Removal and Replacement

CYLINDER HEAD

COMPONENTS (Part 1):

COMPONENTS (Part 2):

COMPONENTS (Part 3):

COMPONENTS (Part 4):

REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
2. REMOVE TIMING BELT
3. REMOVE CAMSHAFT (for RH Side)
(a) Remove the camshaft (for RH side).

4. REMOVE CAMSHAFT (for LH Side)
(a) Remove the camshaft (for LH side).

5. REMOVE TRANSMISSION OIL FILLER TUBE SUBASSEMBLY
(a) Remove the bolt and transmission oil filler tube.

6. REMOVE OIL LEVEL GAGE GUIDE
(a) Remove the bolt and oil level gauge guide.

7. REMOVE INTAKE MANIFOLD ASSEMBLY
8. REMOVE WATER INLET HOUSING
(a) Remove the 2 bolts.
(b) Remove the water inlet housing and O-ring from the engine.

9. REMOVE WATER BY-PASS JOINT FR
(a) Remove the 4 nuts.
(b) Remove the water by-pass joint and 2 gaskets.

10. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY
(a) Remove the bolt and water by-pass pipe.

11. REMOVE NO. 2 AIR SWITCHING VALVE
12. REMOVE WATER BY-PASS JOINT RR
(a) Remove the 4 nuts, water by-pass joint and 2 gaskets.

13. REMOVE ENGINE WIRE
14. REMOVE NO. 2 REAR TIMING BELT PLATE RH
(a) Remove the 2 bolts and No. 2 rear timing belt plate RH.

15. REMOVE REAR TIMING BELT PLATE RH
(a) Remove the bolt, stud bolt and rear timing plate RH.

16. REMOVE NO. 2 REAR TIMING BELT PLATE LH
(a) Remove the 2 bolts and No. 2 rear timing belt plate LH.

17. REMOVE REAR TIMING BELT PLATE LH
(a) Remove the bolt and rear timing belt plate LH.

18. SEPARATE FRONT EXHAUST PIPE
(a) Remove the 2 bolts and separate the front exhaust pipe.

19. REMOVE CYLINDER HEAD SUB-ASSEMBLY

(a) Uniformly loosen the 12 cylinder head bolts in the order shown in the illustration. Remove the bolts and plate washers.

NOTICE:
^ Cylinder head warpage or cracking could result from removing bolts in incorrect order.
^ Do not drop the plate washer for cylinder head bolt into portion A as shown in the illustration. If dropped into the portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.

(b) Remove the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench.

HINT: If the cylinder head is lifted off, pry off between the cylinder head and cylinder block with a screwdriver.

NOTICE:
^ Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
^ The cylinder head should not be tilted so as to secure the valve lifter. If the cylinder head is tilted, remove the valve lifter and check that the adjusting shim is set correctly.

20. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH

(a) Uniformly loosen the 12 cylinder head bolts in the order shown in the illustration. Remove the bolts and plate washers.

HINT:
^ Cylinder head warpage or cracking could result from removing bolts in incorrect order.
^ Do not drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.

(b) Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench.

HINT: If the cylinder head cannot be lifted easily, pry between the cylinder head and cylinder block with a screwdriver.

NOTICE:
^ Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
^ The cylinder head should not be tilted so as to secure the valve lifter. If the cylinder head is tilted, remove the valve lifter and check that the adjusting shim is set correctly.

21. REMOVE CYLINDER HEAD GASKET
22. REMOVE NO. 2 CYLINDER HEAD GASKET

INSTALLATION

1. INSTALL NO. 2 CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket in position on the cylinder block.

HINT: A mark is placed on the rear side of the cylinder head gasket to distinguish the LH and RH banks, a "2R" mark for the RH bank and a "2L" mark for the LH bank.

NOTICE: Be careful of the installation direction.

(b) Place the cylinder head in position on the cylinder head gasket.

2. INSTALL CYLINDER HEAD GASKET
(a) Place a new cylinder head gasket in position on the cylinder block.

HINT: A mark is placed on the rear side of the cylinder head gasket to distinguish the LH and RH banks, a "2R" mark for the RH bank and a "2L" mark for the LH bank.

NOTICE: Be careful of the installation direction.

(b) Place the cylinder head in position on the cylinder head gasket.

3. INSTALL CYLINDER HEAD SUB-ASSEMBLY LH

(a) Check that the timing mark of the crankshaft timing pulley is in the position shown in the illustration, and that the piston is below the TDC of compression.
(b) Install the cylinder head with the exhaust manifold to the cylinder block.

HINT:
^ The cylinder head bolts are tightened in 2 progressive steps.
^ If any cylinder head bolt is broken or deformed, replace it.

(c) Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
(d) Install the plate washer to the cylinder head bolt.

(e) Install and uniformly tighten the 12 cylinder head bolts, and plate washers, in the order shown in the illustration.
Torque: 40 N*m (408 kgf*cm, 30 ft.*lbf)
If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.

NOTICE: Do not drop the plate washer for the cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.

(f) Mark the front of the cylinder head bolt head with paint.
(g) Retighten the cylinder head bolts by 90° in the order shown.
(h) Retighten the cylinder head bolts by an additional 90°.
(i) Check that the painted mark is now at a 180° angle to front.

4. INSTALL CYLINDER HEAD SUB-ASSEMBLY

(f) Mark the front of the cylinder head bolt head with paint.
(g) Retighten the cylinder head bolts by 90° in the order shown.
(h) Retighten the cylinder head bolts by an additional 90°.
(i) Check that the painted mark is now at a 180° angle to front.

5. INSTALL FRONT EXHAUST PIPE
(a) Place a new gasket to the front exhaust pipe.
(b) Install the 2 nuts and front exhaust pipe.
Torque: 62 N*m (632 kgf*cm, 46 ft.*lbf)

6. INSTALL REAR TIMING BELT PLATE LH
(a) Install the bolt and rear timing belt plate LH.
Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf)

7. INSTALL NO. 2 REAR TIMING BELT PLATE LH
(a) Install the 2 bolts and No. 2 rear timing belt plate LH.
Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf)

8. INSTALL REAR TIMING BELT PLATE RH
(a) Install the timing belt plate with the bolt and stud bolt.
Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf)

9. INSTALL NO. 2 REAR TIMING BELT PLATE RH
(a) Install the timing belt plate with the 2 bolts.
Torque: 7.5 N*m (80 kgf*cm, 66 in.*lbf)

10. INSTALL WATER BY-PASS JOINT RR
11. INSTALL NO. 2 AIR SWITCHING VALVE
12. INSTALL WATER BY-PASS JOINT FR
13. INSTALL WATER INLET HOUSING
14. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
(a) Install a new O-ring to the water by-pass pipe.
(b) Apply soapy water to the O-ring.
(c) Push in the water by-pass pipe end into the pipe hole of the water pump.
(d) Install the water by-pass pipe with the bolt.
Torque: 18 N*m (185 kgf*cm, 13 ft.*lbf)

15. INSTALL INTAKE MANIFOLD ASSEMBLY
16. INSTALL OIL LEVEL GAGE GUIDE
(a) Install a new O-ring to the oil level gauge guide.
(b) Install the oil level gauge guide with the bolt.
Torque: 15 N*m (155 kgf*cm, 11 ft.*lbf)

17. INSTALL TRANSMISSION OIL FILLER TUBE SUBASSEMBLY
(a) Install the transmission oil filler tube sub-assembly with the bolt.
Torque: 12 N*m (122 kgf*cm, 9 ft.*lbf)

18. INSTALL CAMSHAFT (for LH Side)
(a) Install the camshaft (for LH side).

19. INSTALL CAMSHAFT (for RH Side)
(a) Install the camshaft (for RH side).

20. INSTALL TIMING BELT