Cylinder Head: Removal and Installation
Cylinder Head: Removal and InstallationREMOVAL
1) Remove camshaft.
2) Remove intake manifold.
3) Remove exhaust manifold.
4) Remove water inlet and thermostat assembly.
5) Remove water outlet, water pipe and heater pipe.
6) Remove cylinder head bolts in reverse order as shown using suitable tool and power tool to remove cylinder heads (right and left banks).
7) 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 the bolt with a new one.
Limit (d1) - (d2)]: 0.11 mm (0.0043 in)
^ 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 checked.
1) Using suitable tool, 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 in)
^ If it exceeds the limit, replace cylinder head.
INSTALLATION
1) Install new cylinder head gasket.
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.
3) Install cylinder head follow the steps below to tighten cylinder head bolts in numerical order as shown.
CAUTION:
If cylinder head bolts re-used, check their outer diameters before installation.
Step a :98 Nm (10 kg-m, 72 ft-lb)
Step b :Loosen to 0 Nm in the reverse order of tightening.
Step c :39.2 Nm (4.0 kg-m, 29 ft-lb)
Measure the tightening angle using Tool.
Tool number :KV10112100 (BT-8653-A)
Step d :90 degrees clockwise
Step e :90 degrees clockwise
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 in)
^ If the measured value is out of the standard, re-install cylinder head.
5) Installation of the remaining parts is in the reverse order of removal.
INSPECTION AFTER INSTALLATION
^ Before starting the engine, check oil/fluid levels including engine coolant and engine oil. If the levels are lower than required quantity, fill to the specified level.
^ Use procedure below to check for fuel leakage.
^ Turn ignition switch ON (with engine stopped). With fuel pressure applied to the fuel piping, check for fuel leakage at the 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.
NOTE:
If hydraulic pressure inside timing chain tensioner drops after removal and installation, slack in the guide may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after hydraulic pressure rises.
^ Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gas, or any oil/fluids including engine oil and engine coolant.
^ Bleed air from passages in lines and hoses, such as in cooling system.
^ After cooling down the engine, again check oil/fluid levels including engine oil and engine coolant. Refill to specified level if necessary.
^ Summary of the inspection items:
