Removal and Replacement

CYLINDER HEAD


Removal and Installation


REMOVAL
1. Remove the following parts:
- Oil level gauge
- Intake manifold collector: Exploded View.
- Rocker cover: Exploded View.
- Fuel tube and fuel injector assembly: Exploded View.
- Intake manifold: Exploded View.
- Exhaust manifold: Exploded View.
- Water inlet and thermostat assembly: Exploded View.
- Water outlet, water connector, water bypass pipe, and heater pipe: Exploded View.
- Timing chain and rear timing chain case: Exploded View and Exploded View.
- Camshaft: Exploded View.









2. Remove cylinder head bolts in the reverse order as shown in the figure with cylinder head bolt wrench (commercial service tool) and power tool to remove cylinder heads (bank 1 and bank 2).
3. Remove cylinder head gaskets.

INSTALLATION
1. Install new cylinder head gaskets.
2. Turn crankshaft until No. 1 piston is set at TDC.




Arrow Indicates: Bank 1 side

- Crankshaft key (1) should line up with the bank 1 cylinder center line as shown in the figure.

A - Bank 1; B - Bank 2:

3. Install cylinder head follow the steps below to tighten cylinder head bolts in numerical order as shown in the figure with cylinder head bolts wrench (commercial service tool).

CAUTION:
- If cylinder head bolts reused, check their outer diameters before installation. Inspection.
- Before installing cylinder head, inspect cylinder head distortion. Inspection.
a. Apply new engine oil to threads and seat surfaces of cylinder head bolts.
b. Tighten all cylinder head bolts.

Torque: 98.1 N.m (10 kg-m, 72 ft-lb)

c. Completely loosen all cylinder head bolts.

Torque: 0 N.m (0 kg-m, 0 ft-lb)

CAUTION:
In step "c", loosen bolts in the reverse order of that indicated in the figure.
d. Tighten all cylinder head bolts.

Torque: 39.2 N.m (4.0 kg-m, 29 ft-lb)

e. Turn all cylinder head bolts 103 degrees clockwise (angle tightening).

CAUTION:





Check the tightening angle by using the angle wrench [SST:
KV10112100 (BT8653-A)] (A). Avoid judgment by visual inspection without.
- Check tightening angle indicated on the angle wrench indicator plate.
f. Turn all cylinder head bolts 103 degrees clockwise again (angle tightening).





4. After installing cylinder head, measure distance between front end faces of cylinder block and cylinder head (bank 1 and bank
2).

Standard : 14.1 - 14.9 mm (0.555 - 0.587 in)

- If measured value is out of the standard, reinstall cylinder head.
5. Install in the reverse order of removal after this step.