Valve and Cylinder Head Removal and Installation

Valve and Cylinder Head Removal and Installation
Reference: Valve and Cylinder Head Components

Removal
1) Remove timing chain.
2) Remove spark plugs.
3) Remove intake camshaft with CMP actuator and exhaust camshaft with timing sprocket.
4) Remove camshaft bearings.
5) Remove heater outlet pipe bolt (1) from cylinder head (2).





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

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





8) Remove cylinder head with its gasket, intake manifold and exhaust manifold from cylinder block.
9) Remove the following components cylinder head if necessary.
^ Intake manifold:
^ Exhaust manifold:
^ Fuel injector:
^ Water outlet cap:
^ Oil venture plug:

Installation
Reference: Valve and Cylinder Head Disassembly and Reassembly
Reference: Cylinder Head Inspection
Reference: Cylinder Head No.1 Bolt Inspection

CAUTION:
If cylinder head No. 1 bolts are reused, check them for deformation.

1) Clean mating surface of cylinder head and cylinder block. Remove oil, old gasket and dust from mating surface.
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 cylinder head to cylinder block, turn crankshaft and position key (1) within specified range (30 - 90°) in counterclockwise direction from top as shown in figure.








a) Install cylinder head to cylinder block.
b) Apply engine oil to cylinder head No. 1 bolts (1) threads.
c) Tighten cylinder head No.1 bolts 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 to cylinder head No.1 bolts.

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

Tightening torque
Cylinder head No.1 bolt * (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 No.2 bolt (2) to specified torque.

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





5) Install intake camshaft and exhaust camshaft.
6) Install timing chain.
7) Install timing chain cover.
8) Install cylinder head cover.
9) Install oil pan.
10) Install water outlet cap if removed.
11) Install heater outlet pipe bolt to cylinder head.
12) Install spark plugs.
13) Install exhaust manifold if removed.
14) Install intake manifold if removed.
15) Install fuel injectors if removed.
16) Install engine assembly.