Removal and Installation

CYLINDER HEAD


Removal and Installation


REMOVAL
1. Remove engine assembly from vehicle, and separate front suspension member and transmission from engine. Refer to Component.
2. Remove the following parts:
- Fuel tube and fuel injector assembly: Refer to Component Removal and Installation.
- Intake manifold: Refer to Component Removal and Installation.
- Exhaust manifold: Refer to Component Removal and Installation.
- Water inlet and thermostat assembly: Refer to Component.
- Water outlet and water pipe: Refer to Component.
- Front and rear timing chain case: Refer to Removal and Installation.
3. Remove camshaft (INT and EXH). Refer to Component Removal and Installation.
4. Remove cylinder head bolts in reverse order as shown in the figure with cylinder head bolt wrench (commercial service tool).





5. Remove cylinder head gaskets.

INSPECTION AFTER REMOVAL

Cylinder Head Bolts Outer Diameter
- Cylinder head bolts are tightened by plastic zone tightening method. Whenever the size difference between (C) and (B) exceeds the limit, replace them with new one.






Limit (C - B) : 0.18 mm (0.0071 in)

- If reduction of outer diameter appears in a position other than (B),
use it as (B) point.

Cylinder Head Distortion

NOTE:
When performing this inspection, cylinder block distortion should be also checked. Refer to Inspection After Disassembly.
1. Using scraper, wipe off oil, scale, gasket, sealant and carbon deposits from surface of cylinder head.

CAUTION:
Never allow gasket fragments to enter engine oil or engine coolant passages.





2. At each of several locations on bottom surface of cylinder head, measure the distortion in six directions (A), (B), (C), (D), (E), and
(F).

Limit : 0.1 mm (0.004 in)

- If it exceeds the limit, replace cylinder head.

INSTALLATION
1. Install new cylinder head gaskets.
2. Turn crankshaft until No. 1 piston is set at TDC.





- Crankshaft key (1) should line up with the bank 1 cylinder center line as shown in the figure.

3. Install cylinder head follow the steps below to tighten cylinder head bolts in numerical order as shown in the figure.

CAUTION:
If cylinder head bolts reused, check their outer diameters before installation. Refer to "Cylinder Head Bolts Outer
Diameter".
a. Apply new engine oil to threads and seat surfaces of cylinder head bolts.
b. Tighten all cylinder head bolts.

Torque: 105 N�m (11 kg-m, 77 ft-lb)






c. Completely loosen all cylinder head bolts.

Torque: 0 N�m (0 kg-m, 0 ft-lb)


CAUTION:
In step "c", loosen bolts in reverse order of that indicated in the figure.
d. Tighten all cylinder head bolts.

Torque: 40.0 N�m (4.1 kg-m, 30 ft-lb)

e. Turn all bolts 95 degrees clockwise (angle tightening).

CAUTION:
Check the tightening angle by using angle wrench [SST:





KV10112100 (BT8653-A)] (A). Avoid judgment by visual inspection without tool.
- Check tightening angle indicated on angle wrench (SST) indicator plate.
f. Turn all bolts 95 degrees clockwise again (angle tightening).





4. After installing cylinder head, measure distance between front end faces of cylinder block and cylinder head (bank 1 and bank
2).

Standard : 14.1 - 14.9 mm (0.555 - 0.587 in)

- If the measured value is out of the standard, reinstall cylinder head.
5. Install in the reverse order of removal after this step.

INSPECTION AFTER INSTALLATION

Inspection for Leakage

The following are procedures for checking fluids leakage, lubricates leakage, and exhaust gases leakage.
- Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level.
- Use procedure below to check for fuel leakage.
- Turn ignition switch "ON" (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points.
- Start engine. With engine speed increased, check again for fuel leakage at connection points.
- Run engine to check for unusual noise and vibration.
- Warm up engine thoroughly to check there is no leakage of fuel, exhaust gases, or any oil/fluids including engine oil and engine coolant.
- Bleed air from lines and hoses of applicable lines, such as in cooling system.
- After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary.