Contents: Removal the camshaft ↓ Removal the cylinder head ↓ Checking the cylinder head mounting…↓ Installing the cylinder head gasket ↓ Installing the cylinder head ↓ Installing camshafts ↓ Installing the intake manifold ↓
Reduce the pressure in the fuel system.
Remove the clamp from the main wiring harness in the engine compartment.
Fig. 2.198. Fastening the upper outer panel of the hood
Remove 7 mounting bolts and remove the upper outer hood panel (fig. 2.198).
Remove the front right wheel
Remove the lower left engine shield.
Remove the lower engine shield No.1.
Remove the lower right engine shield.
Remove the upper radiator shroud.
Remove the cylinder head cover for bank 2.
Remove the coolant.
Remove the front exhaust pipe assembly.
Fig. 2.199. Manifold bracket mounting bolts
Remove 3 mounting bolts and manifold bracket (fig. 2.199).
Fig. 2.200. Collector bracket mounting bolts No.2
Remove 3 bolts and manifold bracket #2 (fig. 2.200).
Remove the fan and alternator V-belt.
Remove the power steering pump assembly.
Remove the generator assembly.
Remove the right engine mount cushion.
Remove the ignition coil assembly.
Remove the cylinder head cover.
Remove the poly V-belt tensioner assembly.
Remove the right engine mount bracket.
Remove the coolant pump assembly.
Remove the crankshaft angle sensor.
Set the piston of cylinder No.1 to TDC of the compression stroke.
Remove the crankshaft pulley.
Remove chain tensioner No.1 assembly.
Remove the timing chain or belt drive cover.
Remove the timing chain or belt drive cover seal.
Remove the crankshaft position sensor toothed disk.
Remove the tensioner shoe and chain.
Remove chain guide #1.
Disconnect the VSV valve connector.
Disconnect the engine wiring harness clamp.
Fig. 2.201. Fuel vapor discharge hoses No.1 and No.3
Disconnect the fuel vapor removal system hoses #1 and #3 from the VSV valve (fig. 2.201).
Fig. 2.202. Air filter hose fastening clamps No.1
Loosen the 2 clamps and disconnect the air filter hose #1 (fig. 2.202).
Remove the dipstick.
Fig. 2.203. Engine wiring harness fastening clamps
Remove 2 engine wiring harness mounting clamps from the bracket (fig. 2.203).
Fig. 2.204. Throttle actuator motor connector
Disconnect the throttle actuator motor connector (fig. 2.204).
Disconnect the coolant bypass hoses from the throttle body.
Fig. 2.205. Hose connecting the inlet manifold with the fitting
Disconnect the hose from the intake manifold that connects to the fitting (fig. 2.205).
Remove 4 bolts, 2 nuts and 2 clamp brackets.
Fig. 2.206. Intake manifold fastening
Remove the intake manifold and throttle body (fig. 2.206).
Remove the gasket from the intake manifold.
Remove the variable valve timing control oil valve assembly.
Removal the camshaft
Fig. 2.207. The procedure for loosening the bearing cap mounting bolts
In several steps, evenly loosen and unscrew the 19 bearing cap mounting bolts, following the sequence shown in Figure 2.207.
Remove the 9 bearing caps, then remove the 2 camshafts from the cylinder head.
Disconnect the fuel supply line.
Removal the cylinder head
Disconnect the engine wiring harness.
Fig. 2.208. Fuel injector connectors
Disconnect 4 fuel injector connectors (fig. 2.208).
Fig. 2.209. Oil pressure sensor connector
Disconnect the oil pressure sensor connector (fig. 2.209).
Disconnect the crankshaft position sensor connector.
Disconnect the knock sensor connector.
Fig. 2.210. Camshaft position sensor connector
Disconnect the camshaft position sensor connector (fig. 2.210).
Fig. 2.211. Sequence of loosening the cylinder head mounting bolts
Using a 10 mm twelve-sided wrench, loosen and remove the 10 cylinder head mounting bolts evenly in several steps, following the sequence shown in Figure 2.211. Remove the 10 cylinder head mounting bolts and 10 flat washers (fig. 2.211).
Note: Be careful not to let the washers fall into the cylinder head.
If the bolts are removed in the wrong order, the cylinder head may warp or break.
Remove the cylinder head.
Remove the cylinder head gasket.
Checking the cylinder head mounting bolts
Fig. 2.212. Length of bolts under the head
Using a vernier caliper, measure the length of the cylinder head mounting bolts from the seating surface of the head to the end of the threaded section (fig. 2.212).
- Nominal length: 146.8–148.2 mm.
- Maximum length: 148.5 mm.
If the bolt length exceeds the maximum permissible value, replace the cylinder head mounting bolt.
Installing the cylinder head gasket
Fig. 2.213. Cylinder head gasket "Lot No." marking
Install the new cylinder head gasket onto the cylinder block surface with the "Lot No." stamp (Batch number) up (fig. 2.213).
Note: Install the gasket in the correct position.
Install the cylinder head carefully to avoid damaging the gasket.
Installing the cylinder head
Apply a thin coat of engine oil to the threads of the cylinder head bolts.
Note: Tighten the cylinder head bolts in 2 stages.
Fig. 2.214. Sequence of tightening the cylinder head bolts
In several stages, using a 10 mm twelve-sided wrench, evenly tighten the 10 cylinder head mounting bolts with flat washers, acting in the sequence shown in Figure 2.214.
Tightening torque: 49 Nm.
Mark the front side of each of the cylinder head bolts with paint.
Fig. 2.215. Tightening the cylinder head mounting bolts
Tighten the cylinder head mounting bolts by 90° in the sequence specified in the previous procedure (fig. 2.215).
Make sure the marks are rotated 90° from their original position.
Secure the cooling system outlet pipe No.1 with a bolt.
Tightening torque: 9.0 Nm.
Connect the heater inlet hose A.
Connect the radiator inlet hose and engine wiring harness.
Connect the heated oxygen sensor connector.
Connect the 2 engine ground wires.
Connect the radio and additional equipment connector.
Connect the coolant temperature sensor connector.
Connect the camshaft position sensor connector.
Connect the knock sensor connector.
Connect the crankshaft position sensor connector.
Connect the oil pressure sensor connector.
Connect 4 injector connectors.
Connect the fuel supply line.
Installing camshafts
Apply a thin layer of engine oil to the camshaft journals.
Fig. 2.216. Diagram of correct installation of camshafts
Install 2 camshafts into the cylinder head as shown in Figure 2.216.
Fig. 2.217. Sequence of tightening the bearing cap bolts
Check that the marks, which should face the front of the engine, and the cover numbers are correctly positioned, then tighten the bolts in the sequence shown in Figure 2.217.
Tightening torque: 23 Nm for bearing cap No.1, 13 Nm for bearing cap No.3.
Install the variable valve timing control oil valve assembly.
Installing the intake manifold
Install a new gasket on the intake manifold.
Install the intake manifold and throttle body and secure with 2 brackets, 4 bolts and 2 nuts.
Tightening torque: 30 Nm.
Attach the connection hose with the fitting to the intake manifold.
Connect coolant bypass hose #2 to the throttle body.
Connect the coolant bypass hose to the throttle body.
Connect the throttle actuator motor connector.
Install 2 engine wiring harness clamps onto the bracket.
Note: Installation and assembly of the remaining components is carried out in the reverse order of removal.