Removal and Installation

REMOVAL
1. Release fuel pressure.
2. Remove the hood.
3. Drain engine coolant and engine oil.
4. Position the RH engine compartment fuse and relay box aside.
5. Remove the engine undercovers using power tool.
6. Remove the timing chain.
7. Remove the camshafts.
8. Remove the exhaust manifold using power tool.
9. Support the engine from above and underneath with suitable hoist and floor jack.





10. Lower the front suspension member for clearance to remove the oil pan by disconnecting the following:
^ Position the power steering reservoir aside.
^ Remove auxiliary drive belts.
^ Dismount the A/C compressor and position it out of the way with wire.
^ Disconnect the upper sway bar links.
^ Remove the through bolts from the front and rear engine mounts.
^ Disconnect the lower ball joints.
^ Remove the two steering gear housing mounting bolts.





11. Remove cylinder head loosening bolts in the order shown, using power tool.
12. If necessary to transfer to new cylinder head or remove for reconditioning, remove the intake manifold collector, intake manifold, and fuel tube assembly.

INSPECTION AFTER REMOVAL
Outer Diameter of Cylinder Head Bolts





^ Cylinder head bolts are tightened by using the plastic zone (Torque-to-yeild) tightening method. Whenever the size difference between d1 and d2 exceeds the limit, replace the bolts with new ones.

- Subtract the head bolt diameter measurement taken at d2 from the head bolt diameter measurement taken at d1. If the difference between d1 and d2 exceeds the limit, replace the bolts with new ones.

Limit (d1 - d2): 0.23 mm (0.0091 inch) or less

^ If reduction of outer diameter appears in a position other than d2, use it as d2 point.

INSTALLATION
1. Install a new cylinder head gasket.

Bolt Tightening Sequence:

2. Follow the steps below to tighten the cylinder head bolts in the numerical order as shown.

CAUTION:
^ If cylinder head bolts are re-used, check their outer diameters before installation.

Bolt Loosening Sequence:

^ In step "c", loosen bolts in the order shown in the figure.

a. Apply new engine oil to the threads and the seating surfaces of mounting bolts.
b. Tighten all bolts to 98.1 Nm (10 kg-m, 72 ft. lbs.).
c. Completely loosen all bolts as shown in the figure.
d. Retighten all bolts to 34.3 - 44.1 Nm (3.5 - 4.4 kg-m, 26 - 32 ft. lbs.).
e. Turn all bolts 75° - 80° degrees (target: 75° degrees) clockwise.





f. Turn all bolts 75° to 80° degrees (target: 75° degrees) clockwise again.

CAUTION: Check and confirm the tightening angle by using angle wrench or protractor. Avoid judgment by visual inspection without the tool.

3. Installation of the remaining components is in reverse order of removal.