Removal and Installation

Removal and Installation
REMOVAL
1. Remove engine assembly from vehicle. Refer to "REMOVAL".
2. Remove the following components and related parts:
^ Auto tensioner of drive belts and idler pulley. Refer to "REMOVAL".
^ Thermostat housing and hose. Refer to "Removal of Thermostat Housing. Water Outlet and Heater Pipe".
^ Oil pan and oil strainer. Refer to "REMOVAL".
^ Fuel tube and fuel injector assembly. Refer to "FUEL INJECTOR AND FUEL TUBE".
^ Intake manifold. Refer to "INTAKE MANIFOLD".
^ Ignition coil. Refer to "IGNITION COIL".
^ Rocker cover. Refer to "ROCKER COVER".
3. Remove crankshaft pulley, front cover, oil pump, and timing chain. Refer to "TIMING CHAIN".
4. Remove camshaft sprockets and camshafts. Refer to "CAMSHAFT".





5. Remove 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 d1 and d2 exceeds the limit, replace the bolt with a new one.
Limit (d1 - d2): 0.18 mm (0.0071 inch)
^ If reduction of diameter appears in a position other than d2, use it as d2 point.

INSTALLATION
1. Install cylinder head gasket.





2. Install the cylinder head. Follow the steps 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.
Step a: 98.1 Nm (10 kg-m, 72 ft. lbs.)
Step b: Loosen in the reverse order of tightening.
Step c: 44.1 Nm (4.5 kg-m, 33 ft. lbs.)





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.

INSPECTION AFTER INSTALLATION
Inspection for Leaks
The following are procedures for checking fluid leaks, lubricant leaks and exhaust gases leaks.
^ Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Refer to "RECOMMENDED FLUIDS AND LUBRICANTS".
^ 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.

NOTE: If hydraulic pressure inside timing chain tensioner drops after removal/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 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.





Summary of the inspection items: