Valve and Cylinder Head Removal and Installation

Precautions: General safety (00)

Reference: Valve and Cylinder Head Components:M16A

Removal

1)Remove engine assembly from vehicle.

2)Remove intake manifold.

3)Remove cooling water pipe.

4)Remove oil pan.

5)Remove cylinder head cover.

6)Remove timing chain cover.

7)Remove timing chain.

8)Remove intake camshaft, exhaust camshaft, camshaft bearings shims and tappets.

9)Remove cylinder head bolt (M8) (1).

10)Loosen cylinder head bolts (M10) in numerical order as shown in figure using a 12-point socket wrenches and remove them.

11)Remove cylinder head with exhaust manifold and cylinder head gasket. Use lifting device, if necessary.

12)Remove the following components of cylinder head, if necessary.

•Exhaust manifold:

•Fuel injector:

•Thermostat assembly:

Installation

Reference: Valve and Cylinder Head Disassembly and Reassembly:M16A

1)Clean mating surfaces of cylinder head and cylinder block. Remove oil, old gasket and dust from mating surfaces.

2)Install dowel pins (1) to cylinder block.

3)Install new cylinder head gasket (2) to cylinder block. Triangle mark (3) provided on gasket comes to crankshaft pulley side [A], facing up (toward cylinder head side).

4)Install cylinder head to cylinder block as follows.

NOTE:

•Before placing cylinder head, position crankshaft within “a” range shown in figure.
•Before tightening cylinder head bolts, turn crankshaft counterclockwise 30° – 90° as shown in figure.
•If cylinder head bolt is reused, check bolt for deformation.

“a”:	30°	1.	Key
“b”:	90°

a)Apply engine oil to cylinder head bolts.

b)Tighten cylinder head bolts (M10) to 20 N·m (2.0 kgf-m, 15.0 lbf-ft) in numerical order (“1” – “10”) as shown using a 12-point socket wrenches.

c)In the same manner as in Step b), tighten them to 40 N·m (4.1 kgf-m, 29.5 lbf-ft).

d)Turn all cylinder head bolts (M10) 60° in numerical order as shown in figure.

e)Repeat Step d).

f)Tighten cylinder head bolt (M8) (1) to specified torque.

Tightening torque

Cylinder head bolt (M8) (a): 25 N·m (2.5 kgf-m, 18.5 lbf-ft)
Cylinder head bolt (M10)* (b): 20 N·m → 40 N·m → +60° → +60° (2.0 kgf-m → 4.1 kgf-m → +60° → +60°, 15.0 lbf-ft → 29.5 lbf-ft → +60° →+60°)

5)Install camshafts, tappets and shims.

6)Install timing chain.

7)Install timing chain cover.

8)Install cylinder head cover.

9)Install oil pan.

10)Install fuel injectors, if removed.

11)Install exhaust manifold, if removed.

12)Install thermostat assembly, if removed.