Removal and Replacement

Valve and Cylinder Head Removal and Installation

Valve and Cylinder Head Components

Removal

1) Remove timing chain. Timing Chain and Chain Tensioner Removal and Installation
2) Remove spark plugs. Spark Plug Removal and Installation
3) Remove intake camshaft and exhaust camshaft. Camshaft and Tappet Removal and Installation
4) Remove camshaft bearings.
5) Remove heater outlet pipe bolt (1) from cylinder head (2).

6) Remove cylinder head bolt No.2 (1).
7) Loosen cylinder head bolts No.1 (2) in numerical order ("1" - "10") evenly and gradually.

NOTE:
Use 12-point socket wrench for cylinder head bolts No.1.

8) Remove cylinder head with gasket, intake manifold and exhaust manifold from cylinder block.
9) Remove following components of cylinder head if necessary.
- Intake manifold: Intake Manifold Removal and Installation
- Exhaust manifold: Exhaust Manifold Removal and Installation
- Fuel injector: Fuel Injector Removal and Installation
- Water outlet cap: [1][2]Cooling System
- Oil venturi plug: Valve and Cylinder Head Disassembly and Reassembly

Installation

Valve and Cylinder Head Disassembly and Reassembly

Cylinder Head Inspection

Cylinder Head Bolt No.1 Inspection

NOTE:

Using cylinder head bolts No. 1 that are deformed exceeding the service limit could lead to engine problems.

When cylinder head bolts No. 1 are reused, make sure that they are not deformed exceeding the service limit referring to Cylinder Head Bolt No.1 Inspection Cylinder Head Bolt No.1 Inspection.

1) Clean mating surface of cylinder head and cylinder block removing old gasket, dust and oil.
2) Install dowel pins (1) to cylinder block.
3) Install new cylinder head gasket (2) to cylinder block.

4) Install cylinder head to cylinder block as follows:

NOTE:
Before Installing the cylinder head to the cylinder block, turn crankshaft counterclockwise and position the key (1) within an angle of 30 to 90° from TDC before rotating the camshaft as shown in the following figure and keep the valves from coming in contact with the pistons.

a) Install cylinder head to cylinder block.
b) Apply engine oil to cylinder head bolts No.1 threads.
c) Tighten cylinder head bolts No.1 to 20 Nm (2.0 kgf-m, 15.0 lbf-ft) in numerical order ("1" - "10") evenly and gradually.

NOTE:
Use 12-point socket wrench for cylinder head bolts No.1.

d) Retighten them to 40 Nm (4.1 kgf-m, 29.5 lbf-ft) in the same manner as in Step c).
e) Retighten them to 60° in the same manner as in Step c).
f) Retighten them to 80° in the same manner as in Step c).

Tightening torque
Cylinder head bolt No.1* (a): (20 Nm -> 40 Nm -> +60� -> +80� (2.0 kgf-m -> 4.1 kgf-m -> +60� -> +80�, 15.0 lbf-ft -> 29.5 lbf-ft -> +60� -> +80�))

g) Tighten cylinder head bolt No.2 (2) to specified torque.

Tightening torque
Cylinder head bolt No.2 (b): 25 Nm (2.5 kgf-m, 18.5 lbf-ft)