Part 2 of 2
Camshaft1. Inspect cam lobes.
Using a micrometer, measure the cam lobe height.
Cam height
[Standard value]
Intake : 44.10 - 44.30mm (1.7362 - 1.7440in.)
Exhaust : 44.90 - 45.10mm (1.7677 - 1.7756in.)
If the cam lobe height is less than standard, 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]
Intake
No.1 journal : 0.022 - 0.057mm (0.0008 - 0.0022in.)
No.2,3,4,5, journal : 0.045 - 0.082mm (0.0018 - 0.0032in.)
Exhaust
No.1 journal : 0 - 0.032mm (0 - 0.0012in.)
No.2,3,4,5, journal : 0.045 - 0.082mm (0.0017 - 0.0032in.)
[Limit] :
Intake
No.1 journal : 0.09mm (0.0035in.)
No.2,3,4,5 journal : 0.12mm (0.0047in.)
Exhaust : 0.12mm (0.0047in.)
If the oil clearance is greater than maximum, replace the camshaft. If necessary, replace cylinder head.
(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] : 0.04 - 0.16mm(0.0015 - 0.0062in.)
[Limit] : 0.24mm (0.0094in.)
If the end play is greater than maximum, replace the camshaft. If necessary, replace cylinder head.
(3) Remove the camshafts.
Exhaust Cam Shaft Bearing
1. Check the cylinder head bore mark.
Location Of Cylinder Head Bore Mark
Discrimination Of Cylinder Head
2. Select class of camshaft bearing same as class of cylinder head as shown on the table below.
Place Of Exhaust Cam Shaft Bearing Identification Mark
Discrimination Of Exhaust Camshaft Bearing
Oil clearence :0 - 0.032mm (0 - 0.0012in.)
CVVT Assembly
1. Inspect CVVT assembly.
(1) Check that the CVVT assembly will not turn.
(2) Apply vinyl tape to the retard hole 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. 150kpa(1.5kgf/cm2, 21psi) 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:
Movable smoothly in the range about
22.5° (Intake) / 20.0° (Exhaust)
(6) Turn the CVVT assembly with your hand and lock it at the maximum delay angle position (counter clockwise).
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) Using SST(09222-4A000), 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.
(2) 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.
(3) Using the SST(09222-3K000, 09222-3K100), 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.
(4) 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.
NOTE:
MLA can be reinstalled in its original position.
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 OCV filter.
CAUTION:
Keep clean the OCV filter.
2. Install the cylinder head gasket (A) on the cylinder block.
NOTE:
- Be careful of the installation direction.
- Apply liquid gasket (Loctite 5900H) on the mark (B).
- After applying sealant, assemble the cylinder head in fire minutes.
3. Place the cylinder head carefully in order not to damage the gasket with the bottom part of the end.
4. Install cylinder head bolts.
A. Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.
B. Using triple square hexagon wrench, install and tighten the 10 cylinder head bolts and plate washers, in several passes, in the sequence shown.
Tightening torque :
32.4 - 36.3Nm (3.3 - 3.7kgf.m, 23.9 - 26.8lb-ft) + (90 - 95°) + (90 - 95°)
NOTE:
Always use new cylinder head bolt.
5. Install the intake OCV (A).
Tightening torque :
9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
6. Install the exhaust OCV (A).
Tightening torque :
9.8 - 11.8N.m (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 during servicing.
- When the OCV is installed on the engine, do not move the engine with holding the OCV yoke.
7. Install the camshafts.
NOTE:
Apply a light coat of engine oil on camshaft journals.
A. Install the exhaust camshaft lower bearing (A).
B. Install the camshafts (A).
C. Install the exhaust camshaft upper bearing (A).
D. Install camshaft bearing caps in their proper locations.
Tightening order.
Group A -> Group B -> Group C.
Tightening torque
Step 1
M6 : 5.9N.m ( 0.6kgf.m, 4.3lb-ft)
M8 : 14.7N.m ( 1.5kgf.m, 10.8lb-ft)
Step 2
M6 : 10.8 - 12.7N.m (1.1 - 1.3kgf.m, 7.9 - 9.4lb-ft)
M8 : 27.5 - 31.4N.m (2.8 - 3.2kgf.m, 20.3 - 23.1lb-ft)
8. Install the water temp control assembly (A).
Tightening torque :
Bolt : 14.7 - 19.6N.m ( 1.5 - 2.0kgf.m, 10.8 - 14.5lb-ft)
Nut : 18.6 - 23.5N.m (1.9 - 2.4 kgf.m,13.7 - 17.4 lb-ft)
CAUTION:
- Assemble water temp control assembly and water inlet pipe to water pump assembly before nuts for assembling of water inlet pipe to be tightened.
- Always use a new O-ring.
9. Install the timing chain.
10. Check and adjust valve clearance.
11. Install the cylinder head cover.
A. The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling cylinder head cover.
B. After applying sealant, it should be assembled within 5 minutes.
Bead width :2.5mm(0.1in.)
Sealant :LOCTITE 5900H
C. The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was assembled.
D. Install the cylinder head core bolts as following method.
Tightening torque :
Step 1 : 3.9 - 5.9N.m(0.4 - 0.6kgf.m, 2.9 - 4.3lb-ft)
Step 2 : 7.8 - 9.8N.m(0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)
CAUTION:
Do not reuse cylinder head cover gasket.
12. Install the intake & exhaust manifold.
13. Connect 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 (E), HO2S (Bank 1 / Sensor 2) connector (F). (SULEV only)
14. Connect the brake booster vacuum hose (D), PCSV hose (C) fuel hose (B) and intake CMP sensor connector (A).
Connect the VCM connector (E). (SULEV only)
15. Connect the ETC connector (A) and MAP sensor connector (B).
16. Install the cylinder head cover (A).
17. Install the ignition coils (A).
18. Connect the injector connectors (A) and ignition coil connectors (B).
19. Install the PCV hose (A).
20. Connect the exhaust OCV connector (A).
21. Connect 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).
22. Install the heater hoses (A).
23. Install the upper radiator hose (A) and lower radiator hose (B).
24. Install the under cover.
25. Connect the breather hose (A), ECM connector (B) and install the air cleaner assembly (C).
26. Install the air duct (A).
27. Install the engine cover (A).
28. Install the negative terminal to the battery.
29. Fill with engine coolant.
30. Start the engine and check for leaks.
31. Recheck engine coolant level and oil level.