Part 1
The content of this article / image reflects Manual update # 02-111-10 dated 08/02/10.Cylinder Head
REMOVAL
CYLINDER HEAD RH
1) Remove the engine from the vehicle.
2) Remove the intake manifold.
3) Remove the tumble generator valve assembly RH.
4) Remove the chain cover.
5) Remove the rocker cover RH.
6) Remove the cam carrier RH.
7) Remove the EGR pipe assembly from the water pipe assembly and the cylinder block RH.
8) Loosen the bolts holding the cylinder head RH equally, a little at a time in numerical sequence and while leaving the cylinder head bolts (1) and (4) engaged by three or four threads, remove the other cylinder head bolts.
NOTE:
Leave the cylinder head bolts (1) and (4) engaged by three or four threads to prevent the cylinder head RH from falling.
9) While tapping the cylinder head RH with a plastic hammer, separate it from cylinder block RH.
10) Remove the bolts (1) and (4) to remove cylinder head RH.
11) Remove the cylinder head gasket RH.
CAUTION:
Be careful not to scratch the mating surface of cylinder head and cylinder block.
12) Remove the liquid gasket from cylinder head RH and cam carrier RH.
CYLINDER HEAD LH
1) Remove the engine from the vehicle.
2) Remove the intake manifold.
3) Remove the tumble generator valve assembly LH.
4) Remove the chain cover.
5) Remove the rocker cover LH.
6) Remove the cam carrier LH.
7) Remove the bolt securing the A/C compressor bracket to the cylinder head LH, and remove the A/C compressor bracket.
8) Loosen the bolts holding the cylinder head LH equally, a little at a time in numerical sequence and while leaving the cylinder head bolts (1) and (4) engaged by three or four threads, remove the other cylinder head bolts.
NOTE:
Leave the cylinder head bolts (1) and (4) engaged by three or four threads to prevent the cylinder head LH from falling.
9) While tapping the cylinder head LH with a plastic hammer, separate it from cylinder block LH.
10) Remove the cylinder head bolts (1) and (4) to remove cylinder head LH.
11) Remove the cylinder head gasket LH.
CAUTION:
Be careful not to scratch the mating surface of cylinder head and cylinder block.
12) Remove the liquid gasket from cylinder head LH and cam carrier LH.
INSTALLATION
CYLINDER HEAD RH
(1) Clean the bolt threads and the bolt holes in the cylinder block
CAUTION:
To avoid erroneous tightening of the bolts, clean out the bolt holes sufficiently by blowing with compressed air to eliminate engine coolant etc.
(2) Apply a sufficient coat of engine oil to the washer and bolt thread.
(3) Tighten all bolts to 40 Nm (4.1 kgf-m, 29.5 ft-lb) in alphabetical order.
(4) Retighten all bolts to 95 Nm (9.7 kgf-m, 70.1 ft-lb) in alphabetical order.
CAUTION:
If the bolt makes stick-slip (squeaking sound) during tightening, start over from step (1). In this case, the cylinder head gasket can be reused.
(5) Loosen all the bolts by 180° in the reverse order of installing, and loosen them further by 180°.
(6) Tighten all bolts to 10 Nm (1.0 kgf-m, 7.4 ft-lb) in alphabetical order.
(7) Retighten all bolts to 30 Nm (3.1 kgf-m, 22.1 ft-lb) in alphabetical order.
(8) Retighten all bolts to 60 Nm (6.1 kgf-m, 44.3 ft-lb) in alphabetical order.
(9) Retighten all bolts by 80 - 90° in alphabetical order.
(10) Retighten all bolts by 40 - 45° in alphabetical order. Caution: Do not exceed 45°
(11) Retighten bolts (a) and (b) by 40 - 45°. Caution: Do not exceed 45°
CAUTION:
Make sure the total "tightening angle" of steps (10) and (11) does not exceed 90°.
NOTE:
^ After tightening, if the liquid gasket is squeezed out onto the seal surface of the chain cover, completely remove any squeezed-out liquid gasket.
^ Attach the magnet used for securing the ST2 (ANGLE GAUGE) to ST1.
ST1 499817100 ENGINE STAND
ST2 18854AA000 ANGLE GAUGE
Tightening angle:
30°±2°
12) Install the EGR pipe assembly to the water pipe assembly and the cylinder block RH.
NOTE:
Use a new gasket.
Tightening torque:
T1: 6.4 Nm (0.7 kgf-m, 4.7 ft-lb)
T2: 51 Nm (5.2 kgf-m, 37.6 ft-lb)
13) Install the cam carrier RH.
14) Install the rocker cover RH.
15) Install the chain cover.
16) Install the tumble generator valve assembly RH.
17) Install the intake manifold.
18) Install the engine to the vehicle.
CYLINDER HEAD LH
(1) Clean the bolt threads and the bolt holes in the cylinder block
CAUTION:
To avoid erroneous tightening of the bolts, clean out the bolt holes sufficiently by blowing with compressed air to eliminate engine coolant etc.
(2) Apply a sufficient coat of engine oil to the washer and bolt thread.
(3) Tighten all bolts to 40 Nm (4.1 kgf-m, 29.5 ft-lb) in alphabetical order.
(4) Retighten all bolts to 95 Nm (9.7 kgf-m, 70.1 ft-lb) in alphabetical order.
CAUTION:
If the bolt makes stick-slip (squeaking sound) during tightening, start over from step (1). In this case, the cylinder head gasket can be reused.
(5) Loosen all the bolts by 180° in the reverse order of installing, and loosen them further by 180°.
(6) Tighten all bolts to 10 Nm (1.0 kgf-m, 7.4 ft-lb) in alphabetical order.
(7) Retighten all bolts to 30 Nm (3.1 kgf-m, 22.1 ft-lb) in alphabetical order.
(8) Retighten all bolts to 60 Nm (6.1 kgf-m, 44.3 ft-lb) in alphabetical order.
(9) Retighten all bolts by 80 - 90° in alphabetical order.
(10) Retighten all bolts by 40 - 45° in alphabetical order. Caution: Do not exceed 45°
(11) Retighten bolts (a) and (b) by 40 - 45°. Caution: Do not exceed 45°
CAUTION:
Make sure the total "tightening angle" of steps (10) and (11) does not exceed 90°.
12) Set the A/C compressor bracket to the cylinder head LH, and tighten the bolts in numerical order as shown in the figure.
Tightening torque:
36 Nm (3.7 kgf-m, 26.6 ft-lb)
13) Install the cam carrier LH.
14) Install the rocker cover LH.
15) Install the chain cover.
16) Install the tumble generator valve assembly LH.
17) Install the intake manifold.
18) Install the engine to the vehicle.