Removal and Replacement

CYLINDER HEAD

Removal and Installation

NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spilling.

REMOVAL

1.Remove camshaft. Removal And Installation.
2.Remove intake manifold. Removal And Installation.
3.Remove exhaust manifold. Removal And Installation.
4.Remove front final drive assembly (4WD models). Front Final Drive R180A.
5.Remove water inlet and thermostat assembly (left bank). Removal And Installation.
6.Remove water outlet, water pipe and heater pipe (left bank). Removal And Installation.





7.Remove cylinder head bolts in reverse order as shown using suitable tool and power tool to remove cylinder heads (right and left banks).
8.Remove cylinder head gaskets.

INSPECTION AFTER REMOVAL

Cylinder Head Bolts Outer 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)]: 0.11 mm (0.0043 in)
- If reduction of outer diameter appears in a position other than (d2), use it as (d2) point.
Cylinder Head Distortion
NOTE:
When performing this inspection, cylinder block distortion should be also checked. Inspection After Disassembly.
1.Using suitable tool, wipe off oil, scale, gasket, sealant and carbon deposits from surface of cylinder head.

CAUTION:
Do not allow gasket fragments to enter engine oil or engine coolant passages.





2.At each of several locations on bottom surface of cylinder head, measure the distortion in six directions.
Limit: 0.1 mm (0.004 in)
- Replace cylinder head If measured distortion exceeds the limit.

INSTALLATION

1.Install new cylinder head gasket.





2.Turn crankshaft until No. 1 piston is set at TDC.
- Crankshaft key should line up with the right bank cylinder center line as shown.





3.Install cylinder head follow the steps below to tighten cylinder head bolts in numerical order as shown.

CAUTION:
If cylinder head bolts are re-used, check their outer diameters before installation. (Cylinder Head Bolts Outer Diameter).

Step a: 98.1 Nm (10 kg-m, 72 ft-lb)
Step b: Loosen to 0 Nm in the reverse order of tightening.
Step c: 39.2 Nm (4.0 kg-m, 29 ft-lb)





Measure the tightening angle using Tool.
Tool number: KV-10112100 (BT-8653-A)

Step d: 90� clockwise
Step e: 90� clockwise





4.After installing cylinder head, measure distance between front end faces of cylinder block and cylinder head (left and right banks).





- If the measured value is out of the standard, re-install cylinder head.
5.Installation of the remaining parts 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.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal and 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 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 oil/fluid levels including engine oil and engine coolant. Refill to specified level, if necessary.
- Summary of the inspection items: