Removal and Replacement
Removal and InstallationEM-101 Component:
REMOVAL
1. Remove camshaft.
NOTE:
It is also possible to perform the following steps 2 and 3 just before removing camshaft.
2. Temporarily fit front suspension member to support engine.
CAUTION:
Temporary fitting means the status that engine is adequately stable though the hoist is released from hanging.
NOTE:
At the time of the start of this procedure front suspension member is removed, and cylinder head is hanged by hoist with the engine slinger installed.
3. Release the hoist from hanging, then remove the engine slinger.
4. Remove the following parts:
^ Fuel tube and fuel injector assembly
^ Intake manifold
^ Exhaust manifold
^ Water inlet and thermostat assembly
^ Water outlet, water pipe and heater pipe
5. Remove cylinder head bolts in reverse order as shown in the figure with cylinder head bolt wrench (commercial service tool) and power tool to remove cylinder heads (right and left banks).
6. Remove cylinder head gaskets.
INSPECTION AFTER REMOVAL
Cylinder Head Bolts Outer Diameter
^ 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 in)
^ If reduction of outer diameter appears in a position other than "d2", use it as "d2" point.
Cylinder Head Distortion
NOTE:
When performing this inspection, cylinder block distortion should be also checking. Refer to EM-138, "Inspection After Disassembly". Inspection After Disassembly
1. Using a scraper, wipe off oil, scale, gasket, sealant and carbon deposits from surface of cylinder head.
CAUTION:
Do not allow gasket fragments to enter engine oil or engine coolant passages.
2. At each of several locations on bottom surface of cylinder head, measure the distortion in six directions.
Limit: 0.1 mm (0.004 in)
^ If it exceeds the limit, replace cylinder head.
INSTALLATION
1. Install new cylinder head gaskets.
2. Turn crankshaft until No. 1 piston is set at TDC.
^ Crankshaft key should line up with the right bank cylinder center line as shown in the figure.
3. Install cylinder head follow the steps below to tighten cylinder head bolts in numerical order as shown in the figure with cylinder head bolts wrench (commercial service tool).
CAUTION:
If cylinder head bolts re-used, check their outer diameters before installation. Refer to "Cylinder Head Bolts Outer Diameter".
a. Apply new engine oil to threads and seat surfaces of cylinder head bolts.
b. Tighten all cylinder head bolts.
Torque: 98.1 Nm (10 kg-m, 72 ft-lb)
c. Completely loosen all cylinder head bolts.
Torque: 0 Nm (0 kg-m, 0 ft-lb)
CAUTION:
In step "c", loosen bolts in reverse order of that indicated in the figure.
d. Tighten all cylinder head bolts.
Torque: 39.2 Nm (4.0 kg-m, 29 ft-lb)
e. Turn all cylinder head bolts 90 degrees clockwise (angle tightening).
CAUTION:
Check the tightening angle by using the angle wrench (SST). Avoid judgment by visual inspection without SST.
^ Check tightening angle indicated on the angle wrench indicator plate.
f. Turn all cylinder head bolts 90 degrees clockwise again (angle tightening).
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 in)
^ If measured value is out of the standard, re-install cylinder head.
5. Install in the reverse order of removal after this step.
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
^ Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level.
^ Use procedure below to check for fuel leakage.
^ Turn ignition switch "ON" (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points.
^ Start engine. With engine speed increased, check again for fuel leakage at connection points.
^ Run engine to check for unusual noise and vibration.
^ Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids including engine oil and engine coolant.
^ Bleed air from lines and hoses of applicable lines, such as in cooling system.
^ After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary.
