Removal and Installation

Removal and Installation
REMOVAL
1. Remove the engine assembly from the vehicle.
2. Remove the following components and related parts:
^ Auto tensioner of drive belts and idler pulley. Refer to "DRIVE BELTS".
^ Thermostat housing and hose. Refer to "Removal of Thermostat Housing, Water Outlet and Heater Pipe"
^ Oil pan and oil strainer. Refer to "OIL PAN AND OIL STRAINER".
^ Fuel tube and fuel injector assembly. Refer to "FUEL INJECTOR AND FUEL TUBE".
^ Intake manifold. Refer to "INTAKE MANIFOLD".
^ Ignition coil. Refer to "IGNITION COIL".
^ Rocker cover. Refer to "ROCKER COVER".
3. Remove the crankshaft pulley, front cover, oil pump, and timing chain. Refer to "TIMING CHAIN".
4. Remove the camshaft sprockets and camshafts. Refer to "CAMSHAFT".





5. Remove the cylinder head bolts in reverse of order shown.

INSPECTION AFTER REMOVAL
Cylinder Head Bolts Diameter





^ Cylinder head bolts are tightened by plastic zone tightening method. Whenever the size difference between d1 and d2 exceeds the limit, replace the bolt with a new one.
Limit (d1 - d2): 0.18 mm (0.0071 inches)
^ If reduction of diameter appears in a position other than d2, use it as d2 point.

INSTALLATION





1. Install a new cylinder head gasket.
2. Install the cylinder head. Follow the steps to tighten the bolts in the numerical order shown.

CAUTION:
^ If cylinder head bolts are re-used, check their diameters before installation. Refer to "Cylinder Head Bolts Diameter".

a. Apply engine oil to threads and seating surface of the bolts.
Step a: 98.1 Nm (10 kg-m, 72 ft. lbs.)
Step b: Loosen in the reverse order of tightening.
Step c: 44.1 Nm (4.5 kg-m, 33 ft. lbs.)





b. Measure the tightening angle using Tool.
Tool number : KV10112100 (BT-8653-A)

CAUTION: Measure the tightening angle using Tool. Do not measure visually.

Step d: 60° clockwise
Step e: 60° clockwise
3. Installation of the remaining components is in the reverse order of removal.