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:
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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.


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Detailed information, notes, and precautions
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Replace


NOTE: Remove the necessary part(s).

21. Ground Cable - Remove


22. 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.

23. Cylinder Head Gasket - Remove


24. Dowel Pin - Remove


25. Coolant Separator - Remove



NOTE: enu_12713377_2.0 Where icon is shown, click for further information.


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Detailed information, notes, and precautions
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Torque: N·m (kgf·m, lbf·ft)
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Replace

1. Coolant Separator - Install

NOTE: Install new coolant separator in the engine block whenever the engine block is replaced.

2. Dowel Pin - Install


3. Cylinder Head Gasket - Install

NOTE: Clean the cylinder head and the engine block surface.

4. Cylinder Head - Install
1.
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.
2.
Install the cylinder head on the engine block.
3.
Measure the diameter of each cylinder head bolt at point A and point B.
4.
If either diameter is less than 10.6 mm (0.417 in), replace the cylinder head bolt.
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 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 go back to step 5.
7.
After torquing, tighten all cylinder head bolts in three steps (90 ° per step) in the numbered sequence shown.
NOTE:
Remove the cylinder head bolt if you tightened it beyond the specified angle, and go back to step 3 of the procedure. Do not loosen it back to the specified angle.
Tighten the cylinder head bolts to the specified angle, using a commercially available angle gauge.
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 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 go back to step 8.
10.
After torquing, tighten all cylinder head bolts in three steps (80 ° per step) in the numbered sequence shown.
NOTE:
Remove the cylinder head bolt if you tightened it beyond the specified angle, and go back to step 3 of the procedure. Do not loosen it back to the specified angle.
Tighten the cylinder head bolts to the specified angle, using a commercially available angle gauge.

5. Ground Cable - Install



NOTE: Make sure to review the hose band precautions before installing the charge air cooler pipe(s).

25. After Installation - Check

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

27. 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 pressurized. Repeat this two or three times, then check for fuel leakage.