Part 1

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 room cover (A), engine cover (B) and radiator grill upper cover (C).




3. Loosen the drain plug (A) and drain the engine coolant. Remove the radiator cap to speed draining.

WARNING:
Never remove the radiator cap when the engine is hot. Serious scalding could be caused by hot fluid under high pressure escaping from the radiator.




4. Remove the air cleaner assembly.
(1) Remove the air duct (A).
(2) Disconnect the breather hose (B).
(3) Loosen the clamp (C) and then disconnect the air intake hose from the throttle body.

Tightening torque :
2.9 - 4.9N.m (0.3 - 0.5kgf.m, 2.2 - 3.6lb-ft)

(4) Remove the chamber air cleaner (D) and air cleaner assembly (E).

Tightening torque
Air cleaner assembly bolts:
7.8 - 9.8N.m (0.8 - 1.0kgf.m, 5.8 - 7.2lb-ft)




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




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




7. Disconnect the heater hoses (A).




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




10. Disconnect the engine wiring harness connectors and hoses.
(1) ETC module connector (A)
(2) PCV hose (B)




(3) Engine coolant temperature sensor (ECTS) connector (A)
(4) RH intake oil control valve (OCV) connector (B)
(5) RH exhaust oil control valve (OCV) connector (C)




(6) Alternator connector (A)




(7) RH ignition coil connectors (A)
(8) RH fuel pump connector (B)
(9) RH exhaust camshaft position sensor (CMPS) connector (C)
(10) RH intake camshaft position sensor (CMPS) connector (D)




(11) RH knock sensor connectors (A,B)
(12) RH front oxygen sensor (HO2S) connector (C)
(13) RH ignition coil condenser connector (D)
(14) Ground (E)




(15) Oil pressure switch (OPS) connector (A)
(16) LH intake oil control valve (OCV) connector (B)
(17) LH exhaust oil control valve (OCV) connector (C)
(18) Compressor connector (D)




(19) Purge control solenoid valve (PCSV) connector (A)
(20) LH ignition coil connectors (B)
(21) LH fuel pump connector (C)
(22) LH intake camshaft position sensor (CMPS) connector (D)
(23) LH exhaust camshaft position sensor (CMPS) connector (E)




(24) LH knock sensor connectors (A,B)
(25) Manifold absolute pressure (MAP) sensor connector (C)
(26) Crankshaft position sensor (CKPS) connector (D)
(27) LH ignition coil condenser connector (E)
(28) LH front oxygen sensor (HO2S) connector (F)
(29) Ground (G)
(30) Injector connectors (H)




11. Remove the oil level gauge (A).




12. Remove the high pressure fuel pipe bracket bolt (A), low pressure fuel tube bracket bolts (B) and the injector connector bracket bolt (C).




13. Remove the intake manifold module (A).




14. Remove the low pressure fuel tube (A).




15. Remove the LH/RH high pressure fuel pipes (A).




16. Disconnect the cross over pipe (A) and then remove the LH/RH injector & rail assembly (B).




17. Remove the LH/RH knock sensors (A) and then remove the wiring assembly bracket (B).








18. Remove the water hose (A).




19. Remove the LH/RH ignition coils (A).








20. Remove the LH/RH fuel pumps (A).








21. Remove the LH/RH cylinder head covers (A).




22. Remove the cylinder head cover gasket (A), oil seal (B) and the fuel pump adapter gasket (C).








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




24. Remove the engine coolant temperature sensor (ECTS) wiring assembly and bracket (A).




25. Remove the LH/RH exhaust manifold heat protectors (A).








26. Remove the LH/RH exhaust manifolds (A).








27. Remove the LH/RH intake/exhaust oil control valve (OCV) & filter assemblies (A).









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




28. Remove the LH/RH timing chain upper covers (A).








29. Remove the LH/RH timing chain upper cover gaskets (A).




30. Remove the LH/RH cam to cam guides (A).








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 frontward (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).