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MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE


C7A11C01
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Air Cleaner Assembly

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the Intake Air Temperature (IAT) sensor connector.
  3. Loosen the clamp and disconnect the air cleaner outlet hose from the resonator.

    4. C7A11C51
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  4. Remove the air cleaner housing bolts.
  5. Unclip the housing from the ball stud and then remove the air cleaner assembly.

C7A11C51
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Installation Procedure

  1. Install the air cleaner assembly.
  2. Install the air cleaner housing to the ball stud and connect the air cleaner outlet hose to the resonator.
  3. Install the air cleaner housing bolts.

    4. Tighten
    Tighten the air cleaner housing bolts to 6 N•m (53 lb-in.).


C7A11C03
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Air Cleaner Element

Removal Procedure

  1. Loosen the clamp and disconnect the air cleaner outlet hose from the air cleaner housing.
  2. Remove the air cleaner element cover screws.

    3. C7A11C04
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  3. Remove the air cleaner element.

C7A11C03
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Installation Procedure

  1. Install the air cleaner element cover.
  2. Tighten the air cleaner element cover screws.

    3. Tighten
    Tighten the air cleaner element cover screws to 2 N•m (18 lb-in.).


C7A11C0K
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Cylinder Head Cover

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the engine beautification cover bolts and nuts.
  3. Remove the engine beautification cover.
  4. Disconnect the breather hose and PCV hose from the cylinder head cover.

    5. C7A11C06
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  5. Disconnect the ignition wires from the spark plugs.
  6. Disconnect the camshaft position sensor connector.
  7. Remove the cylinder head cover bolts.

    8. J3B11C10
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  8. Remove the cylinder head cover.
  9. Remove the cylinder head cover gasket from the cylinder head cover.

J3B11C10
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Installation Procedure

  1. Apply a small amount of gasket sealant to the corners of the front camshaft caps and the top of the rear cylinder head cover-to-cylinder head seal.
  2. Install the new cylinder head cover gasket to the cylinder head cover.

    3. C7A11C06
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  3. Install the cylinder head cover.
  4. Install the cylinder head cover bolts.

    5. Tighten
    Tighten the cylinder head cover bolts to 8 N•m (71 lb-in.).

  5. Connect the ignition wires to the spark plugs.

    6. C7A11C0K
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  6. Connect the camshaft position sensor connector.
  7. Connect the breather hose and PCV hose to the cylinder head cover.
  8. Install the engine beautification cover.

    9. Tighten
    Tighten the engine beautification cover bolts and nuts to 8 N•m (71 lb-in.).

  9. Connect the negative battery cable.

C7A19R18
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Accessory Drive Belt

Removal Procedure

  1. Raise and suitably support the vehicle.
  2. Remove the right front wheel. Refer to Section 2E, Tires and Wheels.
  3. Remove the engine front shield at the position of right front wheel. Refer to Section 9R, Body Front End.

    4. C7A11C0G
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  4. Install a suitable tool to the drive belt tensioner.
  5. Rotate the drive belt tensioner clockwise in order to relieve the belt tension.

    6. C7A11A54
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  6. Remove the drive belt.
  7. Clean and inspect the belt and the mating surfaces of all the pulleys. Refer to Section 1A, General Engine Information.

C7A11C0G
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Installation Procedure

  1. Route the belt around all the pulleys.
  2. Install a suitable tool to the drive belt tensioner.
  3. Rotate the drive belt tensioner clockwise in order to relieve tension on the tensioner.

    4. C7A11A54
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  4. Install the drive belt.
  5. Inspect the drive belt for proper installation and alignment.

C7A11C08
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Cylinder Head and Gasket

Tools Required

KM-470-B Angular Torque Gauge
DW110-060 Engine Assembly Support Fixture

Removal Procedure

  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. Drain the engine coolant. Refer to Section 1D2, Engine Cooling - FAM II 2.4D.

    5. C7A11C09
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  5. Remove the air cleaner assembly. Refer to "Air Cleaner Assembly" in this section.
  6. Remove the engine beautification cover and the engine beautification cover bracket.
  7. Disconnect the breather hose and PCV hose from the cylinder head cover.
  8. Loosen the clamp and remove the resonator from the electronic throttle body.

    9. C7A11C10
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  9. Disconnect the Direct Ignition System (DIS) connector.
  10. Disconnect the front heated oxygen sensor connector.
  11. Disconnect the Electronic Throttle Control (ETC) connector.
  12. Disconnect the Coolant Temperature Sensor (CTS) connector.
  13. Disconnect the Exhaust Gas Recirculation (EGR) valve connector.

    14. C7A11C11
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  14. Remove the right front wheel. Refer to Section 2E, Tires and Wheels.
  15. Remove the engine front shield at the position of the right front wheel.
  16. Remove the serpentine accessory drive belt. Refer to "Accessory Drive Belt" in this section.
  17. Install the engine assembly support fixture DW110-060.
  18. Remove the engine mount assembly. Refer to "Engine Mount Assembly" in this section.

    19. J3B11D10
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  19. Disconnect the upper radiator hose from the thermostat housing.

    20. J3B11C17
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  20. Remove the crankshaft pulley bolts.
  21. Remove the crankshaft pulley.

    22. J3B11C16
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  22. Remove the front timing belt cover bolts.
  23. Remove the front timing belt cover.
  24. Remove the timing belt. Refer to "Timing Belt" in this section.

    25. C7A11C06
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  25. Remove the cylinder head cover and the gasket. Refer to "Cylinder Head Cover" in this section.

    26. J3B11C17
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    Notice : Take extreme care to prevent any scratches, nicks or damage to the camshafts.

  26. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolts.
  27. Remove the intake camshaft gear.
  28. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolts.
  29. Remove the exhaust camshaft gear.

    30. C7A11C16
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  30. Remove the timing belt automatic tensioner bolts.
  31. Remove the timing belt automatic tensioner.

    32. C7A11C17
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  32. Remove the timing belt idler pulley bolt and nut.
  33. Remove the timing belt idler pulley.
  34. Remove the engine mount adapter support bracket bolts.
  35. Remove the engine mount adapter support bracket.

    36. C7A11C18
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  36. Remove the crankshaft gear.
  37. Remove the camshaft position (CMP) sensor.

    38. J3B11C20
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  38. Remove the rear timing belt cover bolts.
  39. Remove the rear timing belt cover.

    40. C7A11C33
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  40. Remove the pup converter-to-exhaust front pipe retaining nuts.
  41. Remove the exhaust front pipe mounting bracket bolt and nut.
  42. Remove the exhaust front pipe from the pup converter. Refer to Section 1G2, Engine Exhaust - FAM II 2.4D.
  43. Disconnect all of the necessary vacuum hoses.

    44. C7A11C20
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  44. Remove the intake manifold support bracket bolts and the bracket.
  45. Remove the ground terminal retaining bolt from the intake manifold.

    46. C7A11C21
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  46. Disconnect the fuel feed line at the fuel rail.
  47. Disconnect the coolant hoses at the rear cylinder head and the exhaust gas recirculation (EGR) valve adapter.
  48. Disconnect the coolant hoses from the electronic throttle body.

    49. C7A11C53
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  49. Remove the fuel rail assembly. Refer to Section 1F2, Engine Controls - FAM II 2.4D.

    50. C7A11C22
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  50. Remove the generator upper bracket bolts.
  51. Remove the generator upper bracket.
  52. Remove the generator-to-intake manifold strap bracket bolts on the generator and the intake manifold.

    53. V3B11F96
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  53. Remove the evaporative (EVAP) emission canister purge solenoid valve bracket bolt.
  54. Remove the EVAP emission canister purge solenoid valve.

    55. C7A11C24
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  55. Remove the camshaft. Refer to "Camshaft" in this section.
  56. Loosen all of the cylinder head bolts gradually in the sequence shown.
  57. Remove the cylinder head bolts.
  58. Remove the cylinder head with the intake manifold and the exhaust manifold attached.

    59. Notice : Prevent any engine oil or coolant from entering the cylinders when removing the cylinder head.

  59. Remove the cylinder head gasket.

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.

C7A11C25
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Installation Procedure

    Important : Before replacing the cylinder head, be sure to install the engine mount and then remove the engine assembly support fixture DW110-060.

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

    4. Tighten
    Tighten the cylinder head bolts to 25 N•m (18 lb-ft) and turn the bolts another 3 turns of 90° using the angular torque gauge KM-470-B.


    J3B11C26
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  4. Install the camshaft. Refer to "Camshaft" in this section.

    5. V3B11F96
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  5. Install the EAVP emission canister purge solenoid valve.

    6. Tighten
    Tighten the evaporative emission canister purge solenoid valve bracket bolt to 5 N•m (44 lb-in.).


    C7A11C0X
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  6. Install the generator upper bracket.

    7. Tighten
    Tighten the generator upper bracket retaining bolts (1) to 25 N•m (18 lb-ft) and the bolt (2) to 35 N·m (26 lb-ft).

  7. Install the generator-to-intake manifold strap bracket.

    8. Tighten
    Tighten the generator-to-intake manifold strap bracket retaining bolt (3) to 35 N•m (26 lb-ft) and the bolt (4) to 25 N•m (18 lb-ft).


    C7A11C53
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  8. Connect the coolant hoses to the electronic throttle body, rear cylinder head and the EGR valve bracket.
  9. Install the fuel rail assembly. Refer to Section 1F2, Engine Controls - FAM II 2.4D.

    10. C7A11C21
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  10. Connect the fuel feed line at the fuel rail.
  11. Connect all of the necessary vacuum hoses.

    12. C7A11C20
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  12. Install the ground terminal retaining bolt.
  13. Install the intake manifold support bracket.

    14. Tighten
    Tighten the intake manifold support bracket bolts to 25 N•m (18 lb-ft).


    C7A11C33
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  14. Install the exhaust front pipe to the pup converter. Refer to Section 1G2, Engine Exhaust - FAM II 2.4D.

    15. Tighten
    Tighten the pup converter-to-exhaust front pipe retaining nuts to 35 N•m (26 lb-ft).
    Tighten the exhaust front pipe mounting bracket bolt and nut to 40 N•m (30 lb-ft).


    J3B11C20
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  15. Install the rear timing belt cover.

    16. Tighten
    Tighten the rear timing belt cover bolts to 7 N•m (62 lb-in.).


    C7A11C17
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  16. Install the engine mount adapter support bracket.

    17. Tighten
    Tighten the engine mount adapter support bracket retaining bolts to 45 N•m (33 lb-ft).

  17. Install the timing belt idler pulleys.

    18. Tighten
    Tighten the timing belt idler pulleys retaining bolt and nut to 25 N•m (18 lb-ft).


    C7A11C18
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  18. Install the camshaft position sensor. Refer to Section 1F2, Engine Controls - FAM II 2.4D.
  19. Install the crankshaft gear.

    20. Tighten
    Tighten the crankshaft timing belt drive gear bolt to 135 N•m (100 lb-ft) and turn the bolt another 30° and 10° using the angular torque gauge.


    C7A11C16
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  20. Install the timing belt automatic tensioner.

    21. Tighten
    Tighten the timing belt automatic tensioner retaining bolt to 25 N•m (18 lb-ft).


    J3B11C27
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  21. Install the camshaft gears with the timing marks at the front.
  22. Insert the guide pin of the intake camshaft into the "IN" bore.
  23. Insert the guide pin of the exhaust camshaft into the "EX" bore.

    24. J3B11C17
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  24. Install the camshaft gears by counter holding on the hex of the camshaft with an open-ended wrench.
  25. While holding the intake camshaft firmly in place, install a new intake camshaft gear bolt.

    26. Tighten
    Tighten the intake camshaft gear bolt to 50 N•m (37 lb-ft) and turn the bolt another 60° and 15° using the angular torque gauge.

  26. While holding the exhaust camshaft firmly in place, install a new exhaust camshaft gear bolt.

    27. Tighten
    Tighten the exhaust camshaft gear bolt to 50 N•m (37 lb-ft) and turn the bolt another 60° and 15° using the angular torque gauge.


    J3B11C10
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  27. Apply a small amount of gasket sealant to the corners of the front camshaft caps and to the top of the rear cylinder head cover-to-cylinder head seal.
  28. Install the cylinder head cover gasket and the cylinder head cover. Refer to "Cylinder Head Cover and Gasket" in this section.

    29. Tighten
    Tighten the cylinder head cover bolts to 8 N•m (71 lb-in.).

  29. Connect the ignition wires to the spark plugs.
  30. Connect the breather hose and the PCV hose to the cylinder head cover.

    31. C7A11C28
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  31. Align the timing marks on the camshaft gears to the notches on the cylinder head cover, using the intake gear mark for the intake gear and the exhaust gear mark for the exhaust gear.

    32. J3B11C29
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  32. Align the mark on the crankshaft gear with the notch at the bottom of the rear timing belt cover.

    33. C7A11C30
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  33. Install the timing belt.
  34. Check and adjust the timing belt tension. Refer to "Timing Belt Check and Adjust" "Timing Belt Check and Adjust" in this section.

    35. J3B11C16
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  35. Install the front timing belt cover.

    36. Tighten
    Tighten the front timing belt cover retaining bolts to 6 N•m (53 lb-in.).


    J3B11C17
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  36. Install the crankshaft pulley.

    37. Tighten
    Tighten the crankshaft pulley bolts to 23 N•m (17 lb-ft).


    C7A11C11
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  37. Install the engine mount assembly. Refer to "Engine Mount Assembly" in this section.

    38. Tighten
    Tighten the engine mount adapter bolts to 50 N•m (11 lb-ft).
    Tighten the engine mount frame side bracket bolt to 100 N•m (74 lb-ft) and nuts to 90 N•m (66 lb-ft).

  38. Remove the engine assembly support fixture DW110-060.
  39. Install the serpentine accessory drive belt. Refer to "Accessory Drive Belt" in this section.
  40. Connect the upper radiator hose to the thermostat housing.

    41. C7A11C51
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  41. Install the engine front shield at the position of right front wheel.
  42. Install the right front wheel. Refer to Section 2E, Tires and Wheels.
  43. Install the air cleaner assembly. Refer to "Air Cleaner Assembly" in this section.

    44. Tighten
    Tighten the air cleaner housing bolts to 10 N•m (89 lb-in.).

  44. Connect the IAT sensor connector.

    45. C7A11C10
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  45. Connect the CTS sensor connector.
  46. Connect the ETC sensor connector.
  47. Connect the DIS coil connector.
  48. Connect the O2 sensor connector.
  49. Connect the EGR valve connector.

    50. C7A11C08
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  50. Install the fuel pump fuse.
  51. Connect the negative battery cable.
  52. Refill the engine cooling system. Refer to Section 1D2, Engine Cooling - FAM II 2.4D.

C7A11C0K
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Camshafts

Removal Procedure

  1. Remove the engine beautification cover.
  2. Remove the timing belt. Refer to "Timing Belt" in this section.
  3. Disconnect the breather hose and PCV hose from the cylinder head cover.

    4. C7A11C06
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  4. Disconnect the ignition wires from the spark plugs.
  5. Remove the cylinder head cover. Refer to "Cylinder Head Cover" in this section.

    6. J3B11C17
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    Notice : Take extreme care to prevent any scratches, nicks of damage to the camshafts.

  6. While holding the intake camshaft firmly in place, remove the intake camshaft gear bolt.
  7. Remove the intake camshaft gear.
  8. While holding the exhaust camshaft firmly in place, remove the exhaust camshaft gear bolt.
  9. Remove the exhaust camshaft gear.

    10. C7A11C31
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  10. Loosen the camshaft bearing cap bolts in stages of one-half to one turn.
  11. Remove the camshaft bearing cap bolts from the cylinder head.
  12. Remove the camshafts.
  13. Remove the seal ring from the camshafts.

    14. Important : The camshaft must be detached evenly from the bearing seats in the front guide bearing.

  14. Check the camshaft and bearing seats for wear and replace them if necessary.

C7A11C31
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Installation Procedure

    Notice : Take extreme care to prevent any scratches, nicks of damage to the camshafts.

  1. Lubricate the camshaft journals and the camshaft caps with engine oil.
  2. Install the intake and exhaust camshafts.
  3. Install the intake and exhaust camshaft bearing caps in their original positions.
  4. Install the intake and exhaust camshaft bearing cap bolts.

  5. Tighten the camshaft bearing cap bolts gradually in the sequence shown for each camshaft caps.

    6. Tighten
    Tighten the camshaft bearing cap bolts to 8 N•m (71 lb-in.).


    J3B11C17
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  6. Measure the intake and exhaust camshaft end play. Refer to "Engine Specification" in this section.
  7. Install the intake camshaft gear.
  8. While holding the intake camshaft firmly in place, install a new intake camshaft gear bolt.

    9. Tighten
    Tighten the intake camshaft gear bolt to 50 N•m (37 lb-ft) plus 60° and 15° using the angular torque gauge KM-470-B.

  9. Install the exhaust camshaft gear.
  10. While holding the exhaust camshaft firmly in place, install a new exhaust camshaft gear bolt.

    11. Tighten
    Tighten the exhaust camshaft gear bolt to 50 N•m (37 lb-ft) plus 60° and 15° using the angular torque gauge KM-470-B.


    C7A11C06
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  11. Install the timing belt. Refer to "Timing Belt" in this section.
  12. Install the cylinder head cover gasket and cylinder head cover.

    13. Tighten
    Tighten the cylinder head cover bolts to 8 N•m (71 lb-in.).


    C7A11C0K
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  13. Connect the ignition wires to the spark plugs.
  14. Connect the breather hose and PCV hose to the cylinder head cover.
  15. Install the engine beautification cover.

    16. Tighten
    Tighten the engine beautification cover bolts and nuts to 8 N•m (71 lb-in.).


C7A11C01
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Timing Belt Check and Adjust

Adjustment Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the intake air temperature (IAT) sensor connector.

    3. C7A11C51
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  3. Remove the air cleaner assembly. Refer to "Air Cleaner Assembly" in this section.
  4. Remove the right front wheel. Refer to Section 2E, Tires and Wheels.
  5. Remove the engine front shield at the position of right front wheel.

    6. J3B11C17
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  6. Remove the serpentine accessory drive belt. Refer to "Accessory Drive Belt" in this section.
  7. Remove the crankshaft pulley.
  8. Remove the engine mount assembly. Refer to "Engine Mount Assembly" in this section.

    9. J3B11C16
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  9. Remove the front timing belt cover bolts.
  10. Remove the front timing belt cover.

    11. J3B11C29
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  11. Rotate the crankshaft at least one full turn clockwise using the crankshaft gear bolt.
  12. Align the mark on the crankshaft gear with the notch at the bottom of the rear timing belt cover.

    13. C7A11C28
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  13. Align the camshaft gear timing marks. Use the exhaust gear mark for the exhaust gear and the intake gear mark for the intake gear, since the gears are not interchangeable.

    14. J3B11C34
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  14. Loosen the automatic tensioner bolt. To relieve the belt tension, turn the hex-key tab counterclockwise.
  15. Rotate the automatic tensioner hex-key tab clockwise until the adjust arm pointer of the timing belt automatic tensioner is aligned with the notch in the timing belt automatic tensioner bracket.

    16. J3B11C29
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  16. Tighten the automatic tensioner bolt.
  17. Rotate the crankshaft two full turns clockwise using the crankshaft gear bolt.
  18. Check the automatic tensioner pointer.

    19. J3B11C34
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  19. When the adjust arm pointer of the timing belt automatic tensioner is aligned with the notch on the timing belt automatic tensioner bracket, the belt is tensioned correctly.

    20. Tighten
    Tighten the automatic tensioner bolt to 25 N•m (18 lb-ft).


    J3B11C16
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  20. Install the front timing belt cover.

    21. Tighten
    Tighten the front timing belt cover bolts to 6 N•m (53 lb-in.).


    J3B11C17
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  21. Install the crankshaft pulley.

    22. Tighten
    Tighten the crankshaft pulley bolt to 23 N•m (17 lb-ft).

  22. Install the engine mount assembly. Refer to "Engine Mount Assembly" in this section.
  23. Install the serpentine accessory drive belt. Refer to "Accessory Drive Belt" in this section.

    24. C7A11C51
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  24. Install the engine front shield. Refer to 9R, Body Front End.
  25. Install the right front wheel. Refer to Section 2E, Tires and Wheels.
  26. Install the air cleaner assembly. Refer to "Air Cleaner Assembly" in this section.

    27. Tighten
    Tighten the air cleaner housing bolts to 6 N•m (53 lb-in.).


    C7A11C01
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  27. Connect the IAT sensor connector.
  28. Connect the negative battery cable.

C7A11C01
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Timing Belt

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the intake air temperature (IAT) sensor connector.
  3. Remove the engine beautification cover.
  4. Disconnect the breather hose and PCV hose from the cylinder head cover.

    5. C7A11C51
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  5. Remove the air cleaner assembly. Refer to "Air Cleaner Assembly" in this section.
  6. Remove the right front wheel. Refer to Section 2E, Tires and Wheels.
  7. Remove the engine front shield at the position of right front wheel.

    8. J3B11C17
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  8. Remove the accessory drive belt. Refer to "Accessory Drive Belt" in this section.
  9. Remove the crankshaft pulley.
  10. Remove the engine mount assembly. Refer to "Engine Mount Assembly" in this section.

    11. J3B11C16
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  11. Remove the front timing belt cover bolts.
  12. Remove the front timing belt cover.

    13. J3B11C29
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  13. Using the crankshaft gear bolt, rotate the crankshaft clockwise until the timing mark on the crankshaft gear is aligned with the notch at the bottom of the rear timing belt cover.

    14. C7A11C28
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    Notice : The camshaft gears must be aligned with the notch on the cylinder head cover or damage to the engine could result.

  14. Align the camshaft gears with the notch on the cylinder head cover.

    15. Important : Use the intake gear mark for the intake camshaft gear and the exhaust gear mark for the exhaust camshaft gear since both gears are not interchangeable.


    C7A11C16
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  15. Loosen the automatic tensioner bolt. Turn the hex-key tab to relieve belt tension.
  16. Remove the timing belt.

J3B11C29
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Installation Procedure

  1. Align the timing mark on the crankshaft gear with the notch on the bottom of the rear timing belt cover.

    2. C7A11C28
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  2. Align the timing mark on the camshaft gears, using the intake gear mark for the intake gear and the exhaust gear mark for the exhaust gear.

    3. C7A11C30
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  3. Install the timing belt.

    4. J3B11C34
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  4. Turn the hex-key in a clockwise direction to tension the belt. Turn until the pointer aligns with the notch.
  5. Install the automatic tensioner.

    6. Tighten
    Tighten the automatic tensioner bolt to 25 N•m (18 lb-ft).

  6. Rotate the crankshaft two full turns clockwise using the crankshaft pulley bolt.
  7. Recheck the automatic tensioner pointer.

    8. J3B11C16
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  8. Install the front timing belt cover.

    9. Tighten
    Tighten the front timing belt cover bolts to 6 N•m (53 lb-in.).

  9. Install the engine mount assembly. Refer to "Engine Mount Assembly" in this section.

    10. J3B11C17
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  10. Install the crankshaft pulley.

    11. Tighten
    Tighten the crankshaft pulley bolt to 23 N•m (17 lb-ft).

  11. Install the serpentine accessory drive belt. Refer to "Accessory Drive Belt" in this section.

    12. C7A11C51
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  12. Install the engine front shield at the position of right front wheel.
  13. Install the right front wheel. Refer to Section 2E, Tires and Wheels. Section 2E, Tires and Wheels.
  14. Install the air cleaner assembly.

    15. Tighten
    Tighten the air cleaner housing bolts to 6 N•m (53 lb-in.).


    C7A11C0K
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  15. Connect the breather hose and PCV hose to the cylinder head cover.
  16. Connect the IAT sensor connector.
  17. Install the engine beautification cover.
  18. Connect the negative battery cable.


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