Removal and Replacement

CYLINDER HEAD

Removal and Installation

Exploded View EM-64:

REMOVAL
1. Remove the engine assembly from the vehicle.
2. Remove the following components and related parts:
^ Drive belt auto tensioner drive belts and idler pulley.
^ Thermostat housing and hose.
^ Oil pan and oil strainer.
^ Fuel tube and fuel injector assembly.
^ Intake manifold.
^ Ignition coil.
^ Rocker cover.
3. Remove the crankshaft pulley, front cover, oil pump, and timing chain.
4. Remove the camshaft sprockets and camshafts.





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 dl and d2 exceeds the limit, replace the bolt with a new one.
Limit (d1 - d2): 0.18 mm (0.0071 in)
^ 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 below to tighten the bolts in the numerical order shown.

CAUTION:
^ If cylinder head bolts are re-used, check their diameters before installation. Refer to GI-47, "Recommended Chemical Products and Sealants". Service and Repair

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





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.