13454260

Removal

Engine removal is not required for this procedure.

caution

CVVL engine's cylinder head assembly has been mounted with its optimum valve adjusting shims, which were selected in accordance with the measured results using precision measuring instruments in an engine production plant in order to minimize the deviation of valve lift between each cylinder. Thus, any part causing a lot of the valve lift variation should be replaced with the cylinder head assembly, not the part itself. Also after completing the replacement, check the valve lift variation values using a GDS then if necessary, adjust the valve lift variation. (Refer to “Valve lift variation adjustment”)

Item	Parts to be replaced	How to repair
Parts related to CVVL valve lift	• Cylinder Head • Intake Valve Seat • Cam carrier • CVVL Assembly	Replace with the new cylinder head assembly ※ Check the valve lift variation values, if necessary, adjust the valve lift variation.
	• Intake Valve • Intake Camshaft	Replace with the new part ※ Check the valve lift variation values then adjust the valve lift variation. (approx. 3 times)
	• Intake Valve Adjusting Shim	Replace with the new same size part
Parts unrelated to CVVL valve lift	Cylinder Head Assembly Component parts except the above parts	Replace with the new part

caution

●

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.

note

●

Mark all wiring and hoses to avoid misconnection.

●

Turn the crankshaft pulley so that the No. 1 piston is at TDC (Top dead center).

Remove the engine cover. (Refer to Engine and transaxle assembly in this group)

Disconnect the battery negative terminal. (Refer to Engine and transaxle assembly in this group)

Remove the air duct and the air cleaner assembly. (Refer to Engine and transaxle assembly in this group)

Remove the RH front wheel. (Refer to SS group – “Wheel”)

Remove the under cover. (Refer to Engine and transaxle assembly in this group)

Loosen the drain plug, and drain the engine coolant. Remove the radiator cap to help drain the coolant faster. (Refer to Cooling system in this group)

Disconnect the radiator upper hose and lower hose. (Refer to Cooling system in this group)

Disconnect the wiring connectors and harness clamps, and then remove the wiring and protectors from the cylinder head and the intake manifold.

(1)

The intake OCV (Oil control valve) connector (A)

(2)

The intake OCV (Oil control valve) connector (A)

(3)

The alternator connector (A) and the cable (B)

(4)

The ignition coil connectors (A)

(5)

The intake CMPS (Camshaft position sensor) connector (A)

(6)

The exhaust CMPS (Camshaft position sensor) connector (B)

(7)

The injector connectors (A)

(8)

The front HO2S (Heated Oxygen Sensor) connector (A)

(9)

The condenser connector (B)

(10)

The PCSV (Purge control solenoid valve) connector (A)

(11)

The ECTS (Engine coolant temperature sensor) connector (B)

(12)

The VIS (Variable Intake Solenoid) connector (A)

(13)

The MAPS (Manifold absolute pressure sensor) & IATS (Intake air temperature sensor) connector (A)

(14)

The ETC (Electronic throttle control) connector (A)

(15)

The CVVL position sensor connector (A)

Disconnect the brake booster vacuum hoses (A) and the heater hoses (B).

10.

Disconnect the fuel hose (A) and PCSV (Purge control solenoid valve) hose (B).

11.

Remove the injector & rail assembly (A). (Refer to FL – “Delivery Pipe”)

12.

Remove the vacuum pipe (A).

13.

Remove the PCSV (Purge Control Solenoid Valve) (A).

14.

Remove the condenser (A).

15.

Remove the intake and exhaust manifold. (Refer to Intake and exhaust system in this group)

16.

Remove the timing chain including the drive belt, the cylinder head cover, the alternator and the timing chain cover. (Refer to Timing system in this group)

17.

Remove the vacuum pump (A).

18.

Remove the vacuum pump adaptor (A) with the gasket (B).

19.

Remove the CVVL motor assembly (A). (Refer to FL – “CVVL Motor”)

note

Slightly rotate the gear of the CVVL shaft using a flat-head driver then the motor worm gear gets out.

In case it is difficult to remove the motor because CVVL shaft can’t rotate, remove the motor after removing the CVVL assembly.

20.

Remove the CVVL position sensor (A). (Refer to FL group)

21.

Remove the CVVL position sensor magnet wheel (A). (Refer to FL group)

22.

Remove the intake CVVT assembly (A) and exhaust CVVT assembly (B).

note

When removing the CVVT assembly bolt, hold the camshaft with a wrench to prevent the camshaft from rotating.

23.

Remove the camshaft and the CVVL assembly.

(1)

Remove the camshaft bearing cap (A) and CVVL shaft bearing cap by loosening the bolts in the sequence as shown.

(2)

Remove the CVVL assembly (A).

(3)

Remove the plunger (A), return spring (B), retainer (C).

(4)

Remove the intake and exhaust camshafts (A).

24.

Remove the cam carrier (A).

25.

Remove the HLA (Hydraulic lash adjuster) (A) and the swing arm (B).

note

The HLA and swing arm should be kept together as pairs during storage after removal and reinstallation.

26.

Disconnect the bypass hose (A).

27.

Unfasten the heater pipe mounting bolts (B).

28.

Remove the water temperature control assembly. (Refer to Cooling system in this group)

29.

Remove the oil control adapter (A) with the gasket (B).

30.

Remove the intake OCV (Oil control valve) (A).

31.

Remove the exhaust OCV (Oil control valve) (A).

32.

Remove the rear engine hanger (A).

33.

Remove the spark plugs (A). (Refer to EE group – “Ignition system”)

34.

Remove the cylinder head.

(1)

Using bit socket (12PT), uniformly loosen and remove the cylinder head bolts, in several passes, in the sequence as shown.

caution

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

(2)

Lift the cylinder head (A) from the dowels on the cylinder block and place the cylinder head on wooden blocks on a bench.

caution

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

(3)

Remove the cylinder head gasket (B).