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 and exhaust camshaft.
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:
^ Exhaust manifold:
^ Fuel injector:
^ Water outlet cap:
^ Oil venturi plug:

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

CAUTION:
Check them for deformation if cylinder head bolts No.1 are reused.

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 degrees 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 degrees in the same manner as in Step c).
f) Retighten them to 80 degrees 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 kg-m, 18.5 lbf-ft)





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