Cylinder Head Removal and Installation

NOTE:
Use fender covers to avoid damaging painted surfaces.
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
Connect the HDS to the DLC, and monitor ECT SENSOR 1. To avoid damaging the cylinder head, wait until the engine coolant temperature drops below 100 °F (38 °C) before loosening the cylinder head bolts.
Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring or hoses, or interfere with other parts.

1. Fuel Pressure - Relieve

Relieve the fuel pressure.

2. Battery Terminal - Disconnect

Do the battery terminal disconnection procedure.

3. Engine Coolant - Drain

Drain the engine coolant.

4. Intake Manifold - Remove

Remove the intake manifold.

5. Warm Up TWC - Remove

Remove the warm up TWC.

6. High Pressure Fuel Pump - Remove

Remove the high pressure fuel pump.

7. Cylinder Head Cover - Remove

Remove the cylinder head cover.

8. Thermostat Housing - Remove

Remove the thermostat housing.

9. Cam Chain - Remove

Remove the cam chain.

10. Rocker Arm Assembly - Remove

Remove the rocker arm assembly.

11. Cylinder Head - Remove
1.
Remove the cylinder head bolts. To prevent warpage, loosen the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened.
2.
Remove the cylinder head.

1. Cylinder Head - Install
1.
Clean the cylinder head and the engine block surface.
2.
Install a new coolant separator (A) in the engine block whenever the engine block is replaced.
3.
Install a new cylinder head gasket (A) and the dowel pins (B) on the engine block. Always use a new cylinder head gasket.
4.
Set the crankshaft to top dead center (TDC). Align the TDC mark (A) on the crankshaft sprocket with the pointer (B) on the engine block.
5.
Install the cylinder head on the engine block.
6.
Measure the diameter of each cylinder head bolt at point A and point B.
7.
If either diameter is less than 10.6 mm (0.417 in), replace the cylinder head bolt.
8.
Apply new engine oil to the threads and under the bolt heads of all cylinder head bolts.
9.
Torque the cylinder head bolts in sequence to 40 N·m (4.1 kgf·m, 30 lbf·ft). Use a beam-type torque wrench. When using a preset click-type torque wrench, be sure to tighten slowly and do not overtighten. If a bolt makes any noise while you are torquing it, loosen the bolt and retighten it from the first step.
10.
After torquing, tighten all cylinder head bolts in two steps (90 ° per step) using the sequence shown in step 9. If you are using a new cylinder head bolt, tighten the bolt an extra 90 °.
NOTE: Remove the cylinder head bolt if you tightened it beyond the specified angle, and go back to step 6 of the procedure. Do not loosen it back to the specified angle.

2. Rocker Arm Assembly - Install

Install the rocker arm assembly.

3. Cam Chain - Install

Install the cam chain.

4. Valve Clearance - Adjust

Adjust the valve clearance.

5. Thermostat Housing - Install

Install the thermostat housing.

6. Cylinder Head Cover - Install

Install the cylinder head cover.

7. High Pressure Fuel Pump - Install

Install the high pressure fuel pump.

8. Warm Up TWC - Install

Install the warm up TWC.

9. Intake Manifold - Install

Install the intake manifold.

10. After Installation - Check

After installation, check that all tubes, hoses, and connectors are installed correctly.

11. Battery Terminal - Connect

Do the battery reconnection procedure.

12. Fuel Leak (Low Pressure) - Check

Turn the ignition switch to ON (II), or press the engine start/stop button to select the ON mode, but do not operate the starter. After the fuel pump runs for about 2 seconds, the fuel rail will be pressurized. Repeat this two or three times, then check for fuel leakage.

15. Engine Coolant - Clean

Clean up any spilled engine coolant.

17. Idle Speed - Inspect

Inspect the idle speed.

18. Ignition Timing - Inspect

Inspect the ignition timing.