Removal and Installation

CYLINDER HEAD:

REMOVAL
1. Remove camshaft.
2. Remove the following components and related parts:
- Fuel tube and fuel injector assembly.
- Intake manifold.
- Exhaust manifold.
- Water inlet and thermostat housing.
- Water outlet and water piping.










3. Remove cylinder head loosening bolts in reverse order shown in the figure.

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 them with new one.

- 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)......................0.11 mm (0.0043 inch)

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


INSTALLATION
1. Install cylinder head gasket.







2. Turn the crankshaft until No. 1 piston is set at TDC on the compression stroke.
he 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 the order shown in figure.
a. Tighten all bolts to 98.1 Nm (10 kgf-cm, 72 ft. lbs.).
b. Completely loosen to 0 Nm (0 kgf-cm, 0 ft. lbs.).

CAUTION: In step "b", loosen bolts in the reverse order of that indicated in figure.

c. Tighten all bolts to 34.3 to 44.1 Nm (3.5 to 4.4 kgf-cm, 26 to 32 ft. lbs.).
d. Turn all bolts 90 to 95 degrees clockwise [target: 90 degrees (angle tightening)].
e. Turn all bolts 90 to 95 degrees clockwise again [target: 90 degrees (angle tightening)].

CAUTION: Check and confirm the tightening angle by using angle wrench (special service tool). Avoid judgment by visual inspection without the tool.







Check tightening angle indicated on the angle wrench indicator plate.







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

Standard..........................14.1 - 14.9 mm (0.555 - 0.587 inch)

If measurement is outside the specified range, re-install cylinder head.

5. Perform steps in reverse order of removal.