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 intake camshaft with CMP actuator and exhaust camshaft with timing sprocket. Camshaft and Tappet Removal and Installation
4) Remove camshaft bearings.
5) Remove heater outlet pipe bolt (1) from cylinder head (2).

6) Remove cylinder head No.2 bolt (1).
7) Loosen cylinder head No.1 bolts (2) in numerical order ("1" - "10") evenly and gradually.

NOTE:
Use 12-point socket wrench to cylinder head No.1 bolts.

8) Remove cylinder head with its gasket, intake manifold and exhaust manifold from cylinder block.
9) 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 venturi plug: Valve and Cylinder Head 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 (1) threads.
c) Tighten cylinder head No.1 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 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)