Removal and Replacement

Removal and Installation

EM-65 Components:

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





5. Remove the 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 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.
Step a: 98.1 Nm (10 kg-m, 72 ft-lb)
Step b: Loosen in the reverse order of tightening.
Step c: 44.1 Nm (4.5 kg-m, 33 ft-lb)





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.
- 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.