Part 1 of 2

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.

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(09222-3K000, 09222-3K100), compress the valve spring and remove retainer lock.




(2) Remove the spring retainer.
(3) Remove the valve spring.
(4) Remove the valve.
(5) Using needle-nose pliers, remove the valve stem seal.

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(0.002in.)




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 of the valve guide.

Valve guide I.D.
Intake / Exhaust : 5.500 - 5.512mm (0.216 - 0.217in.)




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

Valve stem O.D.
Intake : 5.465 - 5.480mm (0.2151 - 0.2157in.)
Exhaust : 5.458 - 5.470mm (0.2149 - 0.2153in.)




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

Valve stem-to-guide clearance
[Standard]
Intake : 0.020 - 0.047mm (0.0008 - 0.0018in.)
Exhaust : 0.030 - 0.054mm (0.0012 - 0.0021in.)
[Limit]
Intake : 0.07mm (0.0027in.)
Exhaust : 0.09mm (0.0035in.)

If the clearance is greater than maximum, replace the valve and valve guide.
2. Inspect valves.
(1) Check the valve is ground to the correct valve face angle.
(2) Check that 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 : 1.02mm(0.0401in.)
Exhaust : 1.09mm(0.0429in.)




(4) Check the valve length.

Valve length
[Standard]
Intake : 113.18mm (4.456in.)
Exhaust : 105.84mm (4.167in.)
[Limit]
Intake : 112.93mm (4.446in.)
Exhaust : 105.59mm (4.157in.)

(5) 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 : 47.44mm (1.8677in.)
Out-of-square : 1.5°




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

MLA
1. Inspect MLA.
Using a micrometer, measure the MLA outside diameter.

MLA O.D.
Intake/Exhaust :
31.964 - 31.980mm(1.2584 - 1.2590in.)

2. Using a caliper gauge, measure MLA tappet bore inner diameter of cylinder head.

Tappet bore I.D.
Intake/Exhaust :
32.000 - 32.025mm(1.2598 - 1.2608in.)

3. Subtract MLA outside diameter measurement from tappet bore inside diameter measurement.

MLA to tappet bore clearance
[Standard]
Intake/Exhaust : 0.020 - 0.061mm(0.0008 - 0.0024in.)
[Limit]
Intake/Exhaust : 0.07mm(0.0027in.)