Part 1
The content of this article / image reflects Manual update # 02-111-10 dated 08/02/10.Cylinder Head
REMOVAL
1) Remove the engine from the vehicle.
2) Remove the rear side belt.
3) Remove the intake manifold.
4) Remove the crank pulley.
5) Remove the timing belt cover.
6) Remove the timing belt.
7) Remove the cam sprocket.
8) Remove the secondary air combination valve.
9) Remove the bolts which secure A/C compressor bracket to cylinder head.
10) Remove the oil pipe.
11) Remove the camshaft.
12) Remove the oil level gauge guide. (LH side only)
13) Remove the cylinder head bolts in alphabetical order shown in the figure.
NOTE:
Leave the bolts (A) and (D) engaged by three or four threads to prevent the cylinder head from falling.
14) While tapping the cylinder head with a plastic hammer, separate it from cylinder block. Remove the bolts (A) and (D) to remove cylinder head.
15) Remove the cylinder head gasket.
CAUTION:
Be careful not to scratch the mating surface of cylinder head and cylinder block.
16) Similarly, remove the right side cylinder head.
INSTALLATION
1) Install the cylinder head to the cylinder block.
CAUTION:
Be careful not to scratch the mating surface of cylinder head and cylinder block.
NOTE:
Use a new cylinder head gasket.
(1) Clean the bolt threads and the bolt holes in the cylinder block
CAUTION:
To avoid erroneous tightening of the bolts, clean out the bolt holes sufficiently by blowing with compressed air to eliminate engine coolant etc.
(2) Apply a sufficient coat of engine oil to the washer and bolt thread.
(3) Tighten all bolts to 40 Nm (4.1 kgf-m, 29.5 ft-lb) in alphabetical order.
(4) Retighten all bolts to 95 Nm (9.7 kgf-m, 70.1 ft-lb) in alphabetical order.
CAUTION:
If the bolt makes stick-slip sound during tightening, repeat the procedure from step (1). In this case, the cylinder head gasket can be reused.
(5) Loosen all the bolts by 180° in the reverse order of installing, and loosen them further by 180°.
(6) Tighten all bolts to 10 Nm (1.0 kgf-m, 7.4 ft-lb) in alphabetical order.
(7) Retighten all bolts to 30 Nm (3.1 kgf-m, 22.1 ft-lb) in alphabetical order.
(8) Retighten all bolts to 70 Nm (7.1 kgf-m, 51.6 ft-lb) in alphabetical order.
(9) Retighten all bolts by 80 - 90° in alphabetical order.
(10) Retighten all bolts by 40 - 45° in alphabetical order.
CAUTION:
The tightening angle of the bolt should not exceed 45°.
(11) Retighten bolts (A) and (B) by 40 - 45°.
CAUTION:
Make sure the total "tightening angle" of steps (10) and (11) does not exceed 90°.
2) Similarly, install the right side cylinder head.
3) Install the oil level gauge guide. (LH side only)
Tightening torque:
6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
4) Install the camshaft.
5) Install the oil pipe.
6) Install the A/C compressor bracket on cylinder head.
Tightening torque:
36 Nm (3.7 kgf-m, 26.6 ft-lb)
7) Install the secondary air combination valve.
8) Install the cam sprocket.
9) Install the timing belt.
10) Adjust the valve clearance.
11) Install the rocker cover.
(1) Install the rocker cover gasket to the rocker cover. (outer section and ignition coil section)
NOTE:
Use a new rocker cover gasket.
(2) Apply liquid gasket to the specified point of the cylinder head.
NOTE:
Install within 5 min. after applying liquid gasket.
Liquid gasket:
THREE BOND 1217G (Part No. K0877Y0100) or equivalent
(3) Install the rocker cover onto cylinder heads. Ensure the gasket is properly positioned during installation.
(4) Temporarily tighten the rocker cover bolts in alphabetical order shown in the figure, and then tighten to specified torque in alphabetical order.
Tightening torque:
6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
12) Connect the PCV hose to the rocker cover.
NOTE:
Use a new clamp for the PCV hose clamp, fit the cut out in the ST with the protrusion on the clamp as shown in the figure, and lock the clamp.
ST 18353AA000 CLAMP PLIERS
13) Install the timing belt cover.
14) Install the crank pulley.
15) Install the intake manifold.
16) Install the rear side belt.
17) Install the engine to the vehicle. Removal and Replacement