Removal and Replacement
Valve and Cylinder Head Removal and Installation
Valve and Cylinder Head Components
Removal
1) Remove timing chain. Timing Chain and Chain Tensioner Removal and Installation
2) Remove spark plugs. Spark Plug Removal and Installation
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:
The CMP actuator will lose its original performance if it is disassembled.
Do not try to disassemble and repair the CMP actuator. If any faulty condition is found, replace the CMP actuator with a new one.
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.
4) Remove intake camshaft and exhaust camshaft. Camshaft and Tappet Removal and Installation
5) Remove camshaft bearings.
6) Remove water outlet pipe from cylinder head. [1][2]Cooling System
7) Remove heater outlet pipe bolt (1) from cylinder head (2).
8) Remove cylinder head No.2 bolt (1).
9) Loosen cylinder head No.1 bolts in numerical order ("1" - "10") evenly and gradually.
NOTE:
Use 12-point socket wrench to cylinder head No.1 bolts (2).
10) Remove cylinder head with its gasket, intake manifold and exhaust manifold from cylinder block.
11) Remove the following components cylinder head if necessary.
- Intake manifold: Intake Manifold Removal and Installation
- Exhaust manifold: Exhaust Manifold Removal and Installation
- Fuel injector: Fuel Injector Removal and Installation
- Water outlet cap: [1][2]Cooling System
- Oil venture plug: Disassembly and Reassembly
Installation
Valve and Cylinder Head Disassembly and Reassembly
Cylinder Head Inspection
Cylinder Head No.1 Bolt Inspection
NOTE:
Using cylinder head No.1 bolts that are deformed exceeding the service limit could lead to engine problems.
When cylinder head No.1 bolts are reused, make sure that they are not deformed exceeding the service limit referring to Cylinder Head No.1 Bolt Inspection Cylinder Head No.1 Bolt Inspection.
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°) in counterclockwise direction from top as shown in figure.
a) Install cylinder head to cylinder block.
b) Apply engine oil to cylinder head No.1 bolts threads.
c) Tighten cylinder head No.1 bolts (1) 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 No.1 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°.
f) In the same manner as Step c), retighten them to 80°.
Tightening torque
Cylinder head No.1* bolt (a): (20 Nm -> 40 Nm -> +60° -> +80° (2.0 kgf-m -> 4.1 kgf-m -> +60° -> +80°, 15.0 lbf-ft -> 29.5 lbf-ft -> +60° ->+80°))
g) Tighten cylinder head No.2 bolt (2) to specified torque.
Tightening torque
Cylinder head No.2 bolt (b): 25 Nm (2.5 kgf-m, 18.5 lbf-ft)
5) Install intake camshaft and exhaust camshaft. Camshaft and Tappet Removal and Installation.
6) Install timing chain. Timing Chain and Chain Tensioner Removal and Installation
7) Install timing chain cover. Timing Chain Cover Removal and Installation
8) Install cylinder head cover. Cylinder Head Cover Removal and Installation
9) Install oil pan. Oil Pan and Oil Pump Strainer Removal and Installation
10) Install water outlet cap if removed. [1][2]Cooling System
11) Install heater outlet pipe bolt to cylinder head. [1][2]Cooling System
12) Install water outlet pipe to cylinder head. [1][2]Cooling System
13) Install spark plugs. Spark Plug Removal and Installation
14) Install exhaust manifold if removed. Exhaust Manifold Removal and Installation
15) Install intake manifold if removed. Intake Manifold Removal and Installation
16) Install fuel injectors if removed. Fuel Injector Removal and Installation
17) Install engine assembly. Removal and Replacement