Removal and Replacement

Removal and Installation

EM-227 Component:

REMOVAL
1. Remove engine assembly from vehicle.
2. Remove exhaust manifold.
3. Remove camshaft.





4. Remove cylinder head bolts in reverse order as shown in the figure with cylinder head bolt wrench (commercial service tool) to remove cylinder heads (right and left banks).
5. 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"): 0.18 mm (0.0071 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-256, "Inspection After Disassembly". Inspection After Disassembly

1. Using 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 gasket.
2. Turn crankshaft until No. 1 piston is set at TDC.





^ Crankshaft key should line up with the left 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 bolt wrench (commercial service tool).

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

a. Apply new engine oil to threads and seating surface 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 cylinder head bolts in reverse order of that indicated in the figure.

d. Tighten all cylinder head bolts.
Torque: 44 Nm (4.5 kg-m, 32 ft-lb)





e. Turn all cylinder head bolts 60 degrees clockwise. (Angle tightening)

CAUTION:
Check the tightening angle by using angle wrench (SST). Avoid judgment by visual inspection without SST.

^ Check tightening angle indicated on angle wrench indicator plate.
f. Turn all cylinder head bolts 60 degrees clockwise again. (Angle tightening)
4. Install in the reverse order of removal.