Part 2 of 4
31. Align the LH/RH timing mark of CVVT sprocket.[RH]
[LH]
NOTE:
In case that the timing system has been completely disassembled, 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, during on-vehicle repair (for cylinder head assembly, timing chain tensioner, CVVT, camshaft, HLA or etc.), when it 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 indication mark with a suitable marking paint pen 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.
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 LH/RH timing chain tensioners (A) and chain guide fixing bolts (B).
35. Remove the LH/RH fuel pump adapters (A) and the roller tappets (B).
36. Remove the LH/RH camshaft bearing caps (A) and the camshaft thrust bearing caps (B).
NOTE:
If removing CVVT assembly only, hold the hexagonal position of camshaft by wrench not to rotate during loosen the CVVT bolts as below.
Tightening torque :
73.5 - 83.4 N.m (7.5 - 8.5 kgf.m, 54.2 - 61.5 lb-ft)
NOTE:
When installing the CVVT assembly.Align the CVVT groove with camshaft drill point.
37. Separate the timing chain from the sprocket and then, remove the LH/RH camshafts and CVVT assemblies (A).
NOTE:
Lift up the rear of camshaft slightly (1) and then remove it from back to engine front ward (2).
Take care not to damage camshaft journal, cam lobe and the camshaft carrier journal.
38. Remove the LH/RH camshaft carriers (A).
39. Remove the roller finger follower and the hydraulic lash adjuster (HLA) assembly (A).
40. Remove the LH/RH cylinder heads (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.
41. Remove the LH/RH cylinder head gaskets (A).
Disassembly
1. Remove the valves.
(1) Using the SST(09222-3K000, 09222-3C300), compress the valve spring and remove retainer lock.
(2) Remove the spring retainer.
(3) Remove the valve spring.
(4) Remove the valve.
(5) Remove the valve stem seal.
NOTE:
Do not reuse old valve stem seals.
Inspection
Cylinder Head
1. Inspect for flatness.
Using a precision straight edge and feeler gauge, measure the surface contacting cylinder block and the manifolds for warpage.
Flatness of cylinder head gasket surface
Standard : Less than 0.05mm(0.002in)
[Less than 0.02mm(0.0008in)/100x100]
Flatness of manifold gasket surface
Standard : Less than 0.1mm(0.004in)
[Less than 0.03mm(0.0012in)/110x110]
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 :
6.000 - 6.012mm (0.2362 - 0.2367in)
(2) Using a micrometer, measure the diameter of the valve stem.
Valve stem O.D.
Intake : 5.965 - 5.980mm (0.2348 - 0.2354in)
Exhaust : 5.958 - 5.970mm (0.2346 - 0.2350in)
(3) Subtract the valve stem diameter measurement from the valve guide inside diameter measurement.
Valve stem-to-guide clearance
Intake : 0.020 - 0.047mm (0.0008 - 0.0018in)
Exhaust : 0.030 - 0.054mm (0.0012 - 0.0021in)
2. Inspect valves.
(1) Check the valve is ground to the correct valve face angle.
Valve face angle :
Intake/Exhaust : 45.25°~ 45.75°
(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
Intake : 1.2mm (0.0472in)
Exhaust : 1.2mm (0.0472in)
(4) Check the valve length.
Length
Intake : 107.77mm (4.2429in)
Exhaust : 107.75mm (4.2421in)
(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.
(1) Check the valve seat for evidence of overheating and improper contact with the valve face. If the valve seat is worn, replace cylinder head.
(2) Check the valve guide for wear. If the valve guide is worn, replace cylinder head.
Valve seat contact width :
Intake : 1.15 - 1.45mm (0.0453 - 0.0571in)
Exhaust : 1.35 - 1.65mm (0.0531 - 0.0650in)
Valve seat angle :
Intake/Exhaust : 44.75°~ 45.10°
4. Inspect valve springs.
(1) Using a steel square, measure the out-of-square of the valve spring.
(2) Using vernier calipers, measure the free length of the valve spring.
Valve spring
Free height : 48.44mm (1.9070in)
Out-of-square : 1.5°
Camshaft
1. Inspect cam lobes.
Using a micrometer, measure the cam lobe height.
Cam height
Intake : 41.77mm (1.6444in)
Exhaust : 41.5mm (1.6338in)
If the cam lobe height is less than standard, replace the camshaft.
2. 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 journals.
(4) Install the bearing cap (A) and thrust bearing cap (B) with specified torque.
Tightening torque
10mm bolts :
11.8 - 13.7 N.m (1.2 - 1.4 kgf.m, 8.7 - 10.1 lb-ft)
12mm bolts :
18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb-ft)
NOTE:
Do not turn the camshaft.
[RH]
[LH]
(5) Remove the bearing caps.
(6) Measure the plastigage at its widest point.
Camshaft bearing oil clearance
Intake/Exhaust :
No.1 journal :
0.025 - 0.057mm (0.0010 - 0.0022in)
No.2, 3, 4, 5 journal :
0.020 - 0.057mm (0.0008 - 0.0022in)
Camshaft journal outer diameter
Intake/Exhaust :
No.1 journal :
35.964 - 35.980mm (1.4159 - 1.4165in)
No.2, 3, 4, 5 journal :
25.964 - 25.980mm (1.0222 - 1.0228in)
Camshaft journal bore inner diameter
Intake/Exhaust :
No.1 journal :
36.005 - 36.021mm (1.4175 - 1.4181in)
No.2, 3, 4, 5 journal :
26.000 - 26.021mm (1.0236 - 1.0244in)
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 the camshaft end play.
(1) Install the camshafts.
(2) Install the bearing cap (A) and thrust bearing cap (B) with specified torque.
Tightening torque
10mm bolts :
11.8 - 13.7 N.m (1.2 - 1.4 kgf.m, 8.7 - 10.1 lb-ft)
12mm bolts :
18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb-ft)
NOTE:
Do not turn the camshaft.
[RH]
[LH]
(3) Using a dial indicator, measure the end play while moving the camshaft back and forth.
Camshaft end play :
0.12 - 0.22mm (0.0047 - 0.0086in)
If the end play is greater than maximum, replace the camshaft. If necessary, replace cylinder head.
(4) Remove the camshafts.
CVVT Assembly
1. Inspect the CVVT assembly.
(1) Check that the CVVT assembly will not turn.
(2) Ex-CVVT: Apply vinyl tape to the retard hole except the advanced hole indicated by the arrow in the illustration.
In-CVVT: Apply vinyl tape to the advance hole except the retard indicated by the arrow in the illustration.
(3) Wrap 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 in order to release the lock pin for the maximum default angle locking.)
In-default :Max retard
Ex-default :Max advance
NOTE:
When the oil splashes, wipe it off with a shop rag.
(4) Under the condition of (2), turn the In-CVVT assembly to the advance angle side (the arrow marked direction in the illustration) with your hand.
Depending on the air pressure, the In-CVVT assembly will turn to the advance side without applying force by hand.
Under the condition of (2), turn the Ex-CVVT assembly to the retard angle side (the arrow marked direction in the illustration) with your hand.
Depending on the air pressure, the Ex-CVVT assembly will turn to the retard side without applying force by hand.
(5) Except the position where the lock pin meets at the maximum default angle, let the CVVT assembly turn back and forth and check the movable range and that there is no interference.
Standard :
Movable smoothly in the range about 22.5°
(6) Turn the In-CVVT assembly with your hand and lock it at the maximum retard angle position (clockwise).
Turn the Ex-CVVT assembly with your hand and lock it at the maximum advance angle position.
HLA (Hydraulic Lash Adjuster)
With the HLA filled with engine oil, hold A and press B by hand. If B moves, replace the HLA.
Air Vent Procedure
[In case of HLA alone]
1. Stroke HLA in gas oil 4 - 5 times by pushing its cap while pushing the ball down slightly by hard steel wire.
NOTE:
Take care not to severely push hard steel wire down since ball is several grams(g).
[After installed on vehicle]
NOTE:
After installed on engine, HLA might give out unusual noise if air is mingled. Then apply slow racing as below.
1. Racing at idle RPM for 1 - 3 minutes.
2. Repeat the racing with below pattern.
3. Check the abnormal noise during racing. (Usually, abnormal noise would be removed after 10 - 30 times racing above pattern. If there is abnormal noise after 30 times racing, find another reason except aeration in HLA)
4. Racing 5 times more after removing the abnormal noise.
5. Stop the air vent procedure after checking removing of abnormal noise for 1 - 3 minutes at idle RPM.