Part 1

Cylinder Head

REMOVAL

CYLINDER HEAD RH

1) Remove the engine from the vehicle.
2) Remove the intake manifold.
3) Remove the tumble generator valve assembly RH.
4) Remove the chain cover.
5) Remove the rocker cover RH.
6) Remove the cam carrier RH.
7) Remove the EGR pipe assembly from the water pipe assembly and the cylinder block RH.

8) Loosen the bolts holding the cylinder head RH equally, a little at a time in numerical sequence and while leaving the cylinder head bolts (1) and (4) engaged by three or four threads, remove the other cylinder head bolts.

NOTE:
Leave the cylinder head bolts (1) and (4) engaged by three or four threads to prevent the cylinder head RH from falling.

9) While tapping the cylinder head RH with a plastic hammer, separate it from cylinder block RH.
10) Remove the bolts (1) and (4) to remove cylinder head RH.
11) Remove the cylinder head gasket RH.

CAUTION:
Be careful not to scratch the mating surface of cylinder head and cylinder block.

12) Remove the liquid gasket from cylinder head RH and cam carrier RH.

CYLINDER HEAD LH

1) Remove the engine from the vehicle.
2) Remove the intake manifold.
3) Remove the tumble generator valve assembly LH.
4) Remove the chain cover.
5) Remove the rocker cover LH.
6) Remove the cam carrier LH.
7) Remove the bolt securing the A/C compressor bracket to the cylinder head LH, and remove the A/C compressor bracket.

8) Loosen the bolts holding the cylinder head LH equally, a little at a time in numerical sequence and while leaving the cylinder head bolts (1) and (4) engaged by three or four threads, remove the other cylinder head bolts.

NOTE:
Leave the cylinder head bolts (1) and (4) engaged by three or four threads to prevent the cylinder head LH from falling.

9) While tapping the cylinder head LH with a plastic hammer, separate it from cylinder block LH.
10) Remove the cylinder head bolts (1) and (4) to remove cylinder head LH.
11) Remove the cylinder head gasket LH.

CAUTION:
Be careful not to scratch the mating surface of cylinder head and cylinder block.

12) Remove the liquid gasket from cylinder head LH and cam carrier LH.

INSTALLATION

CYLINDER HEAD RH

1) Clean the bolt holes in the cylinder block RH.

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 liquid gasket to both sides of the cylinder head gasket RH as shown in the figure.

NOTE:
^ Use a new cylinder head gasket RH.
^ Install within 5 min. after applying liquid gasket.

Liquid gasket:
THREE BOND 1217G (Part No. 0877Y0100) or equivalent

Liquid gasket applying diameter:
3±1 mm (0.1181±0.0394 in)

3) Attach the cylinder head gasket RH.

NOTE:
Check that liquid gasket RH is squeezed out from the cylinder head gasket.

4) Install the cylinder head RH to the cylinder block RH.

CAUTION:
Be careful not to scratch the mating surface of cylinder head RH and cylinder block RH.

(1) Clean the cylinder head bolt threads and apply sufficient engine oil to the washer and cylinder head bolts threads.
(2) Mount the cylinder head RH onto the cylinder block RH, then tighten all bolts with a torque of 29 Nm (3.0 kgf-m, 21.4 ft-lb) in numerical order as shown in the figure.

(3) Tighten all cylinder head bolts further with a torque of 100 Nm (10.2 kgf-m, 73.8 ft-lb) in numerical order as shown in the figure.

CAUTION:
If the bolt makes stick-slip sound during tightening, repeat the procedure from step 1). In that case, the cylinder head gasket RH can be reused. But it is necessary to remove liquid gasket completely from cylinder block RH, cylinder head RH and cylinder head gasket RH and re-apply to them.

(4) Loosen all cylinder head bolts 180° in numerical order as shown in the figure, and then loosen all cylinder head bolts 180° further in numerical order as shown in the figure.

(5) Tighten all cylinder head bolts with a torque of 42 Nm (4.3 kgf-m, 31.0 ft-lb) in numerical order as shown in the figure.

(6) Tighten all cylinder head bolts with specified angle in numerical order as shown in the figure using ST2.

NOTE:
Attach the magnet used for securing the ST2 (ANGLE GAUGE) to ST1.

ST1 499817100 ENGINE STAND
ST2 18854AA000 ANGLE GAUGE

Tightening angle:
80°±2°

(7) Tighten the cylinder head bolts (2 places) with specified angle in numerical order as shown in the figure using ST2.

NOTE:
Attach the magnet used for securing the ST2 (ANGLE GAUGE) to ST1.

ST1 499817100 ENGINE STAND
ST2 18854AA000 ANGLE GAUGE

Tightening angle:
75°±2°

(8) Tighten the cylinder head bolts (4 places) with specified angle in numerical order as shown in the figure using ST2.

NOTE:
^ After tightening, if the liquid gasket is squeezed out onto the seal surface of the chain cover, completely remove any squeezed-out liquid gasket.
^ Attach the magnet used for securing the ST2 (ANGLE GAUGE) to ST1.

ST1 499817100 ENGINE STAND
ST2 18854AA000 ANGLE GAUGE

Tightening angle:
30°±2°

5) Install the EGR pipe assembly to the water pipe assembly and the cylinder block RH.

NOTE:
Use a new gasket.

Tightening torque:
T1: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
T2: 51 Nm (5.2 kgf-m, 37.6 ft-lb)

6) Install the cam carrier RH.
7) Install the rocker cover RH.
8) Install the chain cover.
9) Install the tumble generator valve assembly RH.
10) Install the intake manifold.
11) Install the engine to the vehicle.

CYLINDER HEAD LH

1) Clean the bolt holes in the cylinder block LH.

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 liquid gasket to both sides of the cylinder head gasket LH as shown in the figure.

NOTE:
^ Use a new cylinder head gasket LH.
^ Install within 5 min. after applying liquid gasket.

Liquid gasket:
THREE BOND 1217G (Part No. 0877Y0100) or equivalent

Liquid gasket applying diameter:
3±1 mm (0.1181±0.0394 in)

3) Attach the cylinder head gasket LH.

NOTE:
Check that liquid gasket is squeezed out from the cylinder head gasket LH.

4) Install the cylinder head LH to the cylinder block LH.

CAUTION:
Be careful not to scratch the mating surface of cylinder head LH and cylinder block LH.

(1) Clean the cylinder head bolt threads and apply sufficient engine oil to the washer and cylinder head bolts threads.
(2) Mount the cylinder head LH onto the cylinder block LH, then tighten all bolts with a torque of 29 Nm (3.0 kgf-m, 21.4 ft-lb) in numerical order as shown in the figure.

(3) Tighten all cylinder head bolts further with a torque of 100 Nm (10.2 kgf-m, 73.8 ft-lb) in numerical order as shown in the figure.

CAUTION:
If the bolt makes stick-slip sound during tightening, repeat the procedure from step 1). In that case, the cylinder head gasket LH can be reused. But it is necessary to remove liquid gasket completely from cylinder block LH, cylinder head LH and cylinder head gasket LH and re-apply to them.

(4) Loosen all cylinder head bolts 180° in numerical order as shown in the figure, and then loosen all cylinder head bolts 180° further in numerical order as shown in the figure.

(5) Tighten all cylinder head bolts with a torque of 42 Nm (4.3 kgf-m, 31.0 ft-lb) in numerical order as shown in the figure.

5) Set the A/C compressor bracket to the cylinder head LH, and tighten the bolts in numerical order as shown in the figure.

Tightening torque:
36 Nm (3.7 kgf-m, 26.6 ft-lb)

6) Install the cam carrier LH.
7) Install the rocker cover LH.
8) Install the chain cover.
9) Install the tumble generator valve assembly LH.
10) Install the intake manifold.
11) Install the engine to the vehicle.