Valve and Cylinder Head Removal and Installation

Valve and Cylinder Head Removal and Installation

Removal
1) Remove timing chain.
2) Remove spark plugs.
3) Remove CMP actuator and exhaust camshaft timing sprocket according to the following procedure.
a) Hold hexagonal section of camshaft stationary using wrench or the like.
b) Loosen bolts and remove CMP actuator (1) and exhaust camshaft timing sprocket (2).

NOTE:
^ Do not hold CMP actuator to loosen bolt. Doing so may result in damaged lock pin.
^ Do not use impact wrench to loosen bolt.
^ Do not disassemble CMP actuator (1).





4) Remove intake camshaft and exhaust camshaft.
5) Remove camshaft bearings.
6) Remove water outlet pipe from cylinder head.
7) Remove heater outlet pipe bolt (1) from cylinder head (2).





8) Loosen cylinder head bolts in numerical order ("1" - "10") evenly and gradually.

NOTE:
Use 12-point socket wrench to cylinder head bolts.





9) Remove cylinder head with its gasket, intake manifold and exhaust manifold from cylinder block.
10) Remove the following components cylinder head if necessary.
^ Intake manifold:
^ Exhaust manifold:
^ Fuel injector:
^ Water outlet cap:
^ Oil venture plug:

Installation

CAUTION:
If cylinder head bolts are reused, check them for deformation.

1) Clean mating surface of cylinder head and cylinder block. Remove oil, old gasket and dust from mating surface.
2) Install dowel pins (1) to cylinder block.
3) Install new cylinder head gasket (2) to cylinder block.





4) Install cylinder head to cylinder block as follows.

NOTE:
Before Installing cylinder head to cylinder block, turn crankshaft and position key (1) within specified range (30 - 90 degrees) in counterclockwise direction from top as shown in figure.









a) Install cylinder head to cylinder block.
b) Apply engine oil to cylinder head bolts threads.
c) Tighten cylinder head bolts to 20 Nm (2.0 kgf-m, 15.0 lbf-ft) in numerical order ("1" -"10") evenly and gradually.

NOTE:
Use 12-point socket wrench to cylinder head bolts.

d) In the same manner as in Step c), retighten them to 40 Nm (4.1 kgf-m, 29.5 lbf-ft).
e) In the same manner as Step c), retighten them to 60 degrees.
f) In the same manner as Step c), retighten them to 80 degrees.
Tightening torque
Cylinder head bolt * (a): 20 Nm -> 40 Nm -> +60 degrees -> +80 degrees (2.0 kgf-m -> 4.1 kgf-m -> +60 degrees -> +80 degrees, 15.0 lbf-ft -> 29.5 lbf-ft -> +60 degrees ->+80 degrees)





5) Install intake camshaft and exhaust camshaft.
6) Install timing chain.
7) Install timing chain cover.
8) Install cylinder head cover.
9) Install oil pan.
10) Install water outlet cap if removed.
11) Install heater outlet pipe bolt to cylinder head.
12) Install water outlet pipe to cylinder head.





13) Install spark plugs.
14) Install exhaust manifold if removed.
15) Install intake manifold if removed.
16) Install fuel injectors if removed.
17) Install engine assembly.