Part 1

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.

WARNING:
In case of removing the high pressure fuel pump, high pressure fuel pipe, delivery pipe, and injector, there may be injury caused by leakage of the high pressure fuel. So don't do any repair work right after engine stops.

1. Remove the engine cover.
2. Disconnect the battery terminals (A).




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




4. Remove the battery (A) after removing the mounting bracket.




5. Disconnect the ECM connectors (A) and then remove the ECM (B) and battery tray (C).




6. Remove the RH front wheel.
7. Remove the under covers (A).




8. Loosen the drain plug, and drain the engine coolant. Remove the radiator cap to help drain the coolant faster.
9. Disconnect the radiator upper hose (A) and lower hose (B).








10. Disconnect the wiring connectors and harness clamps, and remove the wiring and protectors from the cylinder head and intake manifold.
(1) The A/C compressor switch connector (A), the alternator connector (B) and the cable from the alternator "B" terminal (C)




(2) The intake OCV (Oil control valve) connector (A) and the exhaust OCV (Oil control valve) connector (B)




(3) The ignition coil connectors (A), the injector extension connector (B), the VIS (Variable intake system) connector (C) and the PCSV (Purge control solenoid valve) connector (D)




(4) The FPCV (Fuel pressure control valve) connector (A), the intake CMPS (Camshaft position sensor) connector (B) and the exhaust CMPS (Camshaft position sensor) connector (C)




(5) Disconnect the oxygen sensor connectors (A) and the condenser connector (B)




(6) The ECTS (Engine coolant temperature sensor) connector (A) and the ground line (B)




(7) The ETC (Electronic throttle control) connector (A) and the MAPS (Manifold absolute pressure sensor) & IATS (Intake air temperature sensor) connector (B)




11. Disconnect the brake booster vacuum hose (A) and heater hose (B).




12. Disconnect the fuel hose (A), the PCV (Positive crankcase ventilation) hose (B) and the PCSV (Purge control solenoid valve) hose (C).




13. Remove the vacuum pipe assembly (A).




14. Remove the high pressure pipe (A).




15. Remove the high pressure fuel pump (A) and the roller tappet (B).




16. Remove the ignition coils (A).




17. Remove the exhaust OCV (Oil control valve) (B).




18. Remove the cylinder head cover (A) with gaskets (B).




19. Remove the exhaust OCV (Oil control valve) adapter (A).




20. Remove the timing chain.

21. Remove the exhaust manifold assembly.
22. Remove the intake manifold module assembly.
23. Remove the intake continues variable valve timing (CVVT) assembly (A) and exhaust continues variable valve timing (CVVT) assembly (B).





NOTE:
When removing the continues variable valve timing (CVVT) assembly bolt, prevent the camshaft from rotating by using a wrench at position (A).




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




25. Remove the camshafts (A).




26. Remove the injector & rail assembly (A).




27. Remove the water temperature control assembly (B) after disconnecting the throttle body cooling hose (A).




28. Remove the heater pipe (A).




29. Remove the intake OCV (Oil Control Valve) (A).




30. 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.

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 the mechanical lash adjusters (MLAs) (A).

CAUTION:
When removing MLAs, mark all the MLAs for their rearrangement.




2. Remove the valves.
(1) Using the SST (09222 - 3K000, 09222 - 3K100), compress the valve spring and remove the retainer lock.




(2) Remove the spring retainer.
(3) Remove the valve spring.
(4) Remove the valve.
(5) Remove the valve stem seal.
(6) Using a magnetic finger, remove the spring seat.

CAUTION:
Do not reuse the valve stem seals.

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 0.05mm (0.0020in) for total area
Less than 0.02mm (0.0008in) for a section of 100mm (3.9370in) X 100mm (3.9370in)




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 the valve stems and valve guides.
(1) Using a caliper gauge, measure the inner diameter of valve guide.

Valve guide inner diameter :
5.500 - 5.512mm (0.2165 - 0.2170in)




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

Valve stem outer diameter
Intake : 5.465 - 5.480mm (0.2152 - 0.2157in)
Exhaust : 5.458 - 5.470mm (0.2149 - 0.2154in)




(3) Subtract the valve stem outer diameter measurement from the valve guide inner diameter measurement.

Valve stem- to-guide clearance
Intake : 0.020 - 0.047mm (0.0008 - 0.0019in)
Exhaust : 0.030 - 0.054mm (0.0012 - 0.0021in)

If the clearance is greater than specification, replace the valve or the cylinder head.
2. Inspect the valves.
(1) Check the valve is ground to the correct valve face angle.
(2) Check that the surface of 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 : 1.10mm (0.0433in)
Exhaust : 1.26mm (0.0496in)




(4) Check the length of valve.

Valve length
Standard
Intake : 93.15mm (3.6673 in)
Exhaust : 92.60mm (3.6457 in)

(5) Check the surface of valve stem tip for wear.
If the valve stem tip is worn, replace the valve.
3. Inspect the valve seats.
(1) Check the valve seat for evidence of overheating and improper contact with the valve face. If the valve seat is worn, replace the cylinder head.
(2) Check the valve guide for wear. If the valve guide is worn, replace the cylinder head.
4. Inspect the valve springs.
(1) Using a steel square, measure the out-of-square of valve spring.
(2) Using a vernier calipers, measure the free length of valve spring.

Valve spring
Standard
Free height : 45.1mm (1.7756in)
Out of square : Less than 1.5°





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

Cam height
Intake : 44.15mm (1.7382in)
Exhaust : 43.55mm (1.7146in)




If the cam lobe height is less than specified, replace the camshaft.
2. Check the crankshaft journal for wear.
If the journal is worn excessively, replace the camshaft.
3. Inspect the 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 and tighten the bolts with specified torque.

Tightening torque :
1st step
M6 bolt :
5.9 N.m (0.6 kgf.m, 4.3 lb-ft)
M8 bolt :
9.8 N.m (1.0 kgf.m, 7.2 lb-ft)
2nd step
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)

CAUTION:
Do not turn the camshaft.

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

Bearing oil clearance
Standard : 0.027 - 0.058mm (0.0011 - 0.0023in)
Limit : 0.1mm ( 0.0039in)




A. If the oil clearance is greater than specification, replace the camshaft.
B. If the oil clearance is still greater than specification after camshaft replacement, replace the bearing caps and cylinder head as a set.
4. Inspect the 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 : 0.1 - 0.2mm (0.0039 - 0.0079in)




A. If the end play is greater than specification, replace the camshaft.
B. If the end play is still greater than specification after camshaft replacement, replace the bearing caps and cylinder head as a set.
(3) Remove the camshafts.

Continuous Variable Valve Timing (CVVT) Assembly
1. Inspect the Continuous variable valve timing (CVVT) assembly.
(1) Fix the Continuous variable valve timing (CVVT ) with its camshaft in a vice.
(2) Check that the CVVT assembly will not turn. If it is not turned, it is in normal condition.
(3) Apply vinyl tape to all the parts except the one hole.
(4) Using an air gun, apply the pressure, 147.10kpa (1.5kg/cm2, 21.33psi) in the hole. This makes the lock pin in maximum retarded state released.

NOTE:
- Wrap around it with a shop rag and the likes, because the oil splashes.
- After releasing the pin, you can turn the CVVT assembly for advance by hand.
- If there may be much air leakage, the pin can not be released.

(5) Under the condition of 3), turn the CVVT assembly to the advance angle side with your hand.
Depending on the air pressure, the CVVT assembly will turn to the advance side.
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.
(6) 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 :Movable smoothly in the range about 25°

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