove the valve.
(5) Remove the oil seal using needle-nose pliers.
(6) Using a magnetic finger, remove the spring seat.

Inspection

Cylinder Head
1. Inspect for flatness.
Using a precision straight edge and feeler gauge, measure the surface the contacting the cylinder block and the manifolds for warpage.

Flatness of cylinder head gasket surface
Standard : Less than 0.03mm(0.0012 in)
Limit : 0.06 mm ( 0.0024 in)




2. Inspect for cracks.
Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If cracked, replace the cylinder head.

Valve And Valve Spring
1. Inspect valve stems and valve guides.
(1) Using a caliper gauge, measure the inside diameter or the valve guide.
Valve guide inside.




(2) Using a micrometer, measure the diameter of the valve stem.




(3) Subtract the valve stem diameter measurement from the valve guide inside diameter measurement.
Valve stem-to-guide clearance

[Standard]
Intake : 0.02 - 0.05mm (0.0008 - 0.0020in)
Exhaust : 0.035 - 0.065mm (0.0014 - 0.0026in)
[Limit]
Intake : 0.1mm (0.0040in)
Exhaust : 0.13mm (0.0051in)

If the clearance is greater than maximum, replace the valve and valve guide.
2. Inspect valves.
(1) Check that the valve is ground to the correct valve face angle.
(2) Check the surface of the valve for wear.
If the valve face is worn, replace the valve.
(3) Check the valve head margin thickness.
If the margin thickness is less than minimum, replace the valve.

Margin
[Standard]
Intake : 1.6 mm(0.0630 in)
Exhaust : 1.8 mm(0.0709 in)
[Limit]
Intake : 1.45 mm(0.0571 in)
Exhaust : 1.65 mm(0.0650 in)




(4) Check the surface of the valve stem tip for wear.
If the valve stem tip is worn, replace the valve.
3. Inspect valve seats
Check the valve seat for evidence of overheating and improper contact with the valve face.
Replace the seat if necessary.
Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace it, then recondition the seat. Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width should be within specifications and centered on the valve face.
4. Inspect valve springs.
(1) Using a steel square, measure the out-of-square of the valve spring.
(2) Using a vernier calipers, measure the free length of the valve spring.

Valve spring
[Standard]
Free height : 48.86mm (1.9236 in)
Load :
18.8±0.9kg/39.0mm (41.4±2.0lb/1.5354in)
41.0±1.5kg/30.5mm (90.4±3.3lb/1.2008in)
Out-of-square : 1.5°
[Limit]
Out-of-square : 3°




If the free length is not as specified, replace the valve spring.

Camshaft
1. Inspect cam lobes.
Using a micrometer, measure the cam lobe height.

Cam height
[Standard value]
Intake : 44.518 - 44.718mm (1.7527 - 1.7605in)
Exhaust : 44.418 - 44.618mm (1.7487 - 1.7566in)




If the cam lobe height is less than minimum, replace the camshaft.
2. Inspect camshaft journal clearance.
(1) Clean the bearing caps and camshaft journals.
(2) Place the camshafts on the cylinder head.
(3) Lay a strip of plastigage across each of the camshaft journal.




(4) Install the bearing caps.

CAUTION:
Do not turn the camshaft.

(5) Remove the bearing caps.
(6) Measure the plastigage at its widest point.

Bearing oil clearance :
[Standard value] : 0.02 - 0.061mm(0.0008 - 0.0024in)
[Limit] : 0.1mm(0.0039in)




If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.
(7) Completely remove the plastigage.
(8) Remove the camshafts.
3. Inspect camshaft end play.
(1) Install the camshafts.
(2) Using a dial indicator, measure the end play while moving the camshaft back and forth.

Camshaft end play
[Standard value] : 0.1 - 0.15mm(0.0039 - 0.0059in)




If the end play is greater than maximum, replace the camshaft. If necessary, replace the bearing caps and cylinder head as a set.
(3) Remove the camshafts.

CVVT Assembly
1. Inspect CVVT assembly.
(1) Check that the CVVT assembly will not turn.
(2) Apply vinyl tape to all the parts except the one indicated by the arrow in the illustration.




(3) Wind tape around the tip of the air gun and apply air of approx. 100kpa(1kgf/cm2, 14psi) to the port of the camshaft.
(Perform this order to release the lock pin for the maximum delay angle locking.)

NOTE:
When the oil splashes, wipe it off with a shop rag and the likes.

(4) Under the condition of (3), turn the CVVT assembly to the advance angle side (the arrow marked direction in the illustration) with your hand.
Depending on the air pressure, the CVVT assembly will turn to the advance side without applying force by hand. Also, under the condition that the pressure can be hardly applied because of the air leakage from the port, there may be the case that the lock pin could be hardly released.
(5) Except the position where the lock pin meets at the maximum delay angle, let the CVVT assembly turn back and forth and check the movable range and that there is no disturbance.

Standard:Moves smoothly in the range about 20°

(6) Turn the CVVT assembly with your hand and lock it at the maximum delay angle position.

Reassembly

NOTE:
Thoroughly clean all parts to be assembled.
Before installing the parts, apply fresh engine oil to all sliding and rotating surfaces.
Replace oil seals with new ones.

1. Install valves.
(1) Install the spring seats.
(2) Using SST(09222-22001), push in a new oil seal.

NOTE:
Do not reuse old valve stem seals.
Incorrect installation of the seal could result in oil leakage past the valve guides.




(3) Install the valve, valve spring and spring retainer.

NOTE:
Place valve springs so that the side coated with enamel faces toward the valve spring retainer and then installs the retainer.

(4) Using the SST (09222-28000, 09222-28100), compress the spring and install the retainer locks. After installing the valves, ensure that the retainer locks are correctly in place before releasing the valve spring compressor.




(5) Lightly tap the end of each valve stem two or three times with the wooden handle of a hammer to ensure proper seating of the valve and retainer lock.




2. Install MLAs.
Check that the MLA rotates smoothly by hand.






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.