Removal and Installation

CYLINDER HEAD





Removal and Installation

REMOVAL
1. Remove camshaft.

NOTE: It is also possible to perform the following steps 2 and 3 just before removing the camshaft.

2. Temporarily fit the front suspension member to support the engine.

CAUTION: Temporary fitting means the status that the engine is adequately stable though the hoist is released from hanging.

NOTE: At the time of the start of this procedure the front suspension member is removed, and cylinder head is hanged by the hoist with engine slinger installed.

3. Release the hoist from hanging, then remove the engine slinger.
4. Remove the following components and related parts:
^ Fuel tube and fuel injector assembly.
^ Intake manifold.
^ Exhaust manifold.
^ Water inlet and thermostat housing.
^ Water outlet and water piping.








5. Remove cylinder head loosening bolts with power tool in reverse order shown in the figure and using cylinder head bolt wrench (commercial service tool).

INSPECTION AFTER REMOVAL
Outer Diameter of Cylinder Head Bolts





^ Cylinder head bolts are tightened by plastic zone tightening method. Whenever the size difference between d1 and d2 exceeds the limit, replace them with new one.
Limit (d1 - d2): 0.11 mm (0.0043 inch)
^ If reduction of outer diameter appears in a position other than d2, use it as d2 point.

INSTALLATION
1. Install cylinder head gasket.





2. Turn the crankshaft until No. 1 piston is set at TDC on the compression stroke.
^ The crankshaft key should line up with the right bank cylinder center line as shown.








3. Install cylinder head follow the steps below to tighten cylinder head bolts in the order shown in figure.
a. Tighten all bolts.
98.1 Nm (10 kg-m, 72 ft. lbs.)
b. Completely loosen.
0 Nm (0 kg-m, 0 ft. lbs.)

CAUTION: In step "b", loosen bolts in the reverse order of that indicated in figure.

c. Tighten all bolts.
39.2 Nm (4.0 kg-m, 29 ft. lbs.)





d. Turn all bolts "90" degrees clockwise (angle tightening).
e. Turn all bolts "90" degrees clockwise again [target: 90 degrees (angle tightening)].

CAUTION: Check and confirm the tightening angle by using angle wrench (SST) and cylinder head bolt wrench (commercial service tool). Avoid judgment by visual inspection without the SST.

^ Check tightening angle indicated on the angle wrench (SST) indicator plate.





4. After installing cylinder head, measure distance between front end faces of cylinder block and cylinder head (left and right banks).
Standard: 14.1 - 14.9 mm (0.555 - 0.587 inch)
^ If measurement is outside the specified range, re-install cylinder head.

5. Perform steps in reverse order of removal for the following operations.