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.

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 VIS connector (A), OPS connector (B), knock sensor connector (C) and A/C switch connector (D).




10. Disconnect the intake OCV connector (A).




11. Disconnect the injector connectors (A) and ignition coil connectors (B).




12. Disconnect the ETC connector (A) and MAP sensor connector (B).




13. Disconnect the VCM connector(A).




14. Disconnect the CMP sensor connector (A), fuel hose (B), brake booster vacuum hose (C) and PCSV hose (D).




15. Disconnect the PCSV connector (A), ECT connector (B), condenser connector (C), CKP sensor connector (D), CMP sensor connector (E) and brake booster vacuum hose (F).




16. Disconnect the front O2 sensor connector and rear O2 sensor connector.
17. Remove the water temp control assembly (A).




18. Remove the timing chain.
19. Remove the intake & exhaust manifold.
20. Remove the intake & exhaust CVVT assembly.




21. 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).




22. Use a torx wrench, remove the intake OCV (A).




23. Remove the exhaust OCV.
24. 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.

25. Remove the cylinder head gasket.


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 the OCV filter clean.

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 five 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 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 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 the OCV filter clean.
- 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.

6. 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)




7. Install the water temp control assembly (A).

Tightening torque :
Bolts & 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.

8. Install the timing chain.
9. Check and adjust valve clearance.
10. 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 cover 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.

11. Install the intake & exhaust manifold.
12. Connect the PCSV connector (A), ECT connector (B), condenser connector (C), CKP sensor connector (D), CMP sensor connector (E) and brake booster vacuum hose (F).




13. Connect the front O2sensor connector and rear O2sensor connector.
14. Connect the brake booster vacuum hose (D), PCSV hose (C) fuel hose(B) and CMP sensor connector(A).




15. Connect the ETC connector (A) and MAP sensor connector (B).




16. Connect the injector connectors (A) and ignition coil connectors (B).




17. Connect the OCV connector (A).




18. Connect the VIS connector (A), OPS connector (B), knock sensor connector (C) and A/C switch connector (D).




19. Install the heater hoses (A).