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Engine Mechanical System

Cylinder Head Repair Procedures

In this manual: Engine Mechanical System
General Information — 15Maintenance — 7Engine Mechanical System — 84Engine Electrical System — 49Emission Control System — 22Fuel System — 95Clutch System — 28Manual Transmission — 21Dual Clutch Transmission (DCT) System — 47Drive Shaft and Axle — 20Suspension System — 36Steering — 23Restraints — 39Brake System — 54Body (Interior and Exterior) — 209Body Electrical System — 254Heating, Ventilation, and Air Conditioning — 56
66steps
~396min
5/5difficulty
0102030405029.422N·mlb·ft
Tightening torque found on this page
Done 0 of 66

Removal

Engine removal is not necessary for this procedure.
  1. Remove the engine cover.
  2. Disconnect the negative battery cable.
  3. Remove the air duct and air cleaner assembly. (Refer to Intake and Exhaust System - "Air Cleaner")
  4. Disconnect the mounting bracket, then remove the battery. (Refer to Engine Electrical System - "Battery")
  5. Disconnect the ECM connector, then remove the battery tray. (Refer to Engine Electrical System - Battery)
  6. Remove the engine room cover.
  7. Loosen the drain plug and drain the coolant. Open the radiator cap to speed up draining. (Refer to Cooling System - Coolant)
  8. Remove the upper radiator hose and the lower hose. (Refer to Cooling System - "Radiator Hose").
  9. Disconnect the compressor connector. (Refer to Heating, Ventilation and Air Conditioning - "Compressor")
  10. Disconnect the alternator connector and the cable from the alternator terminal "B". (Refer to Engine Electrical System - "Alternator")
  11. Disconnect the water temperature sensor. (Refer to Fuel System - "Engine Control System")
  12. Disconnect the ETC (Electronic Throttle Control) connector, the MAPS (Manifold Absolute Pressure Sensor) connector and the IATS (Intake Air Temperature Sensor) connector. (Refer to Fuel System - "ETC System")
  13. Disconnect the heater hose (A) and the brake booster vacuum hose (B).
  14. Remove the vacuum hose assembly (A).
  15. Remove the cylinder head cover. (Refer to Cylinder Head Assembly - Cylinder Head Cover)
  16. Remove the timing chain cover. (Refer to Valve Timing - Timing Chain Cover)
  17. Remove the camshaft. (Refer to Cylinder Head Assembly - "Camshaft")
  18. Remove the intake manifold. (Refer to Intake and Exhaust Systems — Intake Manifold)
  19. Remove the exhaust manifold. (Refer to Intake and Exhaust System - "Exhaust Manifold")
  20. Remove the delivery pipe assembly. (See Fuel System - "Delivery Pipe")
  21. Disconnect the bypass hose, then remove the water temperature control valve assembly. (See Cooling System - "Water Temperature Control Assembly")
  22. Remove the heater pipe. (Refer to Cooling System - "Water Pipe")
  23. Remove the intake OCV (oil control valve). (Refer to Fuel System - "CVVT Oil Control Valve (OCV)").
  24. Remove the cylinder head bolts, then remove the cylinder head.
    1. Loosen and remove the 10 cylinder head bolts evenly in several steps, in the order shown.
    2. Lift the cylinder head off the cylinder block and place the cylinder head on wooden blocks.

Disassembly

  1. Remove the MLA (A).
  2. Remove the valves.
    1. Using SST (09222-3K000, 09222-3K100), compress the valve spring and remove the valve cotter (keeper).
    2. Remove the spring retainer.
    3. Remove the spring retainer.
    4. Remove the valve.
    5. Remove the valve stem seal.
    6. Using a magnetic pick-up tool, remove the spring seat.

Inspection

Cylinder head cover

  1. Inspect for flatness. Using a precision straightedge and feeler gauge, measure the cylinder block and manifold contact surfaces for warpage. Cylinder head gasket surface flatness Standard: Overall less than 0.05 mm (0.0020 in.) Less than 0.02 mm (0.0008 in.) for a 100 mm (3.9370 in.) x 100 mm (3.9370 in.) section
  2. Inspect for cracks. Check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks. If any cracks are found, replace the cylinder head.
  3. Inspect the valve stems and valve guides.
    1. Using a caliper gauge, measure the inside diameter of the valve guide. Valve guide inside diameter: 5.500 - 5.512 mm (0.2165 - 0.2170 in.)
    2. Using a micrometer, measure the outer diameter of the valve stem. Valve Stem Outer Diameter Intake: 5.465 ~ 5.480 mm (0.2152 ~ 0.2157 in.) Exhaust: 5.458 ~ 5.470 mm (0.2149 ~ 0.2154 in.)
    3. Subtract the valve stem outer diameter from the valve guide inner diameter measurement. Valve Stem-to-Guide Clearance Intake: 0.020 ~ 0.047 mm (0.0008 ~ 0.0019 in.) Exhaust: 0.030 ~ 0.054 mm (0.0012 ~ 0.0021 in.) If the clearance is greater than specified, replace the valve or the cylinder head.
  4. Inspect the valves.
    1. Make sure the valve face is ground to the correct valve face angle.
    2. Inspect the valve face 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 the minimum, replace the valve.

      Standard margin thickness — Intake: 1.10 mm (0.0433 in.) Exhaust: 1.26 mm (0.0496 in.)

    4. Check the valve length. Standard valve length Intake: 93.15 mm (3.6673 in.) Exhaust: 92.60 mm (3.6457 in.)
    5. Inspect the valve stem tip for wear. If the valve stem tip is worn, replace the valve.
  5. Inspect the valve seats.
    1. Inspect the valve seat for signs of overheating and improper contact with the valve face. If the valve seat is worn, replace the cylinder head.
    2. Inspect the valve guide for wear. If the valve guide is worn, replace the cylinder head.
  6. Inspect the valve springs.
    1. Using a steel square, measure the valve spring squareness.
    2. Using a caliper gauge, measure the free length of the valve spring. Valve spring Standard free height: 45.1 mm (1.7756 in.) Out-of-square: less than 1.5°
Valve and Valve Spring

Installation

  1. Install the valves.
    1. Install the spring seats.
    2. Using the SST (09222 - 2B100), install a new oil seal.
    3. Install the valve, valve spring and retainer after applying engine oil to the end of each valve stem.
  2. Using the SST (09222 - 3K000, 09222 - 3K100), compress the valve spring and install the valve keepers. After installing the valves, make sure the valve keepers are correctly seated before releasing the valve spring compression.
  3. Lightly tap the end of each valve stem two or three times with a wooden hammer handle to ensure the valve and retainer lock are seated correctly.
  4. Install the MLA (mechanical lash adjuster). Make sure the MLA (A) rotates smoothly by hand.

Installation

  1. Install the cylinder head assembly.
    1. Before installation, remove hardened sealant from the cylinder block and cylinder head surfaces.
    2. Before installing the cylinder head gasket, apply sealant to the upper surface of the cylinder block and install the gasket in place within five minutes.
      Width: 2.0 ~ 3.0 mm (0.0787 ~ 0.1181 in.) Position: 1.0 ~ 1.5 mm (0.0394 ~ 0.0591 in.) Specified Sealant: TB 1217H or LOCTITE 5900H
    3. After installing the cylinder head gasket on the cylinder block, apply sealant to the upper surface of the cylinder head gasket and assemble within five minutes.
  2. Carefully install the cylinder head so as not to damage the gasket.
  3. Install the cylinder head bolts with washers.
    1. Tighten the 10 cylinder head bolts in several passes in the sequence shown.

      Tightening torque: 29 N·m + 90° + 90°

  4. Install the Oil Control Valve (OCV) (A). (Refer to Fuel System - "CVVT Oil Control Valve (OCV)").
  5. Install the heater hose. (Refer to Cooling System - "Water Hose")
  6. Install the humidity control unit and bypass hose. (Refer to Cooling System - "Water Control Assembly")
  7. Install the delivery pipe assembly. (Refer to Fuel System - "Delivery Pipe")
  8. Install the intake manifold. (Refer to Air Intake and Exhaust System - "Intake Manifold").
  9. Install the exhaust manifold. (Refer to Intake and Exhaust System - "Exhaust Manifold")
  10. Install the camshaft. (Refer to Cylinder Head Assembly - "Camshaft")
  11. Install the timing chain. (Refer to Timing System - Timing Chain)
  12. Install the timing chain cover. (Refer to Timing System - "Timing Chain Cover")
  13. Install the OCV (Oil Control Valve) adapter. (Refer to Fuel System - "CVVT Oil Control Valve (OCV)").
  14. Install the cylinder head cover. (Refer to Cylinder Head Assembly - "Cylinder Head Cover")
  15. Install the exhaust OCV (Oil Control Valve). (Refer to Fuel System - "CVVT Oil Control Valve (OCV)").
  16. Install the ignition coil. (Refer to Engine Electrical System - "Ignition Coil")
  17. Install the high pressure fuel pump and roller tappet. (Refer to Fuel System - "High Pressure Fuel Pump")
  18. Install the vacuum hose assembly (A).

    Tightening torque: 9.8 ~ 11.8 N·m

  19. Connect the brake booster vacuum hose (A) and the heater hose (B).
  20. Connect the ETC (Electronic Throttle Control) connector and the MAPS (Manifold Absolute Pressure Sensor) connector. (Refer to Fuel System - "Engine Control System")
  21. Connect the ECTS (Engine Coolant Temperature Sensor) connector. (Refer to Fuel System - "Engine Control System")
  22. Connect the A/C compressor switch connector, the alternator connector, and the cable to the alternator "B" terminal. (Refer to Engine Electrical System - "Alternator")
  23. Connect the A/C compressor connector. (Refer to Heating, Ventilation and Air Conditioning - "Compressor")
  24. Install the upper radiator hose and the lower hose. (Refer to Cooling System - "Radiator Hose")
  25. Install the engine compartment cover.
  26. Install the ECM, then connect the ECM connector. (Refer to Engine Electrical System - "Battery")
  27. Install the battery.
  28. Install the air duct and air cleaner assembly. (Refer to Intake and Exhaust System - "Air Cleaner")
  29. Install the battery assembly.
  30. Install the engine cover.

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