Part 2 of 6

Removal

CAUTION:
- Use fender covers to avoid damaging painted surfaces.
- To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal operating 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.
- Turn the crankshaft pulley so that the No. 1 piston is at top dead center.

1. Disconnect the negative terminal (A) from the battery.




2. Remove the engine cover (A).




3. Remove the engine side cover.
4. Loosen the drain plug and drain the engine coolant.
5. Remove the air duct (A), and the air cleaner assembly (B).




6. Disconnect the radiator upper hose (A) and lower hose (B).




7. Remove the fuel hose (A), the purge control solenoid valve (PCSV) hose (B) and the brake booster vacuum hose (C).




8. Disconnect the heater hoses (A),




9. Remove the radiator & cooling fan assembly from the vehicle.
10. Turn the tensioner (B) clockwise and loosen, then remove the drive belt (A).




11. Remove the drive belt tensioner (A).




12. Remove the engine wiring harness from the cylinder head.
(1) Disconnect the water temperature sensor connector (A) and the CVVT oil control valve connectors (B).




(2) Disconnect the alternator connector (A).




(3) Disconnect the ETC module connector (A).




(4) Disconnect the PCSV connector (A) and the injector connectors (B).




(5) Disconnect the ignition coil connectors (A) and the wiring harness protector (B).




(6) Disconnect the knock sensor connectors (A), the camshaft position sensor connectors (B), the oxygen sensor connector (C) and the condenser connector (D).




(7) Disconnect the variable intake system solenoid valve connector (A) and the wiring harness protector (B).




(8) Disconnect the knock sensor connectors (A), the camshaft position sensor connectors (B), the crankshaft position sensor connector (C), the oxygen sensor connector (D) and the condenser connector (E).




(9) Disconnect the injector connectors (A).




(10) Disconnect the ignition coil connectors (A) and the wiring harness protector (B).




(11) Disconnect the oil pressure switch connector (A), the CVVT oil control valve connectors (B) and the air conditioner compressor switch connector (C).




13. Remove the oil level gauge (A).




14. Remove the oxygen sensor connector bracket (A).








15. Remove the exhaust manifold heat protector (A).








16. Remove the exhaust manifold (A).








17. Disconnect the PCV hose (A), the PCSV hose (B) and the water hoses (C) from the intake manifold module and the throttle body.




18. Remove the intake manifold module (A).




19. Remove the knock sensors (A).








20. Remove the water hose (A).




21. Remove the ignition coils (A).








22. Remove the cylinder head cover (A).








23. Remove the cylinder head cover gasket (A) and oil seal (B).








24. Remove the oil pressure switch wiring assembly and bracket (A).




25. Remove the water temperature sensor wiring assembly and bracket (A).




26. Remove the timing chain upper cover (A).








27. Remove the timing chain upper cover oil seal (A).








28. Remove the oil control valve (A).









NOTE:
- Do not reuse the OCV when dropped.
- Keep the OCV clean.
- Do not hold the OCV sleeve during servicing.
- When the OCV is installed on the engine, do not move the engine while holding the OCV yoke.




29. Remove the cam to cam guide (A).








30. Align the timing mark of camshaft sprocket.

[LH]





[RH]





NOTE:
In case that the timing system has been disassembled wholly, the timing chain can be installed with all of chain installation mark of the sprocket and timing marked chain links aligned without additional marking. However, in case of on-vehicle repair (for cylinder head assembly, timing chain tensioner, CVVT, camshaft, HLA or etc.), which is not necessary to remove the timing chain completely, mark the timing chain links corresponding to the chain installation marks on the sprocket with an identification when the No.1 piston is at TDC position because it is very difficult to align all of the chain installation mark of the sprocket and the timing marked chain links.

31. Remove the alternator (A).




32. Remove the water outlet pipe (A) and the water inlet pipe (B).





NOTE:
Remove the drain plug (A) and drain the engine coolant.




33. Remove the water temperature control assembly (A) and the water outlet fitting assembly (B).




34. Remove the timing chain tensioner (A).








35. Remove the camshaft bearing caps (A) and the camshaft thrust bearing cap (B).








36. Remove the camshaft.








37. Remove the roller finger follower and the hydraulic lash adjuster assembly (A).




38. Remove the cylinder head (A).
(1) Uniformly loosen and remove the cylinder head bolts, in several passes, in the sequence shown.









NOTE:
Head warpage or cracking could result from removing bolts in an incorrect order.

[RH]





[LH]




(2) Lift the cylinder head from the dowels on the cylinder block and place the cylinder head on wooden blocks on a bench.

NOTE:
Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

39. Remove the cylinder head gasket (A).