Removal And Installation

CYLINDER HEAD

Removal and Installation


WARNING:
- Put a "CAUTION: FLAMMABLE" sign in the workshop.
- Be sure to work in a well ventilated area and furnish workshop with a fire extinguisher.
- Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area.
NOTE:
When removing components such as hoses, tubes/lines, etc., cap or plug openings to prevent fluid from spilling.

REMOVAL

1.Release the fuel pressure. Testing and Inspection.
2.Drain engine coolant and engine oil.
CAUTION:
- Perform this step when the engine is cold.
- Do not spill engine coolant and engine oil on drive belt.
3.Remove front fender protector (RH).
4.Remove drive belt. Removal And Installation.
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.





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

CAUTION:
Do not allow gasket debris to enter passages for engine oil or engine coolant.





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. Follow the "Cylinder
Head Bolts Outer Diameter" procedure.





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

White arrow indicates : Engine front
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

CAUTION:





Check and confirm the tightening angle by using Tool (A) or protractor. Do not judge by visual inspection without the tool.
Tool number: KV-10112100 (BT-8653-A)

4.Installation of the remaining components is in the reverse order of removal.