Removal and Installation

REMOVAL
1. Perform fuel line inner pressure release. Refer to Powertrain Management.
2. Drain engine coolant.
3. Drain engine oil.
4. Remove air cleaner.
5. Follow removal steps outlined in illustration, noting the following.





6. Place mating marks on the radiator hose and the hose clamp, and then disconnect the radiator hose.

INSTALLATION
1. Follow removal procedure in reverse order noting the following.
2. Cylinder head bolts should be carefully examined before reuse. If the threads are necked down, the bolts should be replaced.





NOTE: Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale, the bolt should be replaced.

3. Before installing the bolts, the threads should be oiled with clean engine oil.






Without Multi Layer Steel Head Gasket

4. Tighten the cylinder head bolts in the sequence shown in the illustration. Using the 4 step torque turn method, tighten according to the following values.
a. Tighten center fasteners 1 thru 6 to 33 Nm (25 ft. lbs.). Then outer fasteners 7 thru 10 to 27 Nm (20 ft. lbs.).
b. Tighten center fasteners 1 thru 6 to 67 Nm (50 ft. lbs.). Then outer fasteners 7 thru 10 to 27 Nm (20 ft. lbs.).
c. Tighten center fasteners 1 thru 6 to 67 Nm (50 ft. lbs.). Then outer fasteners 7 thru 10 to 27 Nm (20 ft. lbs.).

CAUTION:
1. Always make a tightening angle just 90°. If it is less than 90°, the head bolt will be loosened.
2. If it is more than 90°, remove the head bolt and repeat the procedure from step 1.





d. Turn all fasteners 1 thru 10 90° turn. Do not use a torque wrench for this step.

With Multi Layer Steel Head Gasket

Note: The four short bolts are placed in the corners.

Step 1
Torque all center bolts to 34 Nm (25 Ft Lbs), Torque the 4 corner bolt to 27 Nm (20 Ft Lbs)
Step 2
Torque all center bolts to 68 Nm (50 Ft Lbs), Torque the four corner bolts to 47 Nm (35 Ft Lbs),
Step 3
Re-torque all center bolts to 68 Nm (50 Ft Lbs), Re-torque the 4 corner bolts to 47 Nm (35 Ft Lbs).
Step 4
Tighten all bolts in the Specified sequence an additional 90° (1/4 turn).





5. Insert each hose as far as the projection of the water outlet fitting or water inlet fitting.
6. Place mating marks on the radiator hose and the hose clamp, and then connect the radiator hose.

CAUTION: Do not let the engine oil get into the fuel rail.

7. When connecting the high-pressure fuel hose to the fuel rail, apply a small amount of clean engine oil to the hose union, and then insert, being careful not to damage the O-ring.
8. Fill engine oil.
9. Fill Cooling System.
10. Perform accelerator cable adjustment. Refer to Powertrain Management.