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MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE


T3D11B01
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Valve Cover

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the PCV hose from the valve cover.
  3. Disconnect the ignition wires at the spark plug and the ignition coil.
  4. Remove the ignition coil. Refer to Section 1F, Engine Controls.

    5. T3D11B02
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  5. Remove the valve cover hexagon bolts.
  6. Remove the valve cover with gasket.
  7. Clean the sealing surfaces of the valve cover and the cylinder head.

T3D11B02
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Installation Procedure

  1. Install the new valve cover gasket and the valve cover.
  2. Install the bolts to the valve cover.

    3. Tighten
    Tighten the valve cover hexagon bolts to to 10•5 Nm (93 lb-in)


    T3D11B01
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  3. Connect the PCV hose to the valve cover.
  4. Install the ignition coil. Refer to Section 1F, Engine Controls.
  5. Connect the negative battery cable.

T3D11B03
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Cylinder Head and Gasket

  1. Remove the fuel pump fuse.
  2. Start the engine. After it stalls, crank the engine for 10 seconds to rid the fuel system of fuel pressure.
  3. Disconnect the negative battery cable.

    4. T3D11B01
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  4. Drain the engine coolant. Refer to Section 1D, Engine Cooling.
  5. Disconnect the PCV hose from the valve cover.
  6. Remove the ignition coil. Refer to Section 1F, Engine Controls.

    7. T3D11B04
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  7. Remove the air cleaner housing bolts.
  8. Remove the air cleaner housing.

    9. T3D11B05
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  9. Disconnect the main throttle idle actuator (MTIA) connector.
  10. Disconnect the A/C pressure transducer connector.

    11. T3D11B06
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  11. Disconnect the intake air temperature (IAT) sensor connector.
  12. Disconnect the throttle cable from the throttle body.
  13. Disconnect the brake booster vacuum hose at the intake manifold.

    14. T3D11B11
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  14. Disconnect the fuel injector harness connectors.
  15. Disconnect the fuel line at the fuel rail.

    16. T3D11B07
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  16. Disconnect the camshaft position sensor connector.
  17. Disconnect the coolant temperature sensor connector.

    18. T3D11B08
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  18. Slightly loosen the power steering lower adjusting bolt.

    19. T3D11B09
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  19. Slightly loosen the power steering upper adjusting bolt.
  20. Remove the A/C with power steering drive belt.

    21. T3D11B10
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  21. Remove the upper timing belt cover bolts.
  22. Remove the upper timing belt cover.

    23. T3D11B12
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  23. Align the camshaft gear timing mark to the notch in the rear timing belt cover.

    24. T3D11B13
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  24. Slightly loosen the alternator retaining bolts.
  25. Remove the alternator drive belt.

    26. T3D11B14
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  26. Remove the engine under cover.
  27. Remove the crankshaft pulley bolt.
  28. Remove the crankshaft pulley.

    29. T3D11B15
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  29. Remove the lower timing belt cover bolts.
  30. Remove the lower timing belt cover.

    31. T3D11B16
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  31. Remove the timing belt automatic tensioner bolt.
  32. Remove the timing belt automatic tensioner.
  33. Remove the timing belt. Refer to "Timing Belt" in this section.

    34. T3D11B17
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  34. Remove the camshaft gear bolt from the camshaft.

    35. T3D11B18
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  35. Remove the timing belt rear cover bolts.
  36. Remove the timing belt rear cover from the cylinder head and cylinder block.

    37. T3D11B19
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  37. Remove the heat shield mounting bolts.
  38. Remove the heat shield.

    39. T3D11B20
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  39. Remove the retaining nuts from the catalytic converter at the exhaust manifold flange.

    40. T3D11B02
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  40. Remove the valve cover with the hexagon bolts.
  41. Remove the valve cover gasket.

    42. T3D11B21
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  42. Gradually loosen all of the cylinder head bolts in the sequence shown.
  43. Remove the cylinder head bolts.
  44. Remove the cylinder head assembly from the engine block, with the intake/exhaust manifold, throttle body, water outlet case and cylinder head gasket.

T3D11B65
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Cleaning Procedure

  1. Clean the gasket surfaces of the cylinder head and the engine block.
  2. Make sure the gasket surfaces of the cylinder head and the engine block are free of nicks and heavy scratches.
  3. Clean the cylinder head bolts.
  4. Inspect the cylinder head for warpage. Refer to "Cylinder Head and Valve Train Components" in this section.

T3D11B24
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Installation Procedure

  1. Install the cylinder head gasket.
  2. Install the cylinder head with the intake manifold and the exhaust manifold attached.
  3. Install the cylinder head bolts in the sequence shown.

    4. Tighten
    Tighten the cylinder head bolts in the sequence previously shown to 65-70 N•m (48–52 lb-ft).


    T3D11B02
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  4. Install the cylinder head cover hexagon bolts.

    5. Tighten
    Tighten the cylinder head cover hexagon bolts to 9–12 N•m ( 80–106 lb-in).

  5. Install the catalytic converter nuts at the exhaust manifold flange.

    6. Tighten
    Tighten the catalytic converter to exhaust manifold nuts to 25–35 N•m ( 18-25 lb-ft).


    T3D11B19
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  6. Install the heat shield.
  7. Install the heat shield mounting bolts.

    8. Tighten
    Tighten the heat shield mounting bolts to 8-12 N•m (71-106 lb-in).


    T3D11B18
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  8. Install the timing belt rear cover from the cylinder head and cylinder block.
  9. Remove the timing belt rear cover bolts.

    10. Tighten
    Tighten the timing belt rear cover bolts to 9-12 N•m (80-106 lb-in).


    T3D11B15
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  10. Install the timing belt. Refer to "Timing Belt" in this section.
  11. Install the lower timing belt cover.
  12. Install the lower timing belt cover bolts.

    13. Tighten
    Tighten the lower timing belt cover bolts to 9-12 N•m (80-106 lb-in).


    T3D11B10
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  13. Install the upper timing belt cover.
  14. Install the upper timing belt cover bolts.

    15. Tighten
    Tighten the upper timing belt cover bolts to 9-12 N•m (80-106 lb-in).


    T3D11B14
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  15. Install the crankshaft pulley.
  16. Install the crankshaft pulley bolts.

    17. Tighten
    Tighten the crankshaft pulley bolts to 65-75 N•m ( 48-55 lb-ft)


    T3D11B13
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  17. Install the A/C with power steering drive belt. Refer to Section 6B, Accessory Belt.
  18. Install the alternator drive belt.

    19. T3D11B07
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  19. Connect the coolant temperature sensor connector.
  20. Connect the camshaft position sensor connector.

    21. T3D11B11
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  21. Connect the fuel line at the fuel rail.
  22. Connect the fuel injector harness connectors.

    23. T3D11B06
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  23. Connect the brake booster vacuum hose at the intake manifold.
  24. Connect the throttle cable from the throttle body.
  25. Connect the intake air temperature (IAT) sensor connector.

    26. T3D11B05
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  26. Connect the A/C Pressure transducer connector.
  27. Connect the main throttle idle actuator (MTIA) connector.

    28. T3D11B04
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  28. Install the air cleaner housing.
  29. Install the air cleaner housing bolts.

    30. Tighten
    Tighten the air cleaner housing bolts to 7-9 N•m ( 62–80 lb-in).


    T3D11B01
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  30. Connect the PCV hose from the valve cover.
  31. Install the ignition coil. Refer to Section 1F, Engine Controls.
  32. Connect the negative battery cable.
  33. Install the fuel pump fuse.
  34. Refill the engine cooling system. Refer to Section 1D, Engine Cooling.

T3D11B01
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Camshaft

Removal Procedure

  1. Remove the timing belt. Refer to "Timing Belt" in this section.
  2. Remove the ignition coil at the valve cover.

    3. T3D11B07
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  3. Drain the engine coolant. Refer to Section 1D, Engine Cooling.
  4. Disconnect the coolant temperature sensor connector.
  5. Disconnect the radiator upper hose at the water outlet case.
  6. Disconnect the throttle body and heater feeding hose.

    7. T3D11B02
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  7. Remove the valve cover with gasket.

    8. T3D11B25
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  8. Remove the water outlet case nuts and the bolt.
  9. Remove the water outlet case at the cylinder head.

    10. T3D11B26
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  10. Remove the rocker arm shaft mounting bolts.
  11. Remove the rocker arm spring and the rocker arm.

    12. T3D11B27
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  12. Remove the screws with the camshaft thrust plate.

    13. T3D11B28
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  13. Remove the camshaft.

T3D11B25
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Installation Procedure

  1. Install the camshaft.
  2. Install the camshaft thrust plate.
  3. Install the camshaft thrust plate screws.

    4. Tighten
    Tighten the camshaft thrust plate screws to 10 N•m ( 89 lb-in).


    T3D11B26
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  4. Install the rocker arm spring and the rocker arm.
  5. Install the rocker arm shaft.
  6. Install the rocker arm shaft mounting bolts.

    7. Tighten
    Tighten the rocker arm shaft mounting bolts to 10 N•m ( 89 lb-in).


    T3D11B25
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  7. Install the water outlet case at the cylinder head.
  8. Install the water outlet case nuts and the bolt.

    9. Tighten
    Tighten the water outlet case nuts and the bolt to 10.5 N•m (93 lb-in).


    T3D11B02
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  9. Install the valve cover gasket.
  10. Install the valve cover.
  11. Install the valve cover hexagon bolts.

    12. Tighten
    Tighten the valve cover hexagon bolts to 10.5 N•m (93 lb-in).


    T3D11B01
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  12. Install the ignition coil. Refer to Section 1F, Engine Controls.
  13. Connect the PCV hose to the valve cover.
  14. Connect the negative battery cable.
  15. Install the timing belt. Refer to "Timing Belt" in this section.

T5B11B01
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Adjustment of Valve Clearance

Removal Procedure

  1. Remove the cylinder head cover hexagon bolts and remove the cover.
  2. Turn over the crankshaft to make NO.1 cylinder matched with the compression top dead center. When the camshaft sprocket notch is aligned with the timing belt rear cover triangle pointer and the crankshaft sprocket point is aligned with the oil pump housing point, the compression top dead center is on the ignition sequence for NO.1 cylinder.

    3. T5B11B02
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  3. Check the valve clearance for NO.1 cylinder compression top dead center.
  4. If the checking for the valve clearance of No1 cylinder compression top dead center is over, position No.1 cylinder on the exhaust top dead center as rotating the crankshaft in a 360–degree arc. When the camshaft sprocket point is aligned with the timing belt rear cover triangle pointer, the exhaust top dead center is on the ignition sequence for No.1 cylinder.

    5. T5B11B03
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  5. Check the valve clearance for the No.1 cylinder exhaust top dead center.
    6. Condition
    Cylinder
    No.
    1
    2
    3
    4
    Exhaust top dead center of No.1 cylinder
    Intake
    .
    .
    O
    O
    Exhaust
    .
    O
    .
    O
    * O marks indicates the place where the valve clearance can be checked and adjusted.

    T5B11B04
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  6. Check the adjust the valve clearance using thickness gauge. The measured value of valve clearance should meet the specified value. If not, adjust the valve clearance.

    7. Important : In case of hot engine, warm up the engine until the electric cooling fan begins to work and stop engine to adjust the clearance with 20-30 minutes there from.

    Unit : mm (in.)
    Item
    Specified value
    Valve
    Clearance
    Cold
    Intake
    0.15±0.02
    (0.0059±0.0008)
    .
    Exhaust
    0.2±0.02
    (0.00787±0.0008)
    Hot
    Intake
    0.25±0.02
    (0.0098±0.0008)
    .
    Exhaust
    0.3±0.02
    (0.0118±0.0008)

    T5B11B05
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  7. When adjusting the valve clearance, loosen the adjust nut and then tighten or loosen the adjust rod properly.

T3D11B10
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Valve Timing Check and Adjustment

  1. After removing the air filter housing, loosen the bolts and remove the timing belt front upper cover.

    2. T5B11B06
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  2. Turning the crankshaft clockwise twice, align the notch on the crankshaft pulley with the mark 0 for the timing check on the timing belt front lower cover.

    3. T5B11B07
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  3. Check if the notch on the camshaft sprocket is aligned with the triangle pointer on the timing belt rear cover.

    4. Important : Notch should be aligned with pointer to set the valve timing normally.


    T5B11B08
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  4. Loosen the bolt and remove the timing belt pulley. In loosening the bolt, use the driver in the picture shown.

    5. T5B11B09
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  5. Remove the oil level gauge guide tube and the timing belt front lower cover.

    6. T5B11B10
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  6. Remove the timing belt tensioner and the timing belt.

    7. T5B11B11
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  7. Using the bolt, turn the crankshaft clockwise to align the mark on the crankshaft sprocket with the pointer on the oil pump housing. Then, turn the camshaft to align the notch with the pointer.

    8. T3D11B40
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  8. Install the timing belt and the tensioner.
  9. Turning the crankshaft clockwise twice, align the mark with the pointer and tighten the tensioner bolt.

    10. Tighten
    Tighten the tensioner bolt to 19 N•m (14 lb-ft).


T3D11B04
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Timing Belt

  1. Disconnect the negative battery cable.
  2. Disconnect the intake air temperature (IAT) sensor connector.
  3. Disconnect the air intake tube from the throttle body.
  4. Disconnect the breather tube from the valve.
  5. Remove the air cleaner housing bolts.
  6. Remove the air cleaner housing.
  7. Remove the right front wheel. Refer to Section 2E, Tires and Wheels.
  8. Remove the right front wheel well splash shield.

    9. T3D11B10
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  9. Remove the A/C compressor drive belt.
  10. Remove the alternator drive belt.
  11. Remove the upper timing belt cover bolts.
  12. Remove the upper timing belt cover.

    13. T3D11B12
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  13. Align the mark on the crankshaft gear and camshaft gear.

    14. T3D11B15
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  14. Remove the crankshaft pulley bolt.
  15. Remove the crankshaft pulley.
  16. Remove the lower timing belt cover bolts.
  17. Remove the lower timing belt cover.

    18. T3D11B16
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  18. Loosen the timing belt tensioner bolt.
  19. Remove the timing belt.

T3D11B16
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Installation Procedure

    Important : If the camshaft or crankshaft rotates in the process of installing the timing belt, Perform the valve timing setting necessary. Refer to "Valve Timing Check and Adjustment" in this section.

  1. Install the timing belt tensioner bolt.

    2. Tighten
    Tighten the timing belt tinsioner bolt to 19 N•m ( 14 lb-ft).


    T3D11B15
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    Important : Turn the crankshaft twice to align the notch on the camshaft with the pointer on the rear cover and tighten the tensioner bolt.

  2. Install the timing belt front lower cover bolts.

    3. Tighten
    Tighten the timing belt front lower cover bolts to 10.5 N•m ( 93 lb-in).

  3. Install the oil level gauge guide tube bolt.

    4. Tighten
    Tighten the oil level gauge guide tube bolt to 10.5 N•m (93 lb-in).


    T3D11B10
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  4. Install the timing belt front upper cover bolts.

    5. Tighten
    Tighten the timing belt front upper cover bolts to 10.5 N•m ( 93 lb-in).

  5. Install the crankshaft pulley bolt.

    6. Tighten
    Tighten the crankshaft pulley bolts to 70 N•m (52 lb-ft).


    T3D11B04
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  6. Install the alternator drive belt.
  7. Install the compressor drive belt.
  8. Install the right front wheel. Refer to Section 2E, Tires and Wheels.
  9. Install the air cleaner housing.
  10. Install the air cleaner housing bolts.

    11. Tighten
    Tighten the air cleaner housing bolts to 12 N•m (106 lb-in).



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