Cylinder Head Assembly: Service and Repair

REMOVAL AND INSTALLATION





















REMOVAL SERVICE POINTS

[[A]] FUEL HIGH-PRESSURE HOSE REMOVAL





1. Remove the stopper of the fuel high-pressure hose.





2. Raise the retainer of the fuel high-pressure hose and pull out the fuel high-pressure hose in the direction shown in the figure.
NOTE:
If the retainer is released, install it securely after removing the fuel high-pressure hose.

[[B]] CYLINDER HEAD BOLT/CYLINDER HEAD BOLT ASSEMBLY REMOVAL





Loosen and remove the bolts in two or three steps in the order of number shown in the figure.

INSTALLATION SERVICE POINTS

]]A[[ CYLINDER HEAD GASKET/CYLINDER HEAD ASSEMBLY INSTALLATION





1.
CAUTION:
Do not allow any foreign materials get into the coolant passages, oil passages and cylinder.

Wipe off the sealant and grease on the top surface of the cylinder block and the bottom surface of the cylinder head, and degrease the surface where the sealant is applied.





2. Apply the sealant to the top surface of the cylinder block as shown.
Specified sealant: ThreeBond 1217G or equivalent
NOTE:
Install the cylinder head gasket immediately after applying sealant.

3. Install the cylinder head gasket to the cylinder block.
NOTE:
When the cylinder head gasket is installed to the cylinder block, check that the sealant is securely applied to the bead line of the cylinder head gasket.

4. Apply the sealant to the top surface of the cylinder head gasket as shown.
Specified sealant: ThreeBond 1217G or equivalent
NOTE:
Install the cylinder head assembly immediately after applying sealant.

5.
CAUTION:
After the installation, until a sufficient period of time (one hour or more) elapses, do not apply the oil or water to the sealant application area or start the engine.

Install the cylinder head assembly.

]]B[[ CYLINDER HEAD BOLT ASSEMBLY/CYLINDER HEAD BOLT INSTALLATION

1. Replace a cylinder head bolts with a new one.

2. For two bolts of the timing chain side, the washer can be removed from the bolt. Install the washer, with its sag facing upward, to the bolts.

3. Apply a small amount of engine oil to the cylinder head bolt threads and the washers.









4. Tighten the cylinder head bolts by the following procedure (plastic region angular tightening method).
(1) Tighten the cylinder head bolts to the specified torque in the order shown in the figure in two or three steps.
Tightening torque: 35± 2Nm (26± 1 ft-lb)
(2)

CAUTION:

- When the tightening angle is smaller than the specified tightening angle, the appropriate tightening capacity cannot be secured.
- When the tightening angle is larger than the specified tightening angle, remove the bolt to start from the beginning again according to the procedure.

Apply paint marks to the head of cylinder head bolt and the cylinder head.
(3) Tighten the cylinder head to 90 degrees angle in the tightening order. Additionally tighten to 90 degrees angle, and check that the paint mark on the cylinder head bolt is aligned with the paint mark on the cylinder head.

]]C[[ FUEL HIGH-PRESSURE HOSE INSTALLATION





CAUTION:
After connecting the fuel high-pressure hose, slightly pull it in the pull-out direction to check that it is installed firmly. In addition, check that there is approximately 1 mm (0.04 inch) play. After the check, install the stopper securely.