Repair Procedures

Removal

1. Remove the engine cover.
2. Disconnect the battery negative terminal.
3. Remove the air clean hose.

4. Disconnect the engine wiring connector and haness clamp and then remove the cylinder head protector and wiring from engine.
A. Turbo charger solenoid valve connector
B. Exhaust OCV(Oil Control Valve) connector
C. Ignition connector # 1,2,3,4
D. FPCV(Fuel Pressure Control Valve) connector
E. Condenser connector
F. Exhaust CMPS(Cam position Sensor) connector
G. Intake CMPS(Cam Position Sensor) connector




H. WTS(Water Temperature Sensor) connector
I. Ground Cable
J. Front Oxygen Sensor connector
K. Front Oxygen Sensor connector




5. Disconnect the exhaust OCV(Oil Control Valve) connector.

6. Disconnect the ignition coil.

7. Remove the PCV(Positive Crankcase Ventilation) hose(A).




8. Remove the high pressure fuel pump.

9. Remove the cylinder head cover(A), gasket(B).





NOTE:
Loosen the cylinder head cover bolts with the order and steps.





Installation

1. Install the cylinder head cover.
(1) The hardening sealant located on the upper area between timing chain cover and cylinder head should be removed before assembling cylinder head cover.
(2) After applying sealant, it should be assembled within 5 minutes.

Bead width :2.0 - 3.0mm(0.07 - 0.11 in.)
Sealant :LOCTITE 5900H




(3) Install the cylinder head cover (A) with a new gasket (B).





CAUTION:
Do not reuse the disassembled gasket.

(4) Tighten the cylinder head cover bolts with the order and steps.

Tightening torque
1st step:
3.9 - 5.9 N.m (0.4 - 0.6 kgf.m, 2.9 - 4.3 lb-ft)
2nd step: 7.8 - 9.8 N.m (0.8 - 1.0 kgf.m, 5.8 - 7.2 lb-ft)




2. Install in the reverse order of removal.