Cylinder Head Removal and Installation

Please carefully read "Precaution for Handling Sodium-Filled Valves" and follow the instructions as the exhaust valves contain metal sodium.

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.
Keep the cam chain away from magnetic fields.
The cylinder head bolts can be reused unless there is damage.

7. Intake Air Duct E - Remove
1.
Disconnect the connectors (A).
2.
Remove the harness clamps (B).
3.
USA and Canada models: Disconnect purge tube D.
4.
Remove intake air duct E.

14. Harness Holder Mounting Bolt - Remove

18. High Pressure Fuel Pump Base - Remove
1.
Remove the ground cables (A).
2.
Remove the harness holders (B).
3.
Disconnect the heater hoses (A).
4.
Remove the heater hose bracket (B) and the harness holder bracket (C).
5.
Remove the cam holder cover (A).
6.
Remove the high pressure fuel pump base (A).

23. 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 engine block surfaces.
2.
Install a new coolant separator (A) in the engine block whenever the engine block is replaced.
3.
Install the new cylinder head gasket (B) and the dowel pins (C) on the engine block. Always use a new cylinder head gasket.
4.
Install the cylinder head on the engine block.
When the new cylinder head bolt is installed
5.
Apply new engine oil to the threads and under the bolt heads of all cylinder head bolts.
6.
Torque the cylinder head bolts in sequence to 30 N·m (3.1 kgf·m, 22 lbf·ft) with a beam-type torque wrench if possible. 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 go back to step 5.
7.
After torquing, tighten all cylinder head bolts an additional 165 °, in the numbered sequence shown.
NOTE:
Tighten the cylinder head bolts to the specified angle, using a commercially available angle gauge.
Remove the cylinder head bolt if you tightened it beyond the specified angle and go back to step 5 of the procedure. Do not loosen it back to the specified angle.
When the cylinder head bolt is reused
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 30 N·m (3.1 kgf·m, 22 lbf·ft) with a beam-type torque wrench if possible. 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 go back to step 8.
10.
After torquing, tighten all cylinder head bolts an additional 140 °, in the numbered sequence shown.
NOTE:
Tighten the cylinder head bolts to the specified angle, using a commercially available angle gauge.
Remove the cylinder head bolt if you tightened it beyond the specified angle and go back to step 8 of the procedure. Do not loosen it back to the specified angle.

7. High Pressure Fuel Pump Base - Install
1.
Apply liquid gasket to the cylinder head mating surface of the high pressure fuel pump base and to the inside edge of the threaded bolt holes.
2.
Install the high pressure fuel pump base (A).
3.
Apply liquid gasket to the cylinder head and the high pressure fuel pump base mating surface of the cam holder cover and to the inside edge of the threaded bolt holes.
4.
Install the cam holder cover (A).
5.
Install the harness holder bracket (A) and the heater hose bracket (B).
6.
Connect the heater hoses (C).
7.
Install the harness holders (A).
8.
Install the ground cables (B).

11. Harness Holder Mounting Bolt - Install

18. Intake Air Duct E - Install

2.
USA and Canada models: Connect purge tube D.
3.
Install the harness clamps (A).
4.
Connect the connectors (B).

23. After Installation - Check

1.
After installation, check that all tubes, hoses, and connectors are installed correctly.

25. Fuel Leak (Low Pressure Side) - Check
1.
Turn the vehicle to the ON mode, but do not start the engine. After the fuel pump runs for about 2 seconds, the fuel line will be pressurizesd. Repeat this two or three time, then check for fuel leakage.