Part 2
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.
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 the valves.
(1) Using the SST(09222-28200), push in the new valve stem seals.
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 smaller outer diameter side faces toward the valve spring retainer and then install the retainer.
(3) Using the SST(09222 - 3K000, 09222-3C300), 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 a soft hammer or the wooden handle of a hammer to ensure proper seating of the valve and retainer lock.
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 the cylinder head gasket (A).
(1) The sealant locations on cylinder head gasket, cylinder block and timing chain lower case must be free of engine oil and etc.
(2) Before assembling the cylinder head gasket, the liquid sealant LT5900H or equivalent should be applied on the gap between cylinder block and timing chain lower case.
The part must be assembled within 5 minutes after sealant was applied.
NOTE:
Refer to below illustration to apply the sealant.
Bead width :
3.5 - 4.5 mm (0.1378 - 0.1772 in)
Sealant locations :
1.5 - 2.5mm (0.0591 - 0.0984 in)
from timing chain lower case inner surface
Recommended sealant :Liquid sealant LT5900H or equivalent
(3) Apply sealant on cylinder head gaskets after assembling cylinder head gaskets on cylinder block.
The part must be assembled within 5 minutes after sealant was applied.
NOTE:
Be careful of the installation direction.
(4) Install the LH/RH cylinder heads (A).
NOTE:
Wipe away any excess liquid sealant that may appear after assembling cylinder heads.
2. Install the cylinder head bolts.
(1) Do not apply engine oil on the cylinder head bolts.
(2) Using SST(09221-4A000), install and tighten the cylinder head bolts and plate washers, in several passes, in the sequence shown.
Tightening torque
Cylinder head bolts (1 - 10) :
32.4 - 36.3N.m(3.3 - 3.7kgf.m, 23.9 - 26.8lb-ft) +
88°~92°+ 118°~122°
Flange bolts (11 - 12) :
33.3 - 36.3N.m(3.4 - 3.7kgf.m, 24.6 - 26.8lb-ft)
NOTE:
Always use new cylinder head bolts.
[RH]
[LH]
3. Install the LH/RH camshaft carrier assemblies.
(1) Apply liquid sealant on the bottom surface of the carrier.
Bead width :
2.5 - 3.5mm (0.0984 - 0.1377in.)
Sealant location :
1.0 - 2.0mm (0.0393 - 0.0787in.)
from carrier bottom face chamber edge
Recommended sealant :
Liquid sealant LT 5900 or equivalent
[LH]
[RH]
NOTE:
- The part must be assembled within 5 minutes after sealant was applied.
- To apply the sealant continuously on hatched area of carrier bottom face.
- If when sealant is applied to cylinder head top face, sealant position to be same with position that is applied to carrier rail position.
- To remove oil, dust, etc. on the top face of cylinder head and the bottom face of carrier.
(2) Install the LH/RH camshaft carriers (A).
Tightening torque
Carrier bolts :
18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb-ft)
*LH engine hanger & carrier bolts (2EA) :
18.6 - 23.5 N.m (1.9 - 2.4 kgf.m, 13.7 - 17.4 lb-ft)
NOTE:
To assemble the camshaft bearing caps within 5 minutes after assembling camshaft carrier.
4. Assemble the CVVT and camshaft assembly.
Tightening torque :
73.5 - 83.4N.m(7.5 - 8.5kgf.m, 54.2 - 61.5lb-ft)
A. Align the CVVT groove with camshaft drill point.
B. Assemble the camshaft to the dowel pin of CVVT assembly. At this time, attend not to be assembled to oil hole of camshaft.
C. Hold the hexagonal head wrench portion of the camshaft with a vise, and install the bolt to the CVVT assembly.
D. Do not rotate the CVVT assembly when the camshaft is assembled to the dowel pin of CVVT assembly.
5. Install the roller finger follower and the hydraulic lash adjuster assembly (A).
(1) Until installing HLA shall be held upright so that engine oil in HLA should not spill and assured that dust does not adhere to HLA.
(2) HLA shall be inserted tenderly to the cylinder head not to spill engine oil from HLA. In case of spilling, air vent shall be done in accordance with the air vent procedure.
6. Install the LH/RH CVVT and camshaft assemblies (A).
NOTE:
Install the camshaft & CVVT assemblies from front to engine backward (1) and then put the camshaft rear down slightly (2).
Take care not to damage camshaft journal, cam lobe and the camshaft carrier journal.
CAUTION:
- Apply a light coat of engine oil on camshaft journals.
- Assemble the timing mark of CVVT to the same level of cylinder head top surface.
- Make sure the right, left bank, intake, exhaust side camshaft are correct before assembling.
- Turn the crankshaft to set the No.1 piston at TDC position.
Camshaft identification mark
7. Install the timing chain to the CVVT sprocket.
NOTE:
- Make sure the crankshaft is at TDC position.
- Align the chain installation mark of the crankshaft sprocket and the timing mark of the chain link, and then install the chain.
NOTE:
In case of marking the timing chain links corresponding to the chain installation marks on the sprocket with an identification for on-vehicle repair (for cylinder head assembly, timing chain tensioner, CVVT, camshaft, HLA or etc.), align all of the chain installation mark of the sprocket and the timing marked chain links for reassembly.
NOTE:
To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure.
Crankshaft sprocket -> Timing chain guide -> Exhaust CVVT sprocket -> Intake CVVT sprocket. (LH Bank)
Crankshaft sprocket -> Timing chain guide -> Intake CVVT sprocket -> Exhaust CVVT sprocket. (RH Bank)
When reassembling the timing chain, make sure all of the chain installation mark of the sprocket and the timing marked chain links (orange color) are aligned.
8. Install the LH/RH camshaft bearing caps (A) and the camshaft thrust bearing caps (B).
Tighten the bolts in order to below sequence.
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)
[RH]
[LH]
CAUTION:
Be sure to install the thrust bearing cap and bearing cap bolts in the correct position and facing direction.
9. Install the LH/RH fuel pump adapters (A) and the roller tappets (B).
Tightening torque :
18.6 - 22.6 N.m (1.9 - 2.3 kgf.m, 13.7 - 16.6 lb-ft)
