Removal and Replacement

CYLINDER HEAD


Removal and Installation


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





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

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) : 0.23 mm (0.0091 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 "Cylinder Head Bolts Diameter".
a. Apply engine oil to threads and seating surface of the bolts.





b. Measure the tightening angle using Tool.

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

Step a : 44.1 Nm (4.5 kg-m, 33 ft-lb)
Step b : 70° clockwise
Step c : Loosen in the reverse order of tightening.
Step d : 44.1 Nm (4.5 kg-m, 33 ft-lb)
Step e : 60° clockwise
Step f : 60° clockwise

Tool number : KV10112100 (BT-8653-A)

3. Installation of the remaining components is in the reverse order of removal.

INSPECTION AFTER INSTALLATION
- Before starting the engine, check oil/fluid levels including engine coolant and engine oil. If the levels are lower than required quantity, fill to the specified level. Maintenance.
- Use procedure below to check for fuel leakage.
- Turn ignition switch ON (with engine stopped). With fuel pressure applied to the fuel piping, check for fuel leakage at the 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.

NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal and installation, slack in the guide may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after hydraulic pressure rises.
- Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oils/fluids including engine oil and engine coolant.
- Bleed air from passages in lines and hoses, such as in cooling system.
- After cooling down the engine, again check oil/fluid levels including engine oil and engine coolant. Refill to specified level if necessary.
- Summary of the inspection items: