Cylinder Heads

Cylinder Head





Special Tool(s)





Material

Disassembly





1. Remove the camshaft position (CMP) sensor.





2. CAUTION: Do not pull on the ignition wires directly, as wires may separate from the connector inside the boot.

Disconnect the spark plug wires.





3. NOTE: If an original spark plug is reused, install it in the same cylinder from which it was removed. New spark plugs may be installed in any cylinder.

Remove the spark plugs.





4. Using the special tool remove the camshaft timing belt pulley.





5. CAUTION: Use care not to drop any components.

Remove the intake manifold and IMRC.
^ Discard the gaskets.





6. NOTE: Remove the nuts evenly. Remove the exhaust manifold.
^ Discard the gasket.





7. Remove the water outlet connection, thermostat and gasket.





8. Remove the ignition coil, ignition coil bracket and wires as one assembly.





9. Remove the rocker arms.





10. NOTE: Always return the valve tappets to their original tappet bores unless new tappets are being installed.

Remove the valve tappet(s).
1. Remove the valve tappet guide plate retainers.
2. Remove the valve tappet guide plates.
3. Remove the valve tappets.





11. Remove the camshaft thrust plate.





12. Using the special tool, remove the camshaft front oil seal.





13. NOTE: The camshaft can be removed in either direction.

Remove the camshaft.





14. NOTE: Keep the components in order for reassembly.

Using the special tool, compress the valve spring and remove the valve spring retainer key and the valve spring.
15. Slowly remove the special tool.





16. Remove the valves.





17. Remove and discard the valve stem seals.

Assembly





1. install the valve seals.





2. NOTE: If installing the original valves, make sure, that the valves are installed in the position from which they were removed. Coat the valve stems with engine oil before installation.

Install the exhaust and intake valves.





3. Using special tool, compress the valve spring and install the valve spring retainer.





4. NOTE: Lubricate the camshaft lobes and bearing surfaces with heavy engine oil (SG grade).

NOTE: Inspect for the presence of a clogged oil gallery. Verify that the camshaft contains the camshaft oil flow control rod and the rear end has a cup plug installed prior to the installation of the camshaft.

Install the camshaft.
5. Apply a thin film of light engine oil to the lip of the camshaft front seal.





6. NOTE: The seal depth should be 0.05-0.0 mm below flush with the cylinder head front face.

Using the special tool, install the camshaft front seal.





7. Install the camshaft thrust plate.





8. CAUTION: Color codes on valve tappets must index with oil feed holes in the cylinder head.

Install the valve tappets using Hypoid oil.
1. Install the valve tappets.
2. Install the valve tappet guide plates.
3. Install the valve tappet guide retainers.





9. Install the rocker arms.





10. Install the coil bracket, coil and spark plug wires.





11. NOTE: Inspect the water outlet connection gasket. Install a new gasket if it is cracked, torn, or damaged.

Install the water outlet connection.





12. NOTE: Tighten the bolts evenly.

Install the exhaust manifold.
^ Use a new gasket.





13. Install a new gasket and the intake manifold.
^ Tighten the nuts and bolts to 10 Nm and 90 degrees.





14. Using the special tool. Install the camshaft timing belt pulley.





15. Install the spark plugs (shown with engine removed).





16. CAUTION: Use a blunt object (for example plastic cable tie) to apply the silicone grease, to avoid damaging the spark plug connector seal.

CAUTION: Push on the spark plug connector in a straight movement.

NOTE: Coat the inside of the spark plug connector with silicone grease to a depth of 5-10 mm.

Push on the spark plug connector until it engages.





17. Install the CMP sensor.