1. Cylinder head assembly; 2. Cylinder head bolt; 3. Washer; 4. Cylinder head auxiliary bolt; 5. Auxiliary cylinder head bolt; 6. Gasket
Removal
1. Relieve the fuel pressure. See chapter Engine management system.
2. Drain the engine coolant. See chapter Lubrication system and engine cooling system.
3. Remove the following components:
- protective cover from the front right wing;
- alternator and air conditioning compressor drive belt; see section "Drive belts";
- air duct and air cleaner assembly; see section "Air purifier and air duct";
- upper part of the intake manifold; see section "Upper part of the intake manifold";
- fuel injectors and fuel pipe assembly; see section "Fuel injectors and fuel line";
- upper and lower radiator hoses; see chapter Lubrication system and engine cooling system;
- generator and generator bracket; see chapter Electrical equipment;
- exhaust manifold and three-way catalytic converter; see section "Exhaust manifold and three-way catalytic converter";
- ignition coils; see section "Ignition coil";
- valve cover; see section "Valve cover";
- camshaft; see section "Camshaft";
- heated oxygen sensor wiring bracket; see section "Exhaust manifold and three-way catalytic converter";
- outlet pipe, thermostat, engine coolant temperature sensor and heater pipe; see chapter Lubrication system and engine cooling system;
- suction tube mounting bolt; see chapter Lubrication system and engine cooling system.
Caution: Secure the engine to the bottom of the oil pan.
4. Remove the cylinder heads as an assembly by loosening the bolts in the reverse order to that shown in the figure.
5. Remove the gasket from the cylinder head
Check after removal
Outside diameter of cylinder head bolts
The cylinder head bolts are tightened using the plastic zone method. If the difference between "d1" and "d2" exceeds the limit value, replace the bolts with new ones.
Limit (d1-d2): 0.12 mm.
If the outside diameter narrowing is found at a location other than "d2", mark it as point "d2".
Installation
1. Apply sealant evenly to the areas shown in the figure and install a new gasket on the head.
Use brand name sealant or equivalent.
2. Install the cylinder head assembly and tighten bolts No.1-10 in the order shown by the numbers in the figure.
Note: In step "c", loosen the bolts in the reverse order to that shown in the figure.
Note: Bolts No.11-13 should be tightened in step 3 after tightening bolts No.1-10.
- a. Apply fresh engine oil to the threads and bolt seating surfaces.
- b. Tighten the bolts to 61.7-71.7 N·m (6.3-7.3 kg·m).
- c. Loosen completely to 0 Nm (0 kg·m).
- d. Tighten the bolts to 22.5-32.5 N·m (2.3-3.3 kg·m).
- e. Tighten the bolts 90-95° clockwise (standard: 90°) (tightening at an angle).
Note: Check the tightening angle with a protractor wrench (special tool). Avoid eyeballing without using tools.
Check the tightening angle using the scale of the protractor wrench.
3. Tighten the auxiliary bolts (No. 11-13) in the order indicated by the numbers in the figure.
4. After this operation, installation is carried out in the reverse order of removal.