Hyundai Genesis 2009 2013, GENESIS COUPE BK 2010 Workshop Manual

GENESIS COUPE(BK) > 2010 > G 3.8 DOHC > General Information

General Information > General Information > General Information

Identification Number Locations

Identification Number Description

Vehicle Identification Number

1. World Manufacturer Identifier (WMI)

- KMF : Commercial vehicle (Van)

- KMH : Passenger vehicle or MPV(Multipurpose Passenger Vehicle)/SUV(Sports Utility Vehicle)/RV(Recreational
Vehicle)

- KMJ : Van

- KM8 : MPV/SUV/RV (For U.S.A, Canada, Mexico)

2. Vehicle line

- H : GENESIS COUPE

3. Model & Series

- L : Low grade (L)

- M : Middle-Low grade (GL)

- N : Middle grade (GLS, JSL, TAX)

- P : Middle-High grade (HGS)

- R : High grade (TOP)

4. Body/Cabin type, Gross Vehicle Weight Rating
KMF (Commercial vehicle / Van)
Except U.S.A, Canada, Mexico, Gulf Cooperation Council, China

- X : Standard Cabin / Semi- Bonnet

- Y : Double Cabin / Bonnet

- Z : Super Cabin / Box
For U.S.A, Canada, Mexico, Gulf Cooperation Council, China

- 3 : Standard Cabin Class-E 4×2 / Semi-Bonnet Class-E 4×2

- 4 : Standard Cabin Class-E 4×4 / Semi-Bonnet Class-E 4×4

- 5 : Standard Cabin Class-F 4×2 / Semi-Bonnet Class-F 4×2

- 6 : Standard Cabin Class-F 4×4 / Semi-Bonnet Class-F 4×4

- 7 : Double Cabin Class-E 4×2 / Bonnet Class-E 4×2

- 8 : Double Cabin Class-E 4×4 / Bonnet Class-E 4×4

- 9 : Double Cabin Class-F 4×2 / Bonnet Class-F 4×2

- 0 : Double Cabin Class-F 4×4 / Bonnet Class-F 4×4

- A : Super Cabin Class-E 4×2 / Box Class-E 4×2

- B : Super Cabin Class-E 4×4 / Box Class-E 4×4

- C : Super Cabin Class-F 4×2 / Box Class-F 4×2

- D : Super Cabin Class-F 4×4 / Box Class-F 4×4
KMH

- 1 : Limousine

- 2 : Sedan - 2 door

- 3 : Sedan - 3 door

- 4 : Sedan - 4 door

- 5 : Sedan - 5 door

- 6 : Coupe

- 7 : Convertible

- 8 : Wagon

- 9 : Commercial Van

- 0 : Pick-Up
KMJ

- 1 : Box

- 2 : Bonnet

- 3 : Semi-Bonnet
KM8

- 1 : Wagon 4×2 Class-A

- 2 : Wagon 4×2 Class-B

- 3 : Wagon 4×2 Class-C

- 4 : Wagon 4×2 Class-D

- 5 : Wagon 4×2 Class-E

- 6 : Wagon 4×2 Class-F

- 7 : Wagon 4×2 Class-G

- A : Wagon 4×4 Class-A

- B : Wagon 4×4 Class-B

- C : Wagon 4×4 Class-C

- D : Wagon 4×4 Class-D

- E : Wagon 4×4 Class-E

- F : Wagon 4×4 Class-F

- G : Wagon 4×4 Class-G

5. Restraint system, Brake system
KMH, KM8
Except U.S.A, Canada, Mexico

- 0 : Both side - None

- 1 : Both side - Active belt

- 2 : Both side - Passive belt
For U.S.A, Canada, Mexico

Code

Seat

belt

Front air bag Knee air bag Side air bag Curtain air bag

Driver's Passenger's Driver's Passenger's 1st row 2nd row 3rd row 1st row 2nd row 3rd row

A ○ ○ ○ × × ○ × × ○ ○ ×

B ○ ○ ○ × × × × × × × ×

C ○ ○ ○ × × ○ × × ○ ○ ○

D ○ ○ ○ × × ○ ○ × ○ ○ ×

E ○ ○ × × × × × × × × ×

F ○ ○ ○ × × ○ × × × × ×

N ○ × × × × × × × × × ×

KMJ
Except U.S.A, Canada, Mexico

- 7 : Hydraulic brake system

- 8 : Pneumatic brake system

- 9 : Mixed brake system
For U.S.A, Canada, Mexico

- X : Hydraulic brake system

- Y : Pneumatic brake system

- Z : Mixed brake system
KMF
Except U.S.A, Canada, Mexico

- 7 : Hydraulic brake system

- 8 : Pneumatic brake system

- 9 : Mixed brake system
For U.S.A, Canada, Mexico

Restraint system Brake system

Code

Seat

belt

Front air bag Knee air bag Side air bag

Curtain air

bag

Hydrauric Pneumatic Mixed

Driver's Passenger's Driver's Passenger's

1st

row

2nd

row

3rd

row

1st

row

2nd

row

3rd

row

X ○ × × × × × × × × × × ○ - -

V ○ ○ × × × × × × × × × ○ - -

W ○ ○ ○ × × × × × × × × ○ - -

6. Engine type

- D : Gasoline engine 2.0

- H : Gasoline engine 3.8

7. Check digit or Driver’s side & Transmission
Except U.S.A, Canada, Mexico, Gulf Cooperation Council, China, Yemen

- A : LHD & MT

- B : LHD & AT

- C : LHD & MT+Transfer

- D : LHD & AT+Transfer

- E : LHD & CVT

- L : RHD & MT

- M : RHD & AT

- N : RHD & MT+Transfer

- S : RHD & AT+Transfer

- T : RHD & CVT
For U.S.A, Canada, Mexico, Gulf Cooperation Council, China, Yemen

- Check digit : 0 ~ 9, ×

8. Production year

- A : 2010, B : 2011, C : 2012, D : 2013 …

9. Plant of production

- A : Asan (Korea)

- C : Cheonju (Korea)

- U : Ulsan (Korea)

10. Vehicle production sequence number

- 000001 ~ 999999

Paint Code

Code Color

NAA Ceramic White

NBA Space Black

NCA Sleek Silver

NDA Gray Titanum

NEA Blue Diamond

NFA Dynamic Yellow

NGA Super Red

NHA Blue Sapphire

NJA Lime Green

Engine Number

1. Engine fuel

- G : Gasoline

2. Engine range

- 4 : 4 cycle 4 cylinder

- 6 : 4 cycle 6 cylinder

3. Engine development order

- D : Lamda engine

- K : Theta engine

4. Engine capacity

- A : Lamda 3778 cc

- D : Theta - 2, 1998 cc

5. Production year

- 9 : 2009, A : 2010, B : 2011, C : 2012, D : 2013 …

6. Engine production sequence number

- 000001 ~ 999999

Transaxle Number

Automatic

1. Model

- X : A5SR1

2. Production year

- 9 : 2009, A : 2010, B : 2011, C : 2012, D : 2013 …

3. Vehicle Line

- K : BK

4. Detailed chassification

- T2 : Theta 2.0 TCI

5. Spare

6. Transaxle production sequence number

- 000001 ~ 999999

Warning / Caution Label Locations

1. Radiator Cap Caution

2. Battery Caution

3. Fan Caution

4. Coolant Level Caution

Battery Caution Label Describtion

Warning / Caution Label (Cont'd)

A.
Keep lighted cigarettes and all other flames or sparks away from the battery.

B.
Wear eye protection when charging or working near a battery. Always provide ventilation when working in an
enclosed space.

• When lifting a plastic-cased battery, excesive pressure on acid to leak resulting in personal injury. Lift with a
battery carrier or with your hands on opposite corners.

• Never attempt to change the battery when the battery cables are connected.

• The electrical ignition system works with high voltage.
Never touch these components with the engine running or the ignition switched on.

C.
Keep batteries out of the reach of children because batteries contain highly corrosive SULFURIC ACID. Do not allow
battery acid to contact your skin, eyes, clothing or paint finish.

D.
If any electrolyte gets into your eyes, flush your eyes with clean water for at least 15 minutes and get immediate
medical attention. If possible, continue to apply water with a sponge or cloth until medical attention is received.
If electrolyte gets on your skin, throughly wash the contacted area. If you feel a pain or a burning sensation, get
medical attention immediately.

E.
Always read the following instructions carefully when handing a battery.

F.
Hydrogen, which is a highly combustible gas, is always presents in battery cells and may explode if ignited.

G.
An improperly disposed battery can be harmful to the environment and human health.
Always confirm local regurations for battery disposal.

Handling And Storage The Battery

Battery Itself

• Batteries should be stored in cool, dry (27 degrees Celsius) places and out of
direct sunlight.

• MF batteries are tightly sealed to prevent acid leakage.
However, tilting the battery to an angle of 45 degrees can cause acid to leak
through the vents on the sides. Therefore, batteries should always be stored in
their upright positions. Prevent placing any aqueous or solid (i.e. conductors)
bodies on top of the battery.

• It is extremely dangerous to use tools, such as hammers, on the battery
terminals when connecting cables to the mounted battery.

Battery on Vehicle

• When storing the vehicle for long periods of time, make sure to remove the
memory fuse at junction box to prevent natural discharging.

• Also, run the engine for battery charging within 1 month if the memory fuse
wasn't removed from the start of vehicle storing.
If the memory fuse was removed, run the engine for battery charging within 3
months from the start of vehicle storing.

After reconnecting or recharging a discharged battery, the ESP OFF indicator may illuminate.
In this case, turn the handle half way to the left and right whilst the ignition switch is in the ON position.
Then, restart the engine after the ignition is OFF.
The ESP OFF indicator may turn OFF.
If the ESP OFF indicator does not turn OFF, have the system checked refering to DTC. (Refer to the BR group.)

Lift And Support Points

When heavy rear components such as suspension, fuel tank, spare tire, tailgate and trunk lid are to be removed,
place additional weight in the luggage area before hoisting. When substatial weight is removed from the rear of the
vehicle, the center of gravity may change and cam cause the vehicle to tip forward on the hoist.

• Since each tire/wheel assembly weights approximately 30lbs (14kg), placing the front wheels in the luggage
area can assist with the weight distribution.

• Use the same support points to support the vehicle on safety stands.

1. Place the lift blocks under the support points as shown in the illustration.

2. Raise the hoist a few inches (centimeters) and rock the vehicle to be sure it is firmly supported.

3. Raise the hoist to full height to inspect the lift points for secure support.

Towing

If the vehicle needs to be towed, call a professional towing service. Never tow vehicle with just a rope or chain. It is
very dangerous.

Emergency Towing

There are three popular methods of towing a vehicle :

- The operator loads the vehicle on the back of truck. This is best way of transporting the vehicle.

- The tow truck uses two pivoting arms that go under the tires of the driving axle and lift them off the ground. the
other two wheels remain on the ground.

- The tow truck uses metal cables with hooks on the ends. These hooks go around parts of the frame or suspension,
and the cables lift that end of the vehicle off the ground. The vehicle's suspension and body can be seriously
damaged if this method of towing is attempted.

If the vehicle cannot be transported by flat-bed, should be towed with the wheels of the drivig axle off the ground and
do the following :
Manual Transaxle

• Release the parking brake.

• Shift the Transaxle to neutral

Automatic Transaxle

• Release the parking brake.

• Start the engine.

• Shift to [D] position, then [N] position.

• Turn off the engine.

• The vehicle equipped with full-time 4WD should be only transported on a flat-bed.

• Improper towing preparation will damage the transaxle. follow the above procedure exactly. If you cannot
shift the transaxle or start the engine(automatic transaxle), your vehicle must be transported on a flatbed.

• It is the best to tow vehicle no farther than 30km (19miles), and keep the speed below 50km/h (30mph).
(For the full-time 4WD vehicle, limit the towing to 1.5km (1mile) and 15km/h (10mph)

• Trying to lift or tow your vehicle by the bumpers will cause serious damage. The bumpers are not designed
to support the vehicle's weight.

Front :

Rear :

Tightening Torque Table Of Standard Parts

Bolt niminal diameter

(mm)

Pich (mm)

Torque Nm (kg.cm, lb.ft)

Head Mark 4 Head Mark 7

M5 0.8 3 ~ 4 (30 ~ 40, 2.2 ~ 2.9) 5 ~ 6 (50 ~ 60, 3.6 ~ 4.3)

M6 1.0 5 ~ 6 (50 ~ 50, 3.6 ~ 4.3) 9 ~ 11 (90 ~ 110, 6.5 ~ 8.0)

M8 1.25 12 ~ 15 (120 ~ 150, 9 ~ 11) 20 ~ 25 (200 ~ 250, 14.5 ~ 18.0 )

M10 1.25 25 ~ 30 (250 ~ 300, 18 ~ 22) 30 ~ 50 (300 ~ 500, 22 ~ 36)

M12 1.25 35 ~ 45 (350 ~ 450, 25 ~ 33) 60 ~ 80 (600 ~ 800, 43 ~ 58)

M14 1.5 75 ~ 85 (750 ~ 850, 54 ~ 61) 120 ~ 140 (1,200 ~ 1,400, 85 ~

100)

M16 1.5 110 ~ 130 (1,100 ~ 1,300, 80 ~

94)

180 ~ 210 (1,800 ~ 2,100, 130 ~

150)

M18 1.5 160 ~ 180 (1,600 ~ 1,800, 116 ~

130)

260 ~ 300 (2,600 ~ 3,000, 190 ~

215)

M20 1.5 220 ~ 250 (2,200 ~ 2,500, 160 ~

180)

360 ~ 420 (3,600 ~ 4,200, 260 ~

300)

M22 1.5 290 ~ 330 (2,900 ~ 3,300, 210 ~

240)

480 ~ 550 (4,800 ~ 5,500, 350 ~

400)

M24 1.5 360 ~ 420 (3,600 ~ 4,200, 260 ~

300)

610 ~ 700 (6,100 ~ 7,000, 440 ~

505)

- The torques shown in the table are standard values under the following conditions :

• Nuts and bolts are made of galvanized steel bar.

• Galvanized plain steel washers are inserted.

• All nuts, bolts and plain washers are dry.

- The torques shown in the table are not applicable :

• When spring washers, toothed washers and the like are inserted.

• If plastic parts are fastened.

• If self-tapping screws or self-locking nuts are used.

• If threads and surfaces are coated with oil.

- If you reduce the torques in the table to the percentage indicated below, under the following conditions, if will
be the standard value.

• If spring washers are used : 85%

• If threads and bearing surfaces are stained with oil : 85%

General Service Information

Protection Of The Vehicle

Always be sure to cover fenders, seats, and floor areas before starting work.

The support rod must be inserted into the hole near the edge of the hood whenever you inspect the engine
compartment to prevent the hood from falling and causing possible injury.
Make sure that the support rod has been released prior to closing the hood. Always check to be sure the hood is
firmly latched before driving the vehicle.

Preparation Of Tools And Mesuring Equipment

Be sure that all necessary tools and measuring equipment are available starting work.

Special Tools

Use special tools when they are required.

Removal Of Parts

First find the cause of the problem and then determine whether removal or disassembly before starting the job.

Disassembly

If the disassembly procedure is complex, requiring many parts to be disassembled, all parts should be disassembled in
a way that will not affect their performance or external appearance.

1. Inspection of parts
Each part, when removed, should be carefully on suspected for malfunction, deformation, damage, and other
problems.

2. Arrangement of parts
All disassembled parts should be carefully arranged for effective reassembly.
Be sure to separate and correctly identify the parts to be replaced from those that will be used again.

3. Cleaning parts for reuse
All parts to be used again should be carefully and thoroughly cleaned by an appropriate method.

Parts

When replacing parts, use HYUNDAI genuine parts.

Replacement

Standard values, such as torques and certain adjustments, must be strictly observed in the reassembly of all parts.
If removed, the following parts should always be replaced with new ones.

1. Oil seals

2. Gaskets

3. O-rings

4. Lock washers

5. Cotter pins (split pins)

6. Plastic nuts

Depending on their location.

7. Sealant should be applied to gaskets.

8. Oil should be applied to the moving components of parts.

9. Specified oil or grease should be applied to the prescribed locations (oil seals, etc) before assembly.

Adjustment

Use gauges and testers to adjust correctly the parts to standard values correctly.

Electrical System

1. Be sure to disconnect the battery cable from the negative (-) terminal of the battery.

2. Never pull on the wires when disconnecting connectors.

3. Locking connectors will click when the connector is secure.

4. Handle sensors and relays carefully. Be careful not to drop them against other parts.

Ruber Parts And Tubes

Always prevent gasoline or from touching rubber parts or tubing.

Measuring Body Dimensiongs

1. Basically, all measurements in this manual are taken with a tracking gauge.

2. When a measuring tape is used, check to be sure there is no elongation, twisting or bending.

3. For measuring dimensions, both projected dimensions and actual - measurement dimensions are used in this
manual.

Dimensions Projected

1. These are the dimensions measured when the measurement points are projected from the vehicle's surface, and are
the reference dimensions used for used for body alterations.

2. If the length of the tracking gauge probes is adjustable, measure it by lengthening one of two probes as long as the
different value in height of the two surface.

Measuring Actual Dimensions

1. These dimensions indicate the actual linear distance between measurement points, and are used as the reference
dimensions when a tracking gauge is used for measurement.

2. First adjust both probes to the same length (A=A') before measurement.

Check the probes and gauge itself to make sure there is no free play.

Measurement Point

Measurements should be taken at the center of the hole.

Checking Cables And Wires

1. Check the terminal for tightness.

2. Check terminals and wires for corrosion from battery electrolyte, etc.

3. Check terminals and wires for open circuits.

4. Check wire insulation and coating for damage, cracks and degrading.

5. Check the conductive parts of terminals for contact with other metallic parts (vehicle body and other parts).

6. Check grounded parts to verify that there is complete continuity between their attaching bolt(s) and the vehicle's
body.

7. Check for incorrect wiring.

8. Check that the wiring is so clamped to the prevent contact with sharp corners of the vehicle body, etc. or hot parts
(exhaust manifold, etc.)

9. Check that the wiring is clamped firmly to provide enough clearance from the fan pulley, fan belt and other rotating
or moving parts.

10. Check that the wiring has a little space so that it can vibrate between fixed and moving parts such as the vehicle

body and the engine.

Check Fuses

A blade type fuse test taps provided to allow checking the fuse itself without removing if from the fuse box. The fuse is
good if the test lamp lights up when one lead is connected to the test taps (one at a time) and the other lead is
grounded. (Turn the ignition switch so that the fuse circuit becomes operative)

Serivicing The Electrical System

1. Prior to servicing the electrical system, be sure to turn off the ignition switch and disconnect the battery ground
cable.

In the course of MFI or ELC system diagnosis, when the battery cable is removed, any diagnostic trouble code
retained by the computer will be cleared. There fore, if necessary, read the diagnostic before removing the
battery cable.

2. Attach the wiring harnesses with clamps so that there is no slack. However, for any harness which passes the
engine or other vibrating parts of the vehicle, allow some slack within a range that does not allow the engine
vibrations to cause the harness to come into contact with any of the surrounding parts and then secure the harness
by using a clamp.

3. If any section of a wiring harness interferes with the edge of a parts, or a corner, wrap the section of the harness
with tape or something similar in order to protect if from damage.

4. When installing any parts, be careful not to pinch or damage any of the wiring harness.

5. Never throw relays, sensors or electrical parts, or expose them to strong shock.

6. The electronic parts used in the computer, relays, etc. are readily damaged by heat. If there is a need for service
operations that may cause the temperature to exceed 80°C (176°F), remove the electronic parts before hand.

7. Loose connectors cause problems. Make sure that the connectors are always securely fastened.

8. When disconnecting a connector, be sure to grip only the connector, not the wires.

9. Disconnect connector which have catches by pressing in the direction of the arrows shown the illustration.

10. Connect connectors which have catches by inserting the connectors until they make a clicking sound.

11. When using a circuit tester to check continuity or voltage on connector terminals, insert the test probe into the

harness side. If the connector is a sealed connector, insert the test probe through the hole in the rubber cap until
contacts the terminal, being careful not to damage the insulation of the wires.

12. To avoid overloading the wiring, take the electrical current load of the optional equipment into consideration, and

determine the appropriate wire size.

Noeminal size SAE gauge No.

Permissible current

In engine compartment Other areas

0.3mm² AWG 22 - 5A

0.5mm² AWG 20 7A 13A

0.85mm² AWG 18 9A 17A

1.25mm² AWG 16 12A 22A

2.0mm² AWG 14 16A 30A

3.0mm² AWG 12 21A 40A

5.0mm² AWG 10 31A 54A

Precautions For Catalytic Converter

If a large amount of unburned gasolined gasoline flow into the converter, it may overheat and create a fire hazard.
To prevent this observe the following precations and explain them to your customer.

1. Use only unleaded gasoline.

2. Do not run the engine while the car is at rest for a long time. Avoid running the engine at fast idle for more than

10minutes and idle speed for more than 20 minutes.

3. Avoid start-jump tests. Do start-jumps only when absolutely necessary. Perform this test as rapidly as possible and,
while testing, never race the engine.

4. Do not measure engine compression for and extended time. Engine compression tests must be made as rapidly as
possible.

5. Avoid coasting with the ignition turned and during prolonged braking.

6. Do not dispose of used catalytic converter together with parts contaminated with gasoline or oil.

GENESIS COUPE(BK) > 2010 > G 3.8 DOHC > Engine Mechanical System

Engine Mechanical System > General Information > Specifications

Specifications

Description Specifications Limit

General

Type V-type, DOHC

Number of cylinders 6

Bore 96mm(3.7795in.)

Stroke 87.0mm(3.4252in.)

Total displacement 3,778cc(230.55cu.in.)

Compression ratio 10.4

Firing order 1-2-3-4-5-6

Valve timing

Intake

Opens(ATDC) 10°(3.8L)

Closes(ABDC) 74°

Exhaust

Opens(BBDC) 52°

Closes(ATDC) 0°

Cylinder head

Flatness of gasket surface

Less than 0.05mm (0.0019in.)

[Less than 0.02mm (0.0008in.) / 150x150]

Flatness of
manifold mounting

Intake

Less than 0.1mm(0.0039in.)

[Less than 0.03mm(0.001in.) / 110x110]

Exhaust

Less than 0.1mm(0.0039in.)

[Less than 0.03mm(0.001in.) / 110x110]

Camshaft

Cam height

LH
Camshaft

Intake 47.2mm (1.8582in.)

Exhaust 45.8mm (1.8031in.)

RH
Camshaft

Intake 47.2mm (1.8582in.)

Exhaust 45.8mm (1.8031in.)

Journal outer
diameter

LH, RH
camshaft

Intake

No.1: 27.964 ~ 27.978mm (1.1009 ~ 1.1015in.)

No.2,3,4: 23.954 ~ 23.970mm(0.9430 ~ 0.9437in.)

Exhaust

No.1: 27.964 ~ 27.978mm(1.1009 ~ 1.1015in.)

No.2,3,4: 23.954 ~ 23.970mm(0.9430 ~ 0.9437in.)

Bearing oil
clearance

LH, RH
camshaft

Intake

No.1: 0.027 ~ 0.057mm (0.0011 ~ 0.0022in.)

No.2,3,4: 0.030 ~ 0.067mm (0.0012 ~ 0.0026in.)

Exhaust

No.1: 0.027 ~ 0.057mm (0.0011 ~ 0.0022in.)

No.2,3,4: 0.030 ~ 0.067mm (0.0012 ~ 0.0026in.)

End play 0.02 ~ 0.18mm (0.0008 ~ 0.0071in.)

Valve

Valve length

Intake 105.27mm(4.1445in.)

Exhaust 105.50mm (4.1535in.)

Stem outer
diameter

Intake 5.465 ~ 5.480mm (0.2151 ~ 0.2157in.)

Exhaust 5.458 ~ 5.470mm (0.2149 ~ 0.2153in.)

Face angle 45.25° ~ 45.75°

Thickness of
valvehead(margin)

Intake 1.56 ~ 1.86mm (0.06142 ~ 0.07323in.)

Exhaust 1.73 ~ 2.03mm (0.06811 ~ 0.07992in.)

Valve stem to
valve guide
clearance

Intake 0.020 ~ 0.047mm (0.00078 ~ 0.00185in.)

0.07mm

(0.00275in.)

Exhaust 0.030 ~ 0.054mm (0.00118 ~ 0.00212in.)

0.09mm

(0.00354in.)

Valve guide

Inner diameter

Intake 5.500 ~ 5.512mm (0.2165 ~ 0.2170in.)

Exhaust 5.500 ~ 5.512mm (0.2165 ~ 0.2170in.)

Length

Intake 41.8 ~ 42.2mm (1.6457 ~ 1.6614in.)

Exhaust 41.8 ~ 42.2mm (1.6457 ~ 1.6614in.)

Valve seat

Width of seat
contact

Intake 1.15 ~ 1.45mm(0.05118 ~ 0.05709in.)

Exhaust 1.35 ~ 1.65mm(0.05315 ~ 0.06496in.)

Seat angle

Intake 44.75° ~ 45.20°

Exhaust 44.75° ~ 45.20°

Valve spring

Free length 43.86mm (1.7267in.)

Load

19.3±0.8kg/34.0mm (42.7±1.8 lb/1.3386in.)

42.3±1.3kg/24.2mm (93.2±2.9 lb/0.9527in.)

Out of squareness Less than 1.5°

MLA

MLA outer
diameter

Intake 34.964 ~ 34.980mm (1.3765 ~ 1.3772in.)

Exhaust 34.964 ~ 34.980mm (1.3765 ~ 1.3772in.)

Cylinder head
tappet bore inner
diameter

Intake 35.000 ~ 35.025mm (1.3779 ~ 1.3789in.)

Exhaust 35.000 ~ 35.025mm (1.3779 ~ 1.3789in.)

MLA to tappet
bore clearance

Intake 0.020 ~ 0.061mm (0.0008 ~ 0.0024in.) 0.07mm (0.0027in.)

Exhaust 0.020 ~ 0.061mm (0.0008 ~ 0.0024in.) 0.07mm (0.0027in.)

Valve clearance (At 20°C [68°F])

Intake 0.17 ~ 0.23mm (0.0067 ~ 0.0090in.)

0.10 ~ 0.30mm

(0.0039 ~ 0.0118in.)

Exhaust 0.27 ~ 0.33mm (0.0106 ~ 0.0129in.)

0.20 ~ 0.40mm

(0.0078 ~ 0.0157in.)

Cylinder block

Cylinder bore 96.00 ~ 96.03mm (3.7795 ~ 3.7807in.)

Flatness of gasket surface

Less than 0.05mm (0.0019in.)

[Less than 0.02mm (0.0008in.) / 150x150]

Piston

Piston outer diameter 95.96 ~ 95.99mm(3.7779 ~ 3.7791in.)

Piston to cylinder clearance 0.03 ~ 0.05mm(0.0012 ~ 0.0020in.)

Ring groove width

No. 1 ring groove 1.22 ~ 1.24mm (0.0480 ~ 0.0488in.) 1.26mm (0.0496in.)

No. 2 ring groove 1.22 ~ 1.24mm (0.0480 ~ 0.0488in.) 1.26mm (0.0496in.)

Oil ring groove 2.01 ~ 2.03mm (0.0791 ~ 0.0799in.) 2.05mm (0.0807in.)

Piston ring

Side clearance

No. 1 ring 0.03 ~ 0.07mm (0.0012 ~ 0.0027in.) 0.1mm (0.004in.)

No. 2 ring 0.03 ~ 0.07mm (0.0012 ~ 0.0027in.) 0.1mm (0.004in.)

Oil ring 0.06 ~ 0.15mm (0.0024 ~ 0.0059in.) 0.2mm (0.008in.)

End gap

No. 1 ring 0.17 ~ 0.32mm (0.0067 ~ 0.0126in.) 0.6mm (0.0236in.)

No. 2 ring 0.32 ~ 0.52mm (0.0126 ~ 0.0204in.) 0.7mm (0.0275in.)

Oil ring 0.20 ~ 0.70mm (0.0078 ~ 0.0275in.) 0.8mm (0.0315in.)

Piston pin

Piston pin outer diameter 21.997 ~ 22.000mm (0.8660 ~ 0.8661in.)

Piston pin hole inner diameter 22.004 ~ 22.010mm (0.8663 ~ 0.8665in.)

Piston pin hole clearance 0.004 ~ 0.013mm (0.00015~ 0.00051in.)

Connecting rod small end inner diameter 22.007 ~ 22.018mm (0.8664 ~ 0.8668in.)

Connecting rod small end hole clearance 0.007 ~ 0.021mm (0.00027~ 0.00082in.)

Connecting rod

Connecting rod big end inner diameter 58.000 ~ 58.018mm(2.2834 ~2.2842in.)

Connecting rod bearing oil clearance 0.038 ~ 0.056mm (0.0015 ~ 0.0022in.)

Side clearance 0.1 ~ 0.25mm (0.0039 ~ 0.0098in.)

Crankshaft

Main journal outer diameter 68.942 ~ 68.960mm (2.7142 ~ 2.7149in.)

Pin journal outer diameter 54.954 ~ 54.972mm (2.1635 ~ 2.1642in.)

Main bearing oil clearance 0.022 ~ 0.040mm (0.0008 ~ 0.0016in.)

End play 0.10 ~ 0.28mm (0.0039 ~ 0.0110in.)

Oil pump

Relief valve opening pressure

500 ~ 600kPa

(5.09 ~ 6.11kgf/cm², 72.51 ~ 87.02psi)

Engine oil

Oil quantity

Total 6.0L (6.34US qt, 5.28lmp qt)

When replacing a
short engine or a
block assembly

Oil pan 5.5L (5.81US qt, 4.84lmp qt)

Drain and refill 5.2L (5.49US qt, 4.58lmp qt) Including oil filter

Oil grade

Recommendation 5W-20/GF4&SM

If not available,
refer to the
recommended API
or ILSAC
classification and
SAE viscosity
number.

Classification

API SL, SM or above

ILSAC GF3, GF4 or above

Satisfy the
requirement of the
API or ILSAC
classification.

SAE viscosity grade Recommended SAE viscosity number

Refer to the
"Lubrication
System"

Oil pressure (at 1000rpm) 130kPa (1.32kg/cm², 18.77psi) or above

Oil temperature in
oil pan : 110±2°C
(230±36°F)

Cooling system

Cooling method Forced circulation with cooling fan

Coolant quantity 9.0L (9.50US qt, 7.91lmp qt)

Thermostat

Type Wax pellet type

Opening temperature 82±2°C (179.6±35.6°F)

Fully opened temperature 95°C (203°F)

Full lift 10mm (0.3937in.) MIN

Radiator cap

Main valve opening
pressure

93.16 ~ 122.58kpa

(0.95 ~ 1.25kg/cm², 13.51 ~ 17.78psi)

Vacuum valve opening
pressure

0 ~ 6.86 kpa

(0 ~ 0.07kg/cm², 0 ~ 0.99psi)

Water temperature sensor

Type Thermister type

Resistance

20°C (68°F) 2.31 ~ 2.59KΩ

80°C(176°F) 0.3222 KΩ

Tightening Torques

Item Quantity Nm kgf.m lb-ft

Crankshaft pulley bolt 1 284.4 ~ 304.0 29.0 ~ 31.0 209.8 ~ 224.2

Timing chain cover bolt B 17 18.6 ~ 21.6 1.9 ~ 2.2 13.7 ~ 15.9

Timing chain cover bolt C 4 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Timing chain cover bolt D 2 58.8 ~ 68.6 6.0 ~ 7.0 43.4 ~ 50.6

Timing chain cover bolt F 2 24.5 ~ 26.5 2.5 ~ 2.7 18.1 ~ 19.5

Timing chain cover bolt G 4 21.6 ~ 23.5 2.2 ~ 2.4 15.9 ~ 17.4

Timing chain cover bolt H 1 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Timing chain cover bolt I 1 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Timing chain cover bolt J 1 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Timing chain cover bolt K 4 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Timing chain cover bolt L 1 21.6 ~ 26.5 2.2 ~ 2.7 15.9 ~ 19.5

Timing chain auto tensioner bolt 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Timing chain auto tensioner nut 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Timing chain auto tensioner arm bolt 2 18.6 ~ 21.6 1.9 ~ 2.2 13.7 ~ 15.9

Timing chain guide bolt 4 19.6 ~ 24.5 2.0 ~ 2.5 14.5 ~ 18.1

Oil pump chain cover bolt 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Oil pump chain tensioner bolt 1 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Oil pump chain guide bolt 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Oil pump chain sprocket bolt 1 18.6 ~ 21.6 1.9 ~ 2.2 13.7 ~ 15.9

Lower oil pan bolt 13 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Drive belt auto tensioner bolt(M12) 1 81.4 ~ 85.3 8.3 ~ 8.7 60.0 ~ 62.9

Drive belt auto tensioner bolt(M8) 1 17.7 ~ 21.6 1.8 ~ 2.2 13.0 ~ 15.9

Drive belt idler bolt 1 53.9 ~ 57.9 5.5 ~ 5.9 39.8 ~ 42.7

OCV(oil control valve) bolt 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Cylinder head bolt 16 (37.3~41.2) +

(118~122°) +

(88~92°)

(3.8~4.2) +

(118~122°) +

(88~92°)

(27.5~30.4) +

(118~122°) +

(88~92°)

Cylinder head bolt 1 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4

CVVT & cam sprocket bolt 4 64.7 ~ 76.5 6.6 ~ 7.8 47.7 ~ 56.4

Camshaft bearing cap bolt 32 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Cylinder head cover bolt 38 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Connecting rod bearing bolt 12 (22.6~26.5) +

(98~102°)

(2.3~2.7) +

(98~102°)

(16.6~19.5) +

(98~102°)

Main bearing cap inner bolt(M11) 8 49.0 + 90° 5.0 + 90° 36.2 + 90°

Main bearing cap outer bolt(M8) 8 19.6 + 120° 2.0 + 120° 14.5 + 120°

Main bearing cap side bolt(M8) 8 29.4 ~ 31.4 3.0 ~ 3.2 21.7 ~ 23.1

Rear oil seal case bolt 6 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Baffle plate bolt 6 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Upper oil pan bolt 16 19.6 ~ 21.6 2.0 ~ 2.2 14.5 ~ 15.9

Knock sensor bolt 2 15.7 ~ 23.5 1.6 ~ 2.4 11.6 ~ 17.4

Drive plate bolt 8 71.54 ~ 75.46 7.3 ~ 7.7 52.80 ~ 55.69

Oil filter cap 1 31.4 ~ 38.2 3.2 ~ 3.9 23.1 ~ 28.2

Oil drain bolt 1 34.3 ~ 44.1 3.5 ~ 4.5 25.3 ~ 32.5

Oil pump bolt 3 19.6 ~ 23.5 2.0 ~ 2.4 14.5 ~ 17.4

Oil filter assembly bolt 4 19.6 ~ 21.6 2.0 ~ 2.2 14.5 ~ 15.9

Bell housing cover bolt 1 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Oil cover bolt 4 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Air vent hose bolt 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Water pump bolt(Timing chain cover bolt L) 1 21.6 ~ 26.5 2.2 ~ 2.7 15.9 ~ 19.5

Water pump bolt(Timing chain cover bolt K) 4 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Water pump bolt(Timing chain cover bolt G) 4 21.6 ~ 23.5 2.2 ~ 2.4 15.9 ~ 17.4

Water pump pulley bolt 4 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2

Water temp. control nut 4 19.6 ~ 23.5 2.0 ~ 2.4 14.5 ~ 17.4

Water temp. control bolt 2 19.6 ~ 23.5 2.0 ~ 2.4 14.5 ~ 17.4

Water inlet fitting bolt 3 16.7 ~ 19.6 1.7 ~ 2.0 12.3 ~ 14.5

Air vent pipe bolt 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Intake manifold bolt 6 26.5 ~ 31.4 2.7 ~ 3.2 19.5 ~ 23.1

Intake manifold nut 2 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4

Surge tank bolt (M8 × 28) 4 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4

Surge tank bolt (M6 × 106) 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Surge tank nut (M8) 2 18.6 ~ 23.5 1.9 ~ 2.4 13.7 ~ 17.4

Breather pipe bolt 2 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Surge tank stay bolt (M10 × 20 ) 2 27.5 ~ 31.4 2.8 ~ 3.2 20.3 ~ 23.1

Exhaust manifold nut 16 39.2 ~ 44.1 4.0 ~ 4.5 28.9 ~ 32.6

Heat protector bolt 6 9.8 ~ 11.8 1.0 ~ 1.2 7.2 ~ 8.7

Front muffler nut 8 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4

Center muffler nut 8 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4

Main muffler nut 8 39.2 ~ 58.8 4.0 ~ 6.0 28.9 ~ 43.4

Air cleaner assembly bolt 2 7.8 ~ 9.8 0.8 ~ 1.0 5.8 ~ 7.2

Intake air hose clamp bolt 1 1.9 ~ 2.9 0.2 ~ 0.3 1.4 ~ 2.2

Engine Mechanical System > General Information > Repair procedures

Inspection

Compression Pressure

If the there is lack of power, excessive oil consumption or poor fuel economy, measure the compression pressure.

1. Warm up engine until the normal operating temperature(80~95°C(176-203°F)).

2. Remove the surge tank. (Refer to Intake and exhaust system in this group)

3. Remove the ignition coil connectors (A) and ignition coils (B).

4. Remove the spark plugs.

Using a 16mm plug wrench, remove the 6 spark plugs.

5. Check cylinder compression pressure.

(1) Insert a compression gauge into the spark plug hole.

(2) Fully open the throttle.

(3) Crank the engine over 7 times to measure compression pressure.

Always use a fully charged battery to obtain engine speed of 250 rpm or more.

(4) Repeat step 1) though 3) for each cylinder.

This measurement must be done in as short a time as possible.

Compression pressure :

1,029kPa (10.5kgf/cm², 149psi) (250~400 rpm)

Minimum pressure :

882kPa (9.0kgf/cm², 128psi)

(5) If the cylinder compression in 1 or more cylinders is low, pour a small amount of engine oil into the cylinder

through the spark plug hole and repeat step 1) through 3) for cylinders with low compression.

A. If adding oil helps the compression, it is likely that the piston rings and/or cylinder bore are worn or

damaged.

B. If pressure stays low, a valve may be sticking or seating is improper, or there may be leakage past the

gasket.

6. Reinstall the spark plugs.

7. Install the ignition coils and ignition connectors.

8. Install the surge tank. (Refer to Intake and exhaust system in this group)

Valve Clearance Inspection And Adjustment

Inspect and adjust the valve clearance when the engine is cold (Engine coolant temperature : 20°C(68°F)) and
cylinder head is installed on the cylinder block.

1. Remove the engine cover.

2. Remove the engine side cover.

3. Remove air cleaner assembly.

4. Remove the surge tank. (Refer to Intake and exhaust system in this group)

5. Remove the cylinder head cover. (Refer to Timing system in this group)

6. 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 (A) 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°).

Do not rotate engine counterclockwise.

7. Inspect the valve clearance.

(1) With No.1 cylinder at TDC inspect clearances only on the valves shown in diagram below.

Measurement method.

A. Using a thickness gauge, measure the clearance between the tappet and the base circle of camshaft.

B. Record the out-of-specification valve clearance measurements. They will be used later to determine the

required replacement adjusting tappet.

Valve clearance

Specification
Engine coolant temperature : 20°C [68°F]
Limit
Intake : 0.10 ~ 0.30mm (0.0039 ~ 0.0118in.)
Exhaust : 0.20 ~ 0.40mm (0.0078 ~ 0.0157in.)

(2) Turn the crankshaft pulley clockwise one revolution (360°) and align the groove with timing mark "T" of the lower

timing chain cover.

(3) With No.4 cylinder at TDC inspect clearances only the valves shown in diagram below. (Refer to procedure step

1.)

8. Adjust the intake and exhaust valve clearance.

(1) Set the No.1 cylinder to the TDC/compression.

(2) Remove the timing chain.

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.

(3) Remove the LH/RH camshaft bearing cap (A) and thrust bearing cap (B).

(4) Remove the LH/RH camshaft assembly (A).

(5) Remove the MLA.

(6) Measure the thickness of the removed tappet using a micrometer.

(7) Calculate the thickness of a new tappet so that the valve clearance comes within the specified value.

T : Thickness of removed tappet
A : Measured valve clearance
N : Thickness of new tappet
Intake : N = T + [A - 0.20mm(0.0079in.)]
Exhaust : N = T + [A - 0.30mm (0.0118in.)]

(8) Select a new tappet with a thickness as close as possible to the calculated value.

Shims are available in 41size increments of 0.015mm (0.0006in.) from 3.00mm (0.118in.) to 3.600mm
(0.1417in.)

(9) Place a new tappet on the cylinder head.

Apply engine oil at the selected tappet on the periphery and top surface.

(10) Install the intake and exhaust camshaft.

(11) Install the bearing caps. (Refer to Cylinder head assembly in this Group)

(12) Install the timing chain. (Refer to Timing system in this Group)

(13) Turn the crankshaft two turns in the operating direction (clockwise) and realign crankshaft sprocket and

camshaft sprocket timing marks (A).

(14) Recheck the valve clearance.

Valve clearance (Engine coolant temperature : 20°C [68°F])
[Specification]

Intake : 0.17 ~ 0.23mm (0.0067 ~ 0.0090in.)
Exhaust : 0.27 ~ 0.33mm (0.0106 ~ 0.0129in.)

Engine Mechanical System > General Information > Troubleshooting

Troubleshooting

Symptom Suspect area Remedy

Engine misfire with abnormal internal
lower engine noises.

Worn crankshaft bearings.
Loose or damaged engine drive plate.

Replace the crankshaft and bearings
as required.
Repair or replace the drive plate as

required.

Worn piston rings.
(Oil consumption may or may not
cause the engine to misfire.)

Inspect the cylinder for a loss of
compression.
Repair or replace as required.

Worn crankshaft thrust bearings Replace the crankshaft and bearings

as required.

Engine misfire with abnormal valve
train noise.

Stuck valves.
(Carbon buildup on the valve stem)

Repair or replace as required.

Excessive worn or mis-aligned timing
chain.

Replace the timing chain and sprocket
as required.

Worn camshaft lobes. Replace the camshaft and valve lifters.

Engine misfire with coolant
consumption.

• Faulty cylinder head gasket and/or
cranking or other damage to the
cylinder head and engine block
cooling system

• Coolant consumption may or may
not cause the engine to overheat.

• Inspect the cylinder head and
engine block for damage to the
coolant passages and/or a faulty
head gasket.

• Repair or replace as required.

Engine misfire with excessive oil
consumption.

Worn valves, guides and/or valve
stem oil seals.

Repair or replace as required.

Worn piston rings.
(Oil consumption may or may not
cause the engine to misfire)

• Inspect the cylinder for a loss of
compression.

• Repair or replace as required.

Engine noise on start-up, but only
lasting a few seconds.

Incorrect oil viscosity.

• Drain the oil.•Install the correct
viscosity oil.

Worn crankshaft thrust bearing.

• Inspect the thrust bearing and
crankshaft.

• Repair or replace as required.

Upper engine noise,regardless of
engine speed.

Low oil pressure. Repair or replace as required.

Broken valve spring. Replace the valve spring.

Worn or dirty valve lifters. Replace the valve lifters.

Stretched or broken timing chain
and/or damaged sprocket teeth.

Replace the timing chain and
sprockets.

Worn timing chain tensioner, if
applicable.

Replace the timing chain tensioner as
required.

Worn camshaft lobes.

• Inspect the camshaft lobes.

• Replace the timing camshaft and
valve lifters as required.

Worn valve guides or valve stems. Inspect the valves and valve guides,

then repair as required.

Stuck valves. Carbon on the valve
stem or valve seat may cause the
valve to stay open.

Inspect the valves and valve guides,
then repair as required.

Worn drive belt, idler, tensioner and
bearing.

Replace as required.

Lower engine noise,regardless of
engine speed.

Low oil pressure. Repair as required.

Loose or damaged drive plate. Repair or replace the drive plate.

Damaged oil pan, contacting the oil
pump screen.

• Inspect the oil pan.

• Inspect the oil pump screen.

• Repair or replace as required.

Oil pump screen loose, damaged or
restricted.

• Inspect the oil pump screen.

• Repair or replace as required.

Excessive piston-to-cylinder bore
clearance.

• Inspect the piston, piston pin and
cylinder bore.

• Repair as required.

Excessive piston pin-to-piston
clearance.

• Inspect the piston, piston pin and
the connecting rod.

• Repair or replace as required.

Excessive connecting rod bearing
clearance

Inspect the following components and
repair as required.

• The connecting rod bearings.

• The connecting rods.

• The crankshaft pin journals.

Excessive crankshaft bearing
clearance.

Inspect the following components, and
repair as required.

• The crankshaft bearings.

• The crankshaft main journals.

• The cylinder block.

Incorrect piston, piston pin and
connecting rod installation

• Verify the piston pins and
connecting rods are installed
correctly.

• Repair as required.

Engine noise under load. Low oil pressure Repair or replace as required.

Excessive connecting rod bearing
clearance .

Inspect the following components and
repair as required :

• The connecting rod bearings.

• The connecting rods.

• The crankshaft.

Excessive crankshaft bearing
clearance.

Inspect the following components, and
repair as required.

• The crankshaft bearings.

• The crankshaft main journals.

• The cylinder block.

Engine will not crank-crankshaft will
not rotate.

Hydraulically locked cylinder.

• Coolant/antifreeze in cylinder.

• Oil in cylinder.

• Fuel in cylinder.

1. Remove spark plugs and check for
fluid.

2. Inspect for broken head gasket.

3. Inspect for cracked engine block or
cylinder head.

4. Inspect for a sticking fuel injector
and/or leaking fuel regulator.

Broken timing chain and/or timing
chain and/or timing chain gears.

1. Inspect timing chain and gears.

2. Repair as required.

Material in cylinder.

• Broken valve

• Piston material

• Foreign material

1. Inspect cylinder for damaged
components and/or foreign
materials.

2. Repair or replace as required.

Seized crankshaft or connecting rod
bearings.

1. Inspect crankshaft and connecting
rod bearing.

2. Repair as required.

Bent or broken connecting rod.

1. Inspect connecting rods.

2. Repair as required.

Broken crankshaft.

1. Inspect crankshaft.

2. Repair as required.

Engine Mechanical System > General Information > Special Service Tools

Special Service Tools

Tool (Number and name) Illustration Use

Crankshaft front oil seal
installer
(09231-3C100)

Installation of the front oil seal

Crankshaft pulley adapter
holder
(09231-2J210)
Crankshaft pulley adapter
(09231-2J200)

Removal and installation of the crankshaft
pulley. (In vehicle use)
A : 09231-2J200
B : 09231-2J210 (holder)

Flywheel stopper
(09231-2B100)

Removal and installation of the flywheel and
crankshaft pulley
(Engine disassembly)

Torque angle adapter
(09221-4A000)

Installation of bolts & nuts needing an angular
method

Valve stem seal remover
(09222-29000)

Removal of the valve stem seal

Valve stem seal installer
(09222-3C100)

Installation of the valve stem seal

Valve spring compressor &
holder
(09222-3K000)
(09222-3C300)

Removal and installation of the intake or
exhaust valves
A : 09222-3K000
B : 09222-3C300 (holder)

Crankshaft rear oil seal
installer
(09231-3C200)
(09231-H1100)

Installation of the crankshaft rear oil seal
A : 09231-3C200
B : 09231-H1100

Oil pan remover
(09215-3C000)

Removal of oil pan

Engine Mechanical System > Engine And Transmission Assembly > Engine Mounting >
Components and Components Location

Components

1. Engine mounting bracket

2. Engine support bracket (RH)

3. Engine support bracket (LH)

Engine Mechanical System > Engine And Transmission Assembly > Engine And
Transmission Assembly > Repair procedures

Removal

• Use fender covers to avoid damaging painted surfaces.

• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

For release the fuel pressure, start the engine and wait until fuel in fuel line is exhausted. After the engine stop

turn the ignition switch OFF.

• Mark all wiring and hoses to avoid misconnection.

1. Disconnect the battery negative cable (A).

2. Remove the transmission before removing the engine. (Refer to AT group)

3. Remove the strut bar (B).

4. Loosen the drain plug and drain the engine coolant.

5. After recovering refrigerant, remove the high & low pressure pipe. (Refer to HA group)

6. Remove the air duct (A).

7. Remove the air cleaner assembly (C) after removing the AFS connector (B).

Tightening torque :

Bolt : 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb -ft)
Clamp : 2.9 ~ 4.9N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6lb-ft)

8. Remove the radiator upper hose (A).

9. Remove the radiator lower hose (A).

10. Disconnect the fuel hoses (B) and brake vacuum hose (A).

11. Remove the cooling fan.
(1) Remove the cooling fan connector (A).

(2) Remove the reservoir tank (B).

(3) Remove the fan assembly (C).

12. Remove the oil hose from the power steering pump. (Refer to ST group)

13. Disconnect the ECM connector (A), brake oil level sensor connector (B) and ground (C).

14. Remove the alternator cable. (Refer to EE group)

15. Disconnect the wirings (A) from the fuse box.

16. Remove the heater hoses (A).

17. Remove the engine mounting bracket nut (A).

Tightening torque :

66.7 ~ 83.4N.m (6.8 ~ 8.5kgf.m, 49.2 ~ 61.5lb-ft)

[LH]

[RH]

18. Remove the hood. (Refer to BD group)

19. Remove the engine assembly by lifting the engine jack.

• When removing the engine assembly, be careful not to damage any surrounding parts or body
components.

Installation

Installation is in the reverse order of removal.
Perform the following :

• Adjust a shift cable.

• Refill engine with engine oil.

• Refill a transmission with fluid.

• Clean battery posts and cable terminals with sandpaper. Reassemble, then apply grease to prevent corrosion.

• Inspect for fuel leakage.

- After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump runs for
approximately two seconds and fuel line pressurizes.

- Repeat this operation two or three times, then check for fuel leakage at any point in the fuel line.

• Refill a radiator and a reservoir tank with engine coolant.

• Bleed air from the cooling system.

- Start engine and let it run until it warms up. (until the radiator fan operates 3 or 4 times.)

- Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be removed
from the cooling system.

- Put radiator cap on tightly, then run the engine again and check for leaks.

Engine Mechanical System > Timing System > Timing Chain > Components and
Components Location

Components

1. Drive belt

2. Drive belt tensioner

3. Idler

4. Crank shaft pulley

5. Water pump pulley

6. Oil pan

7. Cylinder head cover

8. OCV cap

1. Timing chain cover

2. Oil pump chain cover

3. Oil pump sprocket

4. Oil pump chain

5. Crankshaft sprocket

6. Timing chain auto tensioner

7. Timing chain tensioner arm

8. Timing chain

9. Timing chain guide

10. Timing chain auto tensioner

11. Timing chain tensioner arm

12. Crankshaft sprocket

13. Timing chain

14. Timing chain guide

15. Tensioner adapter

16. Gasket

17. Oil pump chain guide

18. Oil pump tensioner assembly

Engine Mechanical System > Timing System > Timing Chain > Repair procedures

Removal

• Use fender covers to avoid damaging painted surfaces.

• To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

• 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. Loosen the drain plug and drain the engine coolant.

3. Remove the engine cover.

4. After recovering refrigerant, remove the high & low pressure pipe. (Refer to HA group)

5. Remove the air duct (A).

6. Remove the air cleaner assembly (C) after removing the AFS connector (B).

Tightening torque :

Bolt : 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb -ft)
Clamp : 2.9 ~ 4.9N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6lb-ft)

7. Remove the radiator upper hose (A).

8. Remove the radiator lower hose (A).

9. Disconnect the engine wiring connectors.
(1) Disconnect the power steering oil pressure switch connector(A) and RH knock sensor connector(B).

(2) Disconnect the MAP sensor connector (A), ETC connector (B) and PVC hose (C).

(3) Disconnect the RH exhaust OCV connector (A), RH injector connector (B) and RH ignition coil connector (C),

LH/RH intake OCV connector (D) and LH exhaust OCV connector (E), Oil pressure switch connector (F).

(4) Disconnect the LH injector connector (A) and LH ignition coil connector (B).

(5) Disconnect the PCSV connector (A), PCSV hose (B) and throttle body coolant hoses (C).

(6) Disconnect the LH exhaust CMP sensor connector (A).

(7) Disconnect the LH intake CMP sensor connector (A) and water temperature sensor connector (B).

(8) Disconnect the RH intake CMP sensor connector (A) and oil temperature sensor connector (B).

(9) Disconnect the RH exhaust CMP sensor connector (A).

10. Remove the LH side coolant pipe and hose (A).

11. Remove the RH side coolant pipe(A).

12. Remove the surge tank (A).

13. Disconnect the RH ignition coil connector (A) and the injector connector (B).

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

15. Remove the LH/RH cylinder head cover (A).

16. Remove the drive belt (B) after removing the oil level gauge tube (A).

17. Remove the power steering pump (A). (Refer to ST group)

18. Remove the air conditioner compressor (A). (Refer to HA group)

19. Remove the alternator (A). (Refer to EE group)

20. Remove the drive belt idler (A).

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

22. Remove the water pump pulley (A).

23. Remove the oil filter body (A).

24. 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 (A) 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°).

Do not rotate engine counterclockwise.

25. 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.

• 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.

26. Remove the crankshaft pulley (A).

• Use the SST(09231- 2J210, 09231-2J200) to fix the crankshaft pulley.

27. Remove the water vent hose (A) from the timing chain cover.

28. Remove the timing chain cover (A).

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

• 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.

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

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

31. Remove the oil pump chain guide (A).

32. Install a set pin after compressing the RH timing chain tensioner.

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

34. Remove the RH timing chain guide (A) and RH timing chain (B).

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

36. Remove the crankshaft sprocket (A) (O/P & RH camshaft drive).

37. Install a set pin after compressing the LH timing chain tensioner.

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

39. Remove the LH timing chain guide (A) and LH timing chain (B).

40. Remove the crankshaft sprocket (A). (LH camshaft drive).

41. 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 timing chain cover. 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 sprocket (A). (LH camshaft drive).

4. Install the LH timing chain guide (A) and LH timing chain (B).

Tightening torque :

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

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 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)

6. Install the crankshaft sprocket (A) (O/P & RH camshaft drive).

7. Install the oil pump chain sprocket (A) and oil pump chain (B).

Tightening torque :

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

8. Install the RH timing chain guide (A) and RH timing chain (B).

Tightening torque :

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

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

9. Install the RH timing chain tensioner arm (B) and RH 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)

10. Install the oil pump chain guide (A).

Tightening torque :

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

11. Install the oil pump chain tensioner assembly (A).

Tightening torque :

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

12. Pull out the pins of hydraulic tensioner (LH & RH).

13. Install the oil pump chain cover (A).

Tightening torque :

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

14. After rotating the crankshaft 2 revolutions in regular direction (clockwise viewed from front), confirm the timing mark.

Always turn the crankshaft clockwise.
Turning the crankshaft counter clockwise before building up oil pressure in the hydraulic timing chain tensioner
may result in the chain disengaging from the sprocket teeth.

15. Install the timing chain cover.

(1) The sealant locations on chain cover and on counter parts (cylinder head, cylinder block, and lower oil pan)

must be free of engine oil and etc.

(2) Before assembling the timing chain cover, the liquid sealant TB 1217H should be applied on the gap between

cylinder head and cylinder block.
The part must be assembled within 5 minutes after sealant was applied.

Bead width : 2.5mm(0.1in.)

(3) After applying liquid sealant TB1217H on timing chain cover. The part must be assembled within 5 minutes

after sealant was applied.
Sealant should be applied without discontinuity.

(4) Install the new gasket (A) to the timing chain cover.

During timing cover installation, care not to take off applied sealant on the timing cover by contact with
other parts.

(5) The dowel pins on the cylinder block and holes on the timing chain cover should be used as a reference in

order to assemble the timing chain cover (A) to be in exact position.

Tightening torque

A(16) :

18.62 ~ 25.49N.m (1.9 ~ 2.6kgf.m, 13.74 ~ 18.80lb-ft)
F(1) :

9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
B(2) :

58.80 ~ 68.80N.m (6.0 ~ 7.0kgf.m, 43.40 ~ 50.63lb-ft)
D(1) :

24.50 ~ 26.46N.m (2.5 ~ 2.7kgf.m, 18.08 ~ 19.53lb-ft)
C(4) :

21.56 ~ 23.52N.m (2.2 ~ 2.4kgf.m, 15.91 ~ 17.36lb-ft)
G(1) :

9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
H(1) :

9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
I(4) :

9.80 ~ 11.76N.m (1.0 ~ 1.2kgf.m, 7.23 ~ 8.68lb-ft)
E(1) :

24.50 ~ 26.46N.m (2.5 ~ 2.7kgf.m, 18.08 ~ 19.53lb-ft)

(6) The firing and/or blow out test should not be performed within 30 minutes after the timing chain cover was

assembled.

16. Install the water vent hose (A) to the timing chain cover.

17. Using SST(09231-3C100), install timing chain cover oil seal.

18. Install the lower oil pan (A).

(1) Using a gasket scraper, remove all the old packing material from the gasket surfaces.

(2) Before assembling the oil pan, the liquid sealant TB 1217H should be applied on oil pan. The part must be

assembled within 5 minutes after the sealant was applied.

Bead width : 2.5mm(0.1in.)

• Clean the sealing face before assembling two parts.

• Remove harmful foreign matters on the sealing face before applying sealant.

• When applying sealant gasket, sealant must not be protruded into the inside of oil pan.

• To prevent leakage of oil, apply sealant gasket to the inner threads of the bolt holes.

(3) Install the oil pan (A).

Uniformly tighten the bolts in several passes.

Tightening torque :

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

19. Install the crankshaft pulley (A).

Tightening torque :

284.4 ~304.0N.m (29.0~31.0kgf.m, 209.8~224.2lb-ft)

• Use the SST(09231- 2J210, 09231-2J200) to install the crankshaft pulley bolt.

20. Install the water pump pulley (A).

Tightening torque :

7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb -ft)

21. Install the oil filter assembly (A).

Tightening torque

19.6 ~ 21.56N.m (2.0 ~ 2.2kgf.m, 14.4 ~ 15.9lb-ft)

22. Install the drive belt auto tensioner (A).

Tightening torque

Bolt (B) :

81.4 ~ 85.3N.m (8.3 ~ 8.7kgf.m, 60.0 ~ 62.9lb-ft)
Bolt (C) :

17.7 ~ 21.6N.m (1.8 ~ 2.2kgf.m, 13.0 ~ 15.9lb-ft)

23. Install the drive belt idler (A).

Tightening torque :

52.9 ~ 57.9N.m (5.4 ~ 5.9kgf.m, 39.1 ~ 42.7lb-ft)

24. Install the alternator (A). (Refer to EE group)

Tightening torque :

26.5 ~ 33.3N.m (2.7 ~ 3.4kgf.m, 19.5 ~ 24.6lb-ft)

25. Install the air conditioner compressor (A). (Refer to HA group)

26. Install the power steering pump (A). (Refer to ST group)

27. Install the drive belt (A).

Tightening torque :

18.6 ~ 22.5N.m (1.9 ~ 2.3kgf.m, 13.7 ~ 16.6lb-ft)

28. Install the LH/RH cylinder head cover (A).

• Install the cylinder head cover under the exhaust OCV cap is removed.

• To prevent engine oil leakage, surely install the new exhaust OCV cap after installing the cylinder head
cover.

(1) Remove the exhaust OCV cap (A) from the cylinder head cover.

(2) The hardening sealant located on the upper area between timing chain cover and cylinder head should be

removed before assembling cylinder head cover.

(3) After applying sealant(TB1217H), it should be assembled within 5 minutes.

Bead width : 2.5mm(0.1in.)

(4) The firing and/or blow out test should not be performed within 30 minutes after the cylinder head cover was

assembled.

(5) Install the cylinder head cover bolts as following method.

Tightening torque :

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

Do not reuse cylinder head cover gasket.

(6) Install the new exhaust OCV cap (A).

Tightening torque :

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

29. Install the LH/RH ignition coils (A).

30. Connect the RH ignition coil connector (A) and the injector connector (B).

31. Install the surge tank assembly (A).

Tightening torque :

18.6 ~ 23.5N.m (1.9 ~ 2.4kgf.m,13.7 ~ 17.3lb-ft)

32. Install the RH side coolant pipe (A).

Tightening torque :

19.6 ~ 23.5N.m (2.0 ~ 2.4kgf.m, 14.5 ~ 17.4lb-ft)

33. Install the LH side coolant pipe and hose (A).

Tightening torque

19.6 ~ 23.5Nm (2.0 ~ 2.4kgf.m, 14.5 ~ 17.4lb-ft)

34. Connect the engine wiring connectors.
(1) Connect the RH exhaust CMP sensor connector (A).

(2) Connect the RH intake CMP sensor connector (A) and oil temperature sensor connector (B).

(3) Connect the LH intake CMP sensor connector (A) and water temperature sensor (B).

(4) Connect the LH exhaust CMP sensor connector (A).

(5) Connect the PCSV hose (B), PCSV connector (A) and throttle body coolant hoses (C).

(6) Connect the LH injector connectors (A) and LH ignition coil connectors (B).

(7) Connect the RH exhaust OCV connector (A), RH inject connector (B), RH ignition coil connector (C), RH/LH

intake camshaft OCV connector (D), LH exhaust OCV connector (E) and oil pressure switch connector (F).

(8) Connect the MAP sensor connector (A), ETC connector (B) and PCV hose (C).

(9) Connect the power steering oil pressure switch connector(A) and RH knock sensor connector(B).

35. Remove the cooling fan.
(1) Install the fan assembly (C).

(2) Install the reservoir tank (B).

(3) Install the cooling fan connector (A).

36. Install the fuel hose (B) and brake vacuum hose (A).

37. Install the radiator lower hose (A).

38. Install the radiator upper hose (A).

39. Connect the AFS connector (B) after installing the air cleaner assembly (C).

Tightening torque :

Bolt : 7.8 ~ 9.8N.m (0.8 ~ 1.0kgf.m, 5.8 ~ 7.2lb -ft)
Clamp : 2.9 ~ 4.9N.m (0.3 ~ 0.5kgf.m, 2.2 ~ 3.6lb-ft)

40. Install the air duct (A).

41. Install the engine cover.

42. Connect the battery negative cable.

• Refill engine oil.

• Clean the battery posts and cable terminals with sandpaper. Assemble and then apply grease to prevent
corrosion.

• Inspect for fuel leakage.

- After assembling the fuel line, turn on the ignition switch (do not operate the starter) so that the fuel pump
runs for approximately two seconds and fuel line pressurizes.

- Repeat this operation two or three times, then check for fuel leakage at any point in the fuel lines.

• Refill radiator and reservoir tank with engine coolant.

• Bleed air from the cooling system.

- Start engine and let it run until it warms up. (Until the radiator fan operates 3 or 4 times.)

- Turn Off the engine. Check the level in the radiator, add coolant if needed. This will allow trapped air to be
removed from the cooling system.

- Put radiator cap on tightly, then run the engine again and check for leaks.

Engine Mechanical System > Cylinder Head Assembly > Cylinder Head > Components and
Components Location

Components

1. RH Cylinder head

2. RH Cylinder head gasket

3. LH Cylinder head

4. LH Cylinder head gasket

5. Cylinder block

1. Camshaft bearing cap

2. Camshaft thrust bearing cap

3. Exhaust camshaft

4. Intake camshaft

5. Exhaust CVVT assembly

6. Intake CVVT assembly

7. Mechanical lash adjuster (MLA)

8. Retainer lock

9. Retainer

10. Valve spring

11. Valve stem seal

12. Valve

13. Intake camshaft OCV (RH)

14. Exhaust camshaft OCV (RH)

15. Cylinder head

16. Exhaust camshaft OCV (LH)

17. Intake camshaft OCV (LH)

Engine Mechanical System > Cylinder Head Assembly > Cylinder Head > Repair
procedures

Removal

• Use fender covers to avoid damaging painted surfaces.

• To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal
temperature (20°C [68°F]) 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.

• Mark all wiring and hoses to avoid misconnection.

• Turn the crankshaft pulley so that the No. 1 piston is at top dead center.

1. Remove the timing chain. (Refer to Timing system in this group)

2. Disconnect the heater hoses (A).

3. Remove the water temperature control assembly (A).

4. Disconnect the air vent hose (A) and then remove the intake the manifold (B).

• 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.

5. Remove the LH/RH exhaust manifold heat protector (A).

6. Remove the LH/RH exhaust manifold (A).

7. Remove the LH/RH exhaust camshaft OCV (A).

8. Remove the LH/RH camshaft bearing cap (A) and thrust bearing cap (B).

9. Remove the LH/RH camshaft assembly (A).

10. Remove the cylinder head.
(1) Uniformly loosen and remove the cylinder head bolts, in several passes, in the sequence shown.

Head warpage or cracking could result from removing bolts in an incorrect order.

(2) Lift the cylinder head from the dowels on the cylinder block and place the cylinder head on wooden blocks on a

bench.

Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

Disassembly

Identify MLA, valves and valve springs as they are removed so that each item can be reinstalled in its original
position.

1. Remove the MLAs(A).

2. 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) Using the SST(09222-29000), remove the valve stem seal.

Do not reuse old valve stem seals.

3. Remove the OCV(A).

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.)/150x150]

Flatness of manifold gasket surface

Standard : Less than 0.01mm(0.0004in)/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 : 5.500 ~ 5.512mm (0.216 ~ 0.217in.)

(2) Using a micrometer, measure the diameter of the valve stem.

Valve stem O.D.

Intake : 5.465 ~ 5.480mm (0.2151 ~ 0.2157in.)
Exhaust : 5.458 ~ 5.470mm (0.2149 ~ 0.2153in.)

(3) Subtract the valve stem diameter measurement from the valve guide inside diameter measurement.

Valve stem-to -guide clearance

[Standard]
Intake : 0.020 ~ 0.047mm (0.0008 ~ 0.0018in.)
Exhaust : 0.030 ~ 0.054mm (0.0012 ~ 0.0021in.)
[Limit]
Intake : 0.07mm (0.0027in.)
Exhaust : 0.09mm (0.0035in.)

2. Inspect valves.

(1) Check the valve is ground to the correct valve face angle.

(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

[Standard]
Intake : 1.56 ~ 1.86mm (0.06142 ~ 0.07323in.)
Exhaust : 1.73 ~ 2.03mm (0.06811 ~ 0.07992in.)

(4) Check the valve length.

Length

Intake : 105.27mm (4.1445in)
Exhaust : 105.50mm (4.1535in)

(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

Check the valve seat for evidence of overheating and improper contact with the valve face.
If the valve seat is worn, replace cylinder head.
Before reconditioning the seat, check the valve guide for wear. If the valve guide is worn, replace cylinder head.
Recondition the valve seat with a valve seat grinder or cutter. The valve seat contact width should be within
specifications and centered on the valve face.

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

[Standard]
Free height : 43.86mm (1.7267in.)
Out-of-square : 1.5°

MLA

1. Inspect MLAs.

Using a micrometer, measure the MLA outside diameter.

MLA O.D.

Intake/Exhaust :

34.964 ~ 34.980mm(1.3765 ~ 1.3771in.)

2. Using a caliper gauge, measure MLA tappet bore inner diameter of cylinder head.

Tappet bore I.D.

Intake/Exhaust :

35.000 ~ 35.025mm(1.3779 ~ 1.3789in.)

3. Subtract MLA outside diameter measurement from tappet bore inside diameter measurement.

MLA to tappet bore clearance

[Standard]
Intake/Exhaust : 0.020 ~ 0.061mm(0.0008 ~ 0.0024in.)
[Limit]
Intake/Exhaust : 0.07mm(0.0027in.)

Camshaft

1. Inspect cam lobes.

Using a micrometer, measure the cam lobe height.

Cam height

[Standard value]
Intake : 47.2mm (1.8582in.)
Exhaust : 45.8mm (1.8031in.)

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 :

1st step : 5.8N.m (0.6kgf.m, 4.3lb-ft)
2nd step : 9.8 ~ 11.8N.m (1.0 ~ 1.2kgf.m, 7.2 ~ 8.7lb-ft)

Do not turn the camshaft.

(5) Remove the bearing caps.

(6) Measure the plastigage at its widest point.

Bearing oil clearance

[Standard value]
Intake
No.1 journal : 0.020 ~ 0.057mm (0.0008 ~ 0.0022in.)
No.2,3,4 journal : 0.030 ~ 0.067mm (0.0012 ~ 0.0026in.)
Exhaust
No.1 journal : 0.027 ~ 0.057mm (0.0010 ~ 0.0022in.)
No.2,3,4 journal : 0.030 ~ 0.067mm (0.0012 ~ 0.0026in.)

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) Using a dial indicator, measure the end play while moving the camshaft back and forth.

Camshaft end play

[Standard value] : 0.02 ~ 0.18mm(0.0008 ~ 0.0071in.)

If the end play is greater than maximum, replace the camshaft. If necessary, replace cylinder head.

(3) Remove the camshafts.

CVVT Assembly

1. Inspect the CVVT assembly.

(1) Check that the CVVT assembly will not turn.

(2) Apply vinyl tape to the retard hole except the one indicated by the arrow in the illustration.

[Intake CVVT]

[Exhaust CVVT]

(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 delay angle locking.)

When the oil splashes, wipe it off with a shop rag.

(4) Under the condition of (3), turn the CVVT assembly to the advance angle side (the arrow marked direction in the

illustration) with your hand.
Depending on the air pressure, the CVVT assembly will turn to the advance side without applying force by hand.

(5) Except the position where the lock pin meets at the maximum delay 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 30°

(6) Turn the CVVT assembly with your hand and lock it at the maximum delay angle position (clockwise).

Reassembly

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(09222-3C100), push in a new oil seal.

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.

Place valve springs so that the side coated with enamel 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 the wooden handle of a hammer to ensure proper

seating of the valve and retainer lock.

2. Install the MLAs.

Check that the MLA rotates smoothly by hand.

MLA can be reinstalled in its original position.