Removal and Installation

Removal and Installation
REMOVAL
1. Remove camshaft.

NOTE: It is also possible to perform the following steps 2 and 3 just before removing the camshaft.

2. Temporarily fit front suspension member to support engine. Refer to "FRONT SUSPENSION MEMBER".

CAUTION: Temporary fitting means the status that engine is adequately stable though the hoist is released from hanging.

NOTE: At the time of the start of this procedure front suspension member is removed, and cylinder head is hanged by the hoist with engine slinger installed.

3. Release the hoist from hanging, then remove the engine slinger.
4. Remove the following parts:
^ Fuel tube and fuel injector assembly; Refer to "FUEL INJECTOR AND FUEL TUBE".
^ Intake manifold; Refer to "INTAKE MANIFOLD".
^ Exhaust manifold; Refer to "EXHAUST MANIFOLD AND THREE WAY CATALYST".
^ Water inlet and thermostat assembly; Refer to "WATER INLET AND THERMOSTAT ASSEMBLY".
^ Water outlet and water pipe; Refer to "WATER OUTLET AND WATER PIPING".





5. Remove cylinder head bolts in reverse order as shown in the figure with cylinder head bolt wrench (commercial service tool).
6. 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 them with new one.
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.

Cylinder Head Distortion

NOTE: When performing this inspection, cylinder block distortion should be also checking. Refer to EM-133, "CYLINDER BLOCK DISTORTION". Inspection After Disassembly

1. Using scraper, 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 inch)
^ If it exceeds the limit, replace cylinder head.

INSTALLATION
1. Install new cylinder head gaskets.





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 in the figure.





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

CAUTION: If cylinder head bolts re-used, check their outer diameters before installation. Refer to "Cylinder Head Bolts Outer Diameter".

a. Apply new engine oil to threads and seat surfaces of cylinder head bolts.
b. Tighten all cylinder head bolts.
Tightening Torque: 98.1 Nm (10 kg-m, 72 ft. lbs.)
c. Completely loosen all cylinder head bolts.
Tightening Torque: 0 Nm (0 kg-m, 0 ft. lbs.)

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

d. Tighten all cylinder head bolts.
Tightening Torque: 34.3 - 44.1 Nm (3.5 - 4.4 kg-m, 26 - 32 ft. lbs.)





e. Turn all bolts 90 to 95 degrees clockwise [target: 90 degrees (angle tightening)].

CAUTION: Check the tightening angle by using angle wrench [SST]. Avoid judgment by visual inspection without tool.

^ Check tightening angle indicated on angle wrench [SST] indicator plate.

f. Turn all bolts 90 to 95 degrees clockwise again [target: 90 degrees (angle tightening)].





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

INSPECTION AFTER INSTALLATION
^ Before starting engine, check the levels of engine coolant, engine oil and working fluid. If less than required quantity, fill to the specified level.
^ Use procedure 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 engine coolant, engine oil, working fluid, fuel and exhaust gas.
^ Bleed air from passages in pipes and tubes of applicable lines, such as in cooling system.
^ After cooling down engine, again check levels of engine coolant, engine oil and working fluid. Refill to the specified level, if necessary.





Summary of the inspection items