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 belt and idler pulley. Service and Repair.
- Generator assembly and bracket. 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.
- Starter. Service and Repair.
- Knock sensors. Exploded View.
- Engine coolant temperature sensor (if necessary).
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 using Tool.





Tool number:-(J-45816)
6.Remove the cylinder heads.
7.Remove the cylinder head gaskets.

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.

CAUTION:
Do not reuse 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. Follow the "Cylinder Head Bolts Diameter" procedure.
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) in order (1-10)
Step b: 70� clockwise in order (1-10)
Step c: Loosen to 0 Nm (0 kg-m, 0 ft-lb) in reverse
order (10-1).
Step d: 44.1 Nm (4.5 kg-m, 33 ft-lb) in order (1-10)
Step e: 60� clockwise in order (1-10)
Step f: 60� clockwise in order (1-10)
Tool number: KV-10112100 (BT-8653-A)
3.Installation of the remaining components is in the reverse order of removal.

INSPECTION AFTER INSTALLATION

- 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 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 engine, again check oils/fluids including engine oil and engine coolant. Refill to specified level, if necessary.
- Summary of the inspection items: