Removal and Replacement

CYLINDER HEAD

Exploded View EM-64:

Removal and Installation

REMOVAL

WARNING:
^ Put a "CAUTION: FLAMMABLE" sign in the workshop.
^ Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher.
^ Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area.

1. Release the fuel pressure.
2. Drain engine coolant and engine oil.
3. Remove front fender protector (RH).
4. Remove drive belt.
5. Remove the following components and related parts.
^ Exhaust manifold
^ Intake manifold
^ Fuel tube and fuel injector assembly
^ Water outlet
^ Rocker cover
^ Front cover, timing chain
^ Camshaft





6. Remove cylinder head.
^ Loosen bolts in reverse order as shown.
<-: Engine front
^ Using TORX socket (size E18), loosen cylinder head bolts.
7. Remove cylinder head gasket.

INSPECTION AFTER REMOVAL
Cylinder Head Bolts Outer Diameter





^ Cylinder head bolts are tightened by plastic zone tightening method. Whenever the size difference between "d1" and "d2" exceeds the limit, replace them with a new one.
Limit ("d1" - "d2"): 0.15 mm (0.0059 in)
^ If reduction of outer diameter appears in a position other than "d2", use it as "d2" point.

Cylinder Head Distortion

NOTE: When performing this inspection, cylinder block distortion should be also checked. Refer to EM-95, "CYLINDER BLOCK TOP SURFACE DISTORTION". Service Limits & General Specifications

1. Wipe off engine oil and remove water scale (like deposit), gasket, sealant, carbon, etc. with a scraper.

CAUTION: Use utmost care not to allow gasket debris to enter passages for engine oil or water.





2. At each of several locations on bottom surface of cylinder head, measure the distortion in six directions using straightedge (A) and feeler gauge (B).
Limit: 0.1 mm (0.004 in)
^ If it exceeds the limit, replace cylinder head.

INSTALLATION
1. Install cylinder head gasket.
2. Apply new engine oil to threads and seating surface of bolts.

CAUTION: If cylinder head bolts re-used, check their outer diameters before installation. Refer to "Cylinder Head Bolts Outer Diameter".





3. Install cylinder head, follow the steps below to tighten cylinder head bolts in numerical order as shown.
Step a: 40 Nm (4.1 kg-m, 30 ft-lb)
Step b: 100° clockwise
Step c: Loosen to 0 Nm in the reverse order of tightening.
Step d: 40 Nm (4.1 kg-m, 30 ft-lb)
Step e: 100° clockwise
Step f: 100° clockwise





<-: Engine front

CAUTION: Check and confirm the tightening angle by using Tool (A) or protractor. Never judge by visual inspection without the tool.

Tool number: KV10112100 (BT-8653-A)
4. Installation of the remaining components is in the reverse order of removal.