Cylinder Head Assembly: Service and Repair

REMOVAL AND INSTALLATION

REMOVAL SERVICE POINTS
[A] POWER STEERING OIL PUMP AND BRACKET ASSEMBLY REMOVAL
Remove the power steering oil pump and bracket assembly from the engine with the hose attached.

NOTE: Place the removed power steering oil pump in a place where it will not be a hindrance when removing and installing the cylinder head assembly, and tie it with a cord.

[B] RADIATOR UPPER HOSE DISCONNECTION





After making mating marks on the radiator hose and the hose clamp, disconnect the radiator hose.

[C] CYLINDER HEAD BOLT REMOVAL





Using the special tool, loosen the bolts in 2 or 3 steps in the order of the numbers, and remove the cylinder head assembly.

CAUTION: Because the plug guides cannot be replaced by themselves, be careful not to damage or deform them when removing the cylinder head bolts.

INSTALLATION SERVICE POINTS
]A[ CYLINDER HEAD GASKET INSTALLATION
1. Wipe off all oil and grease from the gasket mounting surface.
2. Install so that the cylinder head holes match the respective cylinder head gasket holes.

]B[ CYLINDER HEAD BOLT INSTALLATION





1. When installing the cylinder head bolts, the length below the head of the bolts should be within the limit. If it is outside the limit, replace the bolts.
Limit (A): 96.4 mm (3.80 inch)
2. The head bolt washer should be installed with the burred side, caused by tapping out, facing upwards.
3. Apply a small amount of engine oil to the thread section and the washer of the cylinder head bolt.








4. Using the special tool, tighten the bolts by the above procedure.





CAUTION:
1. Always make a tightening angle just 90°. If it is less than 90°, the head bolt will be loosened.
2. If it is more than 90°, remove the head bolt and repeat the procedure from step 1.

]C[ RADIATOR UPPER HOSE CONNECTION





1. Insert each hose as far as the projection of the water inlet fitting.
2. Align the mating marks on the radiator hose and hose clamp, and then connect the radiator hose.

]D[ HIGH-PRESSURE FUEL HOSE INSTALLATION





1. Apply a small amount of new engine oil to the O-ring.

CAUTION: Do not let any engine oil get into the fuel rail.

2. While turning the high-pressure fuel hose clockwise and counterclockwise, install the fuel rail, be careful not to damage the O-ring. After installing, check that the hose turns smoothly.
3. If the hose does not turn smoothly, the O-ring is probably being pinched. Disconnect the high-pressure fuel hose and check the O-ring for damage. After this, re-insert the fuel rail and check that the hose turns smoothly.