Downloaded from www.Manualslib.com manuals search engine 1D-35 Engine Mechanical:
Valves and Cylinder Head Removal and
Installation
S7RS0B1406024
Removal1) Remove engine assembly from vehicle referring to “Engine Assembly Removal and Installation”.
2) Remove oil pan referring to “Oil Pan and Oil Pump
Strainer Removal and Installation in Section 1E”.
3) Remove cylinder head cover referring to “Cylinder Head Cover Removal and Installation”.
4) Remove timing chain cover referring to Steps 2) to 11) of “Removal” in “Tim ing Chain Cover Removal
and Installation”.
5) Remove timing chain referring to Steps 2) to 6) of “Removal” in “Timing Chain and Chain Tensioner
Removal and Installation”.
6) Remove intake and exhaust camshafts referring to Steps 3) to 8) of “Removal” in “Camshaft, Tappet and
Shim Removal and Installation”.
7) Loosen cylinder head bolts in such order as indicated in the figure by using a 12 corner socket
wrenches and remove them.
NOTE
• Don’t forget to remove bolt (M8) (1) as shown in figure.
• Never reuse cylinder head bolts once disassembled it due to plastic deformation
tightening. Be sure to use new cylinder
head bolts when installing.
8) Check all around cylinder head for any other parts required to be removed or disconnected and remove
or disconnect whatever necessary.
9) Remove exhaust manifold, if necessary referring to
“Exhaust Manifold Removal and Installation in
Section 1K”.
10) Remove cylinder head wi th intake manifold and
exhaust manifold. Use lifting device, if necessary. Installation
1) Clean mating surface of cylinder head and cylinder block. Remove oil, old gasket and dust from mating
surface.
2) Install knock pins (1) to cylinder block.
3) Install new cylinder head gasket (2) to cylinder block. “Top” or “Triangle/circle” mark provided on gasket
comes to crankshaft pulley side, facing up (toward
cylinder head side).
4) Make sure that oil jet (venturi plug) (1) is not clogged. If it is not install ed, install it as specified
torque.
Tightening torque
Venturi plug (a): 3.5 N·m (0.35 kgf-m, 3.0 lb-ft)
I2RH0B140088-01
I4RS0B140018-01
I2RH0B140089-01
Downloaded from www.Manualslib.com manuals search engine Engine Mechanical: 1D-64
Honing or Reboring Cylinders1) When any cylinder needs reboring, all other cylinders must also be rebored at the same time.
2) Select oversized piston according to amount of cylinder wear.
Oversize piston specification
Oversize 0.50: 78.453 – 78.468 mm (3.0887 –
3.0893 in.)
3) Using micrometer, measure piston diameter. Measurement position for piston diameter
“a”: 7.0 mm (0.28 in.) 4) Rebore and hone cylinder to the following
dimension.
NOTE
Before reboring, install all main bearing caps
in place and tighten to specification to avoid
distortion of bearing bores.
Cylinder bore diameter to be rebored
Oversize 0.50: 78.500 – 78.514 mm (3.0906 –
3.0911 in.)
5) Measure piston clearance after honing. Piston clearance
0.032 – 0.061 mm (0.0013 – 0.0024 in.)
Specifications
Tightening Torque SpecificationsS7RS0B1407001
I2RH01140157-01
Fastening part Tightening torque
Note
N ⋅mkgf-mlb-ft
Camshaft housing bolt 11 1.1 8.0 )
Cylinder head cover bolt Tighten 3 N ⋅m (0.3 kgf-m, 2.5 lb-ft), 5 N ⋅m
(0.5 kgf-m, 4.0 lb-ft) and 8 N ⋅m (0.8 kgf-m,
6.0 lb-ft) by the specified procedure )
Intake manifold bolt 23 2.3 17.0 )
Intake manifold nut 23 2.3 17.0 )
Intake manifold ground terminal bolt 11 1.1 8.0 )
Engine left mounting bracket nut 55 5.5 40.0 )
Engine right mounting nut 65 6.5 47.0 )
Engine rear mounting bush bolt 55 5.5 40.0 )
Starting motor terminal nut 11 1.1 8.0 )
Generator terminal nut 6 0.6 4.5 )
Intake manifold ground terminal bolt 11 1.1 18.0 )
Timing chain cover bolt 25 2.5 18.0 )
Timing chain cover nut 25 2.5 18.0 )
Cap bolt 25 2.5 18.0 )
Oil gallery pipe No.2 and No.3 bolt 11 1.1 8.0 )
Crankshaft pulley bolt 150 15.0 108.5 )
Oil control valve mounting nut 11 1.1 8.0 )
Oil gallery pipe No.1 bolt 30 3.0 21.5 )
Timing chain No.1 guide bolt 9 0.9 6.5 )
Timing chain tensioner bolt 25 2.5 18.0 )
Timing chain tensioner adjuster bolt 11 1.1 8.0 )
Camshaft housing bolt 5 N ⋅m (0.5 kgf-m, 4.0 lb-ft) and 11 N ⋅m (1.1
kgf-m, 8.0 lb-ft) by the specified procedure )
/ )
Intake cam timing sprocket bolt 60 6.0 43.5 )
Venturi plug 3.5 0.35 3.0 )
Cylinder head bolt for M8 25 2.5 18.0 )
Cylinder head bolt for M10 20 N ⋅m (2.0 kgf-m, 14.5 lb-ft), 40 N ⋅m (4.0
kgf-m, 29.0 lb-ft) and then retighten by
turning through to 60 ° twice )
