Special tool
 | Protractor 303-174 (21540) |
 | Cylinder Head Bolt Socket Wrench 303-392 (21167) |
General equipment: Rolling jack.
| Name | Specification |
| Coolant | WSS-M97B44-D |
| Spark Plug Grease (Never Seeze) | ESE-M1244-A |
| Sealant for joining camshaft bearing caps to cylinder heads | WSK-M2G348-A2 |
| Motor oil | WSS-M2C912-A1 |
Removal
1. Standard preparatory activities:
- If necessary, use special tool 303-397 to install and remove coolant hoses and vent hoses.
- Open the expansion tank of the cooling system.
2. Relieve fuel system pressure. Refer to Section 310-00 for additional information.
3. Disconnect the ground cable from the battery. For additional information, refer to Section 414-01.
4.
NOTE: Collect coolant and reuse if necessary.
Drain the coolant (shown from below).
- Unscrew and remove the drain plug.
- After draining, replace the drain plug.
5. Remove the engine ground cable and exhaust manifold heat shield.
- 1.Engine ground cable
- 2. Exhaust manifold heat shield (three bolts)
6. Disconnect the exhaust manifold (shown from below) and tie it in place Remove the gasket.
7. Remove the air filter and intake hose.
- 1.Air intake hose.
- 2. Disconnect the mass air flow (MAF) sensor connector.
- Disconnect the crankcase ventilation hose from the cylinder head.
8. Disconnect the accelerator cable.
- 1. Release the clamp.
- 2. Unscrew the cable from the bracket.
9. Disconnect the crankcase ventilation hose.
10. Disconnect the engine wiring harness connector and the camshaft position (CMP) sensor connector.
11. Disconnect the connector.
- 1. Ignition coil (EI)
- 2. Capacitor
12. Disconnect the hoses and release the plug connector.
- 1.Carbon filter solenoid valve vacuum hose
- 2.Knock sensor (KS) plug connector
- 3. Brake booster vacuum hose
13. Remove the coolant and heater hoses.
- 1. Cooling system expansion tank hose
- 2.Heater hose
- 3.Coolant hose
14. Disconnect the carbon filter vacuum line.
15.
WARNING: Fuel leakage. Handle fuel with care.
NOTE: Fuel supply line nipples are painted white or identified by a white ring. Fuel return line nipples are painted red or identified by a red ring.
Disconnect the fuel lines.
16. Remove the camshafts. For more information, refer to the Camshafts chapter in this section.
17. Remove the three lower intake manifold bolts from the cylinder block and disconnect the oil level dipstick tube. Release the knock sensor (KS sensor) connector from the clamp on the oil level dipstick tube.
18.
CAUTION: Allow the cylinder head to cool to below 30°C before removing it.
CAUTION: Place the cylinder head on a soft supporting surface.
NOTE: Release sequence.
Disconnect the cylinder head. Unscrew the cylinder head bolts. Use a special tool.
Installation
1.
NOTE: Tightening sequence.
NOTE: The cylinder head is installed on two guide bushings.
NOTE: Cylinder head bolts can be reused.
Install the cylinder head.
- Make sure all mating surfaces are clean.
- Install a new cylinder head gasket.
- Install the cylinder head, working in four stages in the sequence shown.
- Stage 1: 15 Nm
- Stage 2: 30 Nm
- Stage 3 using special tool 303-174: 90 degrees
2. Install the three lower intake manifold bolts and connect the oil dipstick tube. Secure the knock sensor (KS) connector to the oil dipstick tube.
3. Connect the fuel lines.
4. Install the camshafts. For more information, refer to the Camshafts chapter in this section.
5. Connect the carbon filter vacuum line.
6. Connect the coolant hoses and heater hoses. Use special tool 303-622.
- 1. Cooling system expansion tank hose
- 2.Heater hose
- 3.Coolant hose
7. Connect the hoses and fit the connector.
- 1.Carbon filter solenoid valve vacuum hose
- 2.Knock sensor (KS) plug connector
- 3. Brake booster vacuum hose
8. Connect the connector.
- 1. Ignition coil (EI)
- 2. Capacitor
9. Connect the engine wiring harness plug connector and the camshaft position (CMP) sensor plug connector.
10. Connect the PCV hose.
11. Connect the accelerator cable.
- 1. Fix the clamp.
- 2. Secure the cable to the bracket.
12. Install the air filter together with the inlet hose.
- 1.Air intake hose
- 2.Mass Air Flow (MAF) Sensor Connector
- Connect the crankcase ventilation hose to the cylinder head cover.
13.
NOTE: Use a new exhaust manifold gasket.
Connect the exhaust manifold (shown from below).
14. Connect the exhaust manifold heat shield and engine ground cable.
- 1. Exhaust manifold heat shield (three bolts)
- 2.Engine ground cable
15. Standard finishing operations:
- Change the oil (and oil filter).
- Connect the ground cable to the battery. Refer to Section 414-01 for additional information.
- Add coolant to the cooling system. Refer to Section 303-03 for additional information.
- Remove air from the fuel supply system.
- Check the engine and cooling system for leaks (visual inspection).
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