Cylinder Head Assembly: Service and Repair

CYLINDER HEAD

Components:

REMOVAL
1. PRECAUTION
Observe Restraint Systems; Service Precautions.
2. REMOVE ENGINE ROOM SIDE LH COVER
3. DISCHARGE FUEL SYSTEM PRESSURE
4. REMOVE SERVICE PLUG GRIP
5. DRAIN COOLANT (Engine side)
6. DRAIN COOLANT (Hybrid side)
7. DRAIN ENGINE OIL
8. REMOVE FRONT WHEEL RH
9. REMOVE ENGINE UNDER COVER NO.1
10. SEPARATE FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH
11. REMOVE FRONT FENDER APRON SEAL RH
12. REMOVE ENGINE UNDER COVER NO.2
13. REMOVE FRONT SUSPENSION BRACE SUB-ASSEMBLY UPPER CENTER
14. REMOVE BATTERY
15. REMOVE BATTERY CARRIER SUB-ASSEMBLY
16. REMOVE AIR CLEANER CAP W/INLET
17. REMOVE AIR CLEANER CASE W/RESONATOR
18. REMOVE W/ CONVERTER INVERTER ASSEMBLY
19. REMOVE EMISSION CONTROL VALVE SET
20. REMOVE INTAKE AIR SURGE TANK
21. DISCONNECT FUEL PIPE SUB-ASSEMBLY NO.1

22. DISCONNECT HEATER INLET WATER HOSE
a) Lock the hose clamp as shown in the illustration (A).
b) Disconnect the heater inlet water hose (B).

23. REMOVE INTAKE MANIFOLD
a) Remove the nut and disconnect the ground cable (A).
b) Disconnect the 6 fuel injector connectors.

c) In order to remove the intake manifold, using several steps, remove the 9 bolts and 2 nuts in the sequence shown in the illustration.

24. DISCONNECT RADIATOR HOSE INLET
25. REMOVE WATER OUTLET
a) Disconnect the ground cable connector (A).

b) Disconnect the engine coolant temperature sensor connector (B).
c) Remove the clamp (C).
d) Remove the 2 bolts, 2 nuts and 2 washers.
e) Lock the hose clamp as shown in the illustration (D) and remove the water outlet together with water bypass hose No.1 (E).
f) Remove the 2 gaskets from the 2 cylinder heads.

26. SEPARATE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
27. REMOVE RESERVOIR BRACKET
28. REMOVE AIR CLEANER BRACKET
29. REMOVE ENGINE MOVING CONTROL ROD
30. REMOVE ENGINE MOUNTING STAY NO.2 RH
31. REMOVE CRANKSHAFT PULLEY
32. REMOVE TIMING BELT NO.1 COVER
33. REMOVE TIMING BELT NO.2 COVER
34. REMOVE ENGINE MOUNTING BRACKET RH
35. REMOVE TIMING BELT GUIDE NO.2
36. REMOVE TIMING BELT
37. REMOVE TIMING BELT IDLER SUB-ASSEMBLY NO.2
38. REMOVE CAMSHAFT TIMING PULLEY
39. REMOVE TIMING BELT NO.3 COVER
40. REMOVE EXHAUST PIPE ASSEMBLY FRONT
41. REMOVE EXHAUST PIPE SUB-ASSEMBLY FRONT NO.3

42. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1
a) Remove the 3 bolts and exhaust manifold heat insulator No.1.

43. REMOVE MANIFOLD STAY
a) Remove the 2 bolts and manifold stay.

44. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
a) Disconnect the heated oxygen sensor connector.

b) Using several steps, loosen and remove the 6 nuts in the sequence shown in the illustration.
c) Remove the exhaust manifold RH and the gasket from the cylinder head RH.

45. REMOVE IGNITION COIL ASSEMBLY
46. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
47. REMOVE CAMSHAFT
48. REMOVE NO.2 CAMSHAFT

49. REMOVE CYLINDER HEAD SUB-ASSEMBLY
a) Disconnect the VVT sensor connector.
b) Disconnect the camshaft timing oil control valve connector.
c) Remove the nut and disconnect the engine wire harness clamp.

d) Using a socket hexagon wrench 8 mm, remove the hexagon bolt.

e) Using several steps, loosen the 8 cylinder head bolts uniformly in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.
SST 09011-38121

NOTICE:
^ Do not drop the washers into the cylinder head.
^ Head warpage or cracking could result from removing bolts in an incorrect order.

50. REMOVE CYLINDER HEAD GASKET

51. REMOVE MANIFOLD CONVERTER INSULATOR NO.3
a) Remove the bolt, nut and manifold converter insulator No.3.

52. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.2
a) Remove the 2 bolts and manifold heat insulator No.2.

53. SEPARATE COOLING FAN ECU
a) Remove the 2 bolts and separate the cooling fan ECU.

HINT:
^ The cooling fan ECU should be separated to prevent it from being interfered with by the exhaust manifold.
^ Be sure to hang the disconnected ECU with the string to ensure safety.

54. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO.2
a) Disconnect the heated oxygen sensor connector.
b) Using several steps, loosen and remove the 6 nuts and bolt in the sequence shown in the illustration.
c) Remove the exhaust manifold converter No.2 and the gasket from the cylinder head LH.

55. REMOVE OIL LEVEL GAUGE GUIDE
a) Remove the bolt which is used to secure the oil level gauge guide from the cylinder head LH.
b) Pull out the oil level gauge guide and the oil level gauge together from the cylinder block.
c) Remove the O-ring from the oil level gauge guide.

56. REMOVE WATER INLET PIPE
57. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
58. REMOVE NO.3 CAMSHAFT SUB-ASSEMBLY
59. REMOVE NO.4 CAMSHAFT SUB-ASSEMBLY

60. REMOVE CYLINDER HEAD LH
a) Disconnect the VVT sensor connector (A).
b) Disconnect the camshaft timing oil control valve connector (B).
c) Remove the 2 nuts and disconnect the ground cable (C).
d) Remove the 2 bolts, wire harness clamp and intake air connector bracket No.2.

e) Using a socket hexagon wrench 8 mm, remove the hexagon bolt.

f) Using several steps, loosen the 8 cylinder head bolts uniformly in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.
SST 09011-38121

NOTICE:
^ Do not drop the washers into the cylinder head.
^ Head warpage or cracking could result from removing bolts in an incorrect order.

61. REMOVE CYLINDER HEAD GASKET NO.2

INSTALLATION

1. INSPECT CYLINDER HEAD SET BOLT
a) Using vernier calipers, measure the tension portion diameter of the bolt.
Standard outside diameter: 8.95 to 9.05 mm (0.3524 to 0.3563 inch)
Minimum outside diameter: 8.75 mm (0.3445 inch)
If the diameter is less than the minimum, replace the bolt.

2. INSTALL CYLINDER HEAD GASKET NO.2
a) Place a new cylinder head gasket on the cylinder block with the L mark upward.

NOTICE:
^ Remove any oil from the contact surface.
^ Be careful to install the gasket in the correct direction.
^ Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.

3. INSTALL CYLINDER HEAD LH

NOTICE: The cylinder head bolts are tightened in 2 successive steps.

a) Apply a light coat of engine oil to the threads of the cylinder head bolts.
b) Install the plate washer to the cylinder head bolt.
c) Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration.
SST 09011-38121
Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.)

d) Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
e) Retighten the cylinder head bolts by 90° in the same sequence as step (C).
f) Check that each painted mark is now at 90° angle to the front.

g) Using a socket hexagon wrench 8 mm, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)

h) Using several steps, install and tighten the 2 bolts and intake air connector bracket No.2 uniformly in the sequence shown in the illustration.
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
i) Connect the ground cable with the 2 bolts.
Torque: Nut A 8.4 Nm (85 kgf-cm, 74 inch lbs.)
Nut B 11 Nm (112 kgf-cm, 97 inch lbs.)

4. INSTALL NO.4 CAMSHAFT SUB-ASSEMBLY
5. INSTALL NO.3 CAMSHAFT SUB-ASSEMBLY
6. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY LH
7. INSTALL WATER INLET PIPE
8. INSTALL OIL LEVEL GAUGE GUIDE
a) Install a new O-ring to the oil level gauge guide.
b) Apply soapy water to the O-ring.
c) Push in the oil level gauge guide end into the guide hole of the cylinder block.

d) Install the oil level gauge guide with the bolt.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
e) Install the oil level gauge.

9. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY NO.2
a) Install a new gasket as shown in the illustration.

b) Install the exhaust manifold converter No.2 with the 6 nuts and bolt. Using several steps, tighten the nuts uniformly in the sequence shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
c) Retighten nuts 1 and 2 shown in the illustration.

10. CONNECT COOLING FAN ECU
a) Connect the 2 bolts and cooling fan ECU.
Torque: 2.6 Nm (26 kgf-cm, 23 inch lbs.)

11. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.2
a) Install the 2 bolts and exhaust manifold heat insulator No.2.
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)

12. INSTALL MANIFOLD CONVERTER INSULATOR NO.3
a) Install the bolt, nut and manifold converter insulator No.3.
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)

13. INSTALL CYLINDER HEAD GASKET
a) Place a new cylinder head gasket on the cylinder block with the R mark upward.

NOTICE:
^ Remove any oil from the contact surface.
^ Be careful to install the gasket in the correct direction.
^ Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.

14. INSTALL CYLINDER HEAD SUB-ASSEMBLY

NOTICE: The cylinder head bolts are tightened in 2 successive steps.

a) Apply a light coat of engine oil to the threads of the cylinder head bolts.
b) Install the plate washers to the cylinder head bolts.

c) Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration.
SST 09011-38121
Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.)

g) Using a socket hexagon wrench 8 mm, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)
h) Connect the engine wire harness clamp with the nut.
Torque: 8.4 Nm (85 kgf-cm, 74 inch lbs.)

15. INSTALL NO.2 CAMSHAFT
16. INSTALL CAMSHAFT
17. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
18. INSTALL IGNITION COIL ASSEMBLY
Torque: 8.0 Nm (80 kgf-cm, 71 inch lbs.)

19. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
a) Install a new gasket as shown in the illustration.

b) Install a new gasket and the exhaust manifold RH with the 6 nuts. Using several steps, tighten the nuts uniformly in the sequence shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
c) Retighten nuts 1 and 2 shown in the illustration.

20. INSTALL MANIFOLD STAY
a) Temporarily install the manifold stay to the exhaust manifold and transaxle.
b) Fully tighten the 2 bolts.
Torque: 34 Nm (347 kgf-cm, 25 ft. lbs.)

21. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
a) Install the 3 bolts and exhaust manifold heat insulator No.1.
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)

22. INSTALL EXHAUST PIPE SUB-ASSEMBLY FRONT NO.3
23. INSTALL EXHAUST PIPE ASSEMBLY FRONT
24. INSTALL TIMING BELT NO.3 COVER
25. INSTALL CAMSHAFT TIMING PULLEY
26. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO.2
27. INSPECT TIMING BELT
28. INSTALL TIMING BELT
29. INSTALL CHAIN TENSIONER ASSEMBLY NO.1
30. INSTALL TIMING BELT GUIDE NO.2
31. INSTALL ENGINE MOUNTING BRACKET RH
32. INSTALL TIMING BELT NO.2 COVER
33. INSTALL TIMING BELT NO.1 COVER
34. INSTALL CRANKSHAFT PULLEY
35. INSTALL ENGINE MOUNTING STAY NO.2 RH
36. INSTALL ENGINE MOVING CONTROL ROD
37. INSTALL AIR CLEANER BRACKET
38. INSTALL RESERVOIR BRACKET
39. INSTALL BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
40. INSTALL WATER OUTLET
a) Install 2 new gaskets to the 2 cylinder heads.
b) Install the water outlet together with water by-pass hose No.1 and unlock the hose clamp.
c) Tighten the 2 bolts, 2 nuts and 2 washers.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
d) Install the clamp.
e) Connect the engine coolant temperature sensor connector.
f) Connect the radiator hose inlet.

41. CONNECT RADIATOR HOSE INLET

42. INSTALL INTAKE MANIFOLD
a) Install the intake manifold with the 9 bolts, 2 nuts and 2 washers. Using several steps, tighten the bolts and nuts uniformly in the sequence shown in the illustration.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
b) Retighten the water outlet mounting bolts and nuts.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
c) Install the ground cable with the nut.
Torque: 8.4 Nm (86 kgf-cm, 74 inch lbs.)
d) Connect the heater inlet water hose.

43. CONNECT FUEL PIPE SUB-ASSEMBLY NO.1
44. INSTALL INTAKE AIR SURGE TANK
45. INSTALL EMISSION CONTROL VALVE SET
46. INSTALL W/CONVERTER INVERTER ASSEMBLY
47. INSTALL AIR CLEANER CASE W/RESONATOR
48. INSTALL AIR CLEANER CAP W/INLET
49. INSTALL FRONT SUSPENSION BRACE SUB-ASSEMBLY UPPER CENTER
50. INSTALL BATTERY CARRIER SUB-ASSEMBLY
51. INSTALL BATTERY
52. INSTALL SERVICE PLUG GRIP
53. INSTALL ENGINE UNDER COVER NO.2
54. INSTALL FRONT FENDER APRON SEAL RH
55. INSTALL FRONT FENDER SPLASH SHIELD SUB-ASSEMBLY RH
56. INSTALL ENGINE UNDER COVER NO.1
57. INSTALL FRONT WHEEL RH
58. ADD ENGINE OIL
59. CHECK FOR FUEL LEAKS
60. ADD COOLANT (Hybrid side)
61. ADD COOLANT (Engine side)
62. CHECK FOR ENGINE OIL LEAKS
63. CHECK FOR ENGINE COOLANT LEAKS (Hybrid side)
64. CHECK FOR ENGINE COOLANT LEAKS (Engine side)
65. CHECK FOR EXHAUST GAS LEAKS
66. INSPECT IGNITION TIMING
67. INSPECT ENGINE IDLE SPEED
68. INSPECT COMPRESSION
69. INSPECT CO/HC
70. PERFORM INITIALIZATION
a) Some system need initialization when reconnecting the battery cable.

71. INSTALL ENGINE ROOM SIDE LH COVER