Part 1

Removal

CAUTION:
- Use fender covers to avoid damaging painted surfaces.
- 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 battery negative cable.
2. Remove the engine cover (A), engine side covers (B) and the radiator grill upper cover (C).




3. Loosen the drain plug and drain the engine coolant.
4. Remove the intake air hose and air cleaner assembly.
(1) Remove the air duct (A).
(2) Disconnect the MAFS connector (B).
(3) Disconnect the breather hose (C).
(4) Disconnect the vacuum hose (D).
(5) Remove the intake air hose (E) and air cleaner assembly (F).




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








6. Disconnect the fuel hose (A), PCSV hose (B) and the intensifier hose (C).




7. Disconnect the engine wiring harness connectors and hoses.
(1) RH ignition coil connector (A)
(2) RH knock sensor connector (B)




(3) RH exhaust oil control valve (OCV) connector (A)
(4) RH injector connector (B)
(5) VIS solenoid valve connector (C)




(6) LH exhaust oil control valve (OCV) connector (A)
(7) LH/RH intake oil control valve (OCV) connector (B)
(8) Oil pressure switch connector (C)
(9) LH Injector connector (D)
(10) Ignition coil condenser connector (E)
(11) LH knock sensor connector (F)




(12) ETC connector (A), PCV hose (B)
(13) RH exhaust camshaft position sensor (CMPS) connector (C)
(14) Water temperature sensor (D)
(15) Ignition coil condenser connector (E)
(16) RH front oxygen sensor connector (F)




(17) Fuel pump connector (A)
(18) LH ignition coil connector (B)
(19) LH exhaust camshaft position sensor (CMPS) connector (C)
(20) LH front oxygen sensor connector (D)




(21) PCSV connector (A)
(22) LH intake camshaft position sensor (CMPS) connector (B)
(23) MAP sensor connector (C)
(24) Oil temperature sensor connector (D)
(25) RH intake camshaft position sensor (CMPS) connector (E)




8. Remove the surge tank assembly (A).




9. Remove the breather pipe & hose (A).




10. Remove the high pressure fuel tube bracket bolt (A).




11. Disconnect the water hose (C) & pipe (A) and then remove the intake manifold (B).





CAUTION:
- Be sure to drain the engine coolant before removing the intake manifold.
- If any coolant drained from the cylinder head vent hole has entered the intake port. This can potentially lead to engine trouble.

12. Remove the high pressure fuel pipe (A).




13. Remove the RH ignition coils (A) and the wiring.




14. Remove the LH ignition coils (A) and the wiring.
15. Remove the fuel pump (B) and the roller tappet (C).




16. Remove the LH/RH cylinder head cover (B) after remove the OCV cap (A).








17. Drain the engine oil.
18. Remove the lower oil pan (A).
Insert the blade of SST(09215-3C000) between the upper oil pan and lower oil pan. Cut off applied sealer and remove the lower oil pan.





NOTE:
- Insert the SST between the oil pan and the ladder frame by tapping it with a plastic hammer in the direction of arrow.
- After tapping the SST with a plastic hammer along the direction of arrow around more than 2/3 edge of the oil pan, remove it from the ladder frame.
- Do not turn over the SST abruptly without tapping. It be result in damage of the SST.
- Be careful not to damage the contact surfaces of Upper oil pan and lower oil pan.

19. Turn the tensioner counterclockwise and loosen then, remove the drive belt (A).




20. Remove the air conditioner compressor (A).




21. Remove the alternator (A).




22. Remove the oil filter body (A).




23. Remove the water pump pulley (A).




24. Remove the drive belt idler (A).




25. Remove the drive belt auto tensioner (A).




26. Set No.1 cylinder to TDC/compression.
(1) Turn the crankshaft pulley clockwise and align its groove with the timing mark "T" of the lower timing chain cover.




(2) Check that the mark of the camshaft timing sprockets are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft clockwise one revolution (360°).





NOTE:
Do not rotate engine counterclockwise.

27. Remove the crankshaft pulley (A).





NOTE:
- Use the SST(09231-3M100) to remove the crankshaft pulley bolt.




28. Remove the water pump (A) and the gaskets (B).








29. Remove the timing chain cover (A).





CAUTION:
- Be careful not to damage the contact surfaces of cylinder block, cylinder head and timing chain cover.

NOTE:
- Before removing the timing chain, mark the RH/LH timing chain with an identification based on the location of the sprocket because the identification mark on the chain for TDC (Top Dead Center) can be erased.
















30. Remove the oil pump chain cover (A).




31. Remove the oil pump chain tensioner assembly (A).




32. Release the ratchet using a thin rod.
Compress the piston and then insert a stopper pin into the hole on the ratchet to hold the compressed piston.




33. Remove the RH timing chain cam to cam guide (A).




34. Remove the RH timing chain auto tensioner (A) and the RH timing chain tensioner arm (B).




35. Remove the RH timing chain guide (A).




36. Remove the RH timing chain (A).




37. Remove the crankshaft RH timing chain sprocket (A).




38. Remove the oil pump chain sprocket (A) and oil pump chain (B).




39. Remove the crankshaft oil pump chain sprocket (A).




40. Release the ratchet using a thin rod.
Compress the piston and then insert a stopper pin into the hole on the ratchet to hold the compressed piston.




41. Remove the LH timing chain cam to cam guide (A).




42. Remove the LH timing chain auto tensioner (A) and LH timing chain tensioner arm (B).




43. Remove the LH timing chain guide (A).




44. Remove the timing chain (A).




45. Remove the crankshaft LH timing chain sprocket (A).




46. Remove the tensioner adapter assembly (A).






Inspection

Sprockets, Chain Tensioner, Chain Guide, Chain Tensioner Arm
1. Check the camshaft sprocket and crankshaft sprocket for abnormal wear, cracks, or damage. Replace as necessary.
2. Inspect the tensioner arm and chain guide for abnormal wear, cracks, or damage. Replace as necessary.
3. Check that the tensioner piston moves smoothly when the ratchet pawl is released with thin rod.

Installation

1. The key (A) of crankshaft should be aligned with the timing mark (B) of cylinder block. As a result of this, the piston of No.1 cylinder is placed at the top dead center on compression stroke.




2. Install the tensioner adapter assembly (A).




3. Install the crankshaft LH timing chain sprocket (A).




4. Install the LH timing chain (A).









NOTE:
To install the timing chain with no slack between each shaft (cam, crank), follow the below procedure.
Crankshaft sprocket -> Timing chain guide -> Exhaust camshaft sprocket -> Intake camshaft sprocket.
The timing mark of each sprockets should be matched with timing mark (color link) of timing chain at installing timing chain.

5. Install the LH timing chain guide (A).

Tightening torque :
19.6 - 24.5N.m (2.0 - 2.5kgf.m, 14.5 - 18.1lb-ft)




6. Install the LH timing chain tensioner arm (B) and LH timing chain auto tensioner (A).

Tightening torque
A : 9.8 - 11.8N.m (1.0 - 1.2kgf.m, 7.2 - 8.7lb-ft)
B : 18.6 - 21.6N.m (1.9 - 2.2kgf.m, 13.7 - 15.9lb-ft)




7. Install the LH timing chain cam to cam guide (A).

Tightening torque :
9.8 - 11.8 N.m (1.0 - 1.2 kgf.m, 7.2 - 8.7 lb-ft)




8. Remove the tensioner stopper pin (A).




9. Install the crankshaft oil pump chain sprocket (A).




10. Install the oil pump chain sprocket (A) with oil pump chain (B).

Tightening torque :
18.6 - 21.6N.m (1.9 - 2.2kgf.m, 13.7 - 15.9lb-ft)




11. Install the RH timing chain (A).