EM-226
< SERVICE INFORMATION >[VK45DE]
CYLINDER HEAD
CYLINDER HEAD
On-Vehicle ServiceINFOID:0000000001325796
CHECKING COMPRESSION PRESSURE
1. Warm up engine thoroughly. Then, stop it.
2. Release fuel pressure. Refer to
EC-665, "
Fuel Pressure Check".
a. Remove fuel pump fuse to avoid fuel injection during measure- ment.
3. Remove engine cover with power tool. Refer to EM-169, "
Component".
4. Remove ignition coil and spark plug from each cylinder. Refer to EM-187, "
Component" and EM-188,
"Component".
5. Connect engine tachometer (not required in use of CONSULT-III).
6. Install compression gauge with adapter (SST or commercial ser- vice tool) onto spark plug hole.
Use compression gauge adapter (SST) which is required onNo. 7 and 8 cylinders.
Use compression gauge adapter (if no SST is used) whose picking up end inserted to spark plug hole is smaller than 20
mm (0.79 in) in diameter. Otherwise, it may be caught by cylin-
der head during removal.
7. With accelerator pedal fully depressed, turn ignition switch to “START” for cranking. When the gauge pointer stabilizes, read the compression pressure and engine rpm. Perform these steps to check each cyl-
inder.
Compression pressure:
Unit: kPa (kg/cm2, psi)/rpm
CAUTION:
Always use a fully changed battery to obtain the specified engine speed.
PBIB1482E
PBIC1554E
SBIA0533E
Standard Minimum Deferential limit between cylinders
1,320 (13.5, 191)/300 1,130 (11.5, 164)/300 98 (1.0, 14)/300
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CYLINDER HEADEM-227
< SERVICE INFORMATION > [VK45DE]
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If the engine speed is out of specified range, check
battery liquid for proper gravity. Check engine speed
again with normal battery gravity.
If compression pressure is below minimum value, check valve clearances and parts associated with
combustion chamber (valve, valve seat, piston, pi ston ring, cylinder bore, cylinder head, cylinder head
gasket). After the checking, measure compression pressure again.
If some cylinders have low compression pressure, pour small amount of engine oil into the spark plug
hole of the cylinder to re-check it for compression.
- If the added engine oil improves the compression, piston rings may be worn out or damaged. Check the piston rings and replace if necessary.
- If the compression pressure remains at low level despite the addition of engine oil, valves may be mal- functioning. Check valves for damage. Repl ace valve or valve seat accordingly.
If two adjacent cylinders have respectively low compression pressure and their compression remains low even after the addition of engine oil, cylinder head gaskets are leaking. In such a case, replace cyl-
inder head gaskets.
8. After inspection is completed, install removed parts in the reverse order of removal.
9. Start engine, and make sure that engine runs smoothly.
10. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-666, "
Trouble Diagnosis Introduction".
ComponentINFOID:0000000001325797
Removal and InstallationINFOID:0000000001325798
REMOVAL
1. Remove engine assembly from vehicle. Refer to EM-237, "Component".
2. Remove exhaust manifold. Refer to EM-179, "
Component".
3. Remove camshaft. Refer to EM-211, "
Component".
1. Engine coolant temperature sensor 2. Washer 3. Cylinder head gasket (left bank)
4. Harness bracket 5. Cylinder head (right bank) 6. Cylinder head bolt
7. Cylinder head gasket (right bank) 8. Cylinder head bolt 9. Cylinder head (left bank)
PBIC2756E
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EM-228
< SERVICE INFORMATION >[VK45DE]
CYLINDER HEAD
4. Remove cylinder head bolts in reverse order as shown in the fig-
ure with cylinder head bolt wrench (commercial service tool) to
remove cylinder heads (right and left banks).
5. Remove cylinder head gaskets.
INSPECTION AFTER REMOVAL
Cylinder Head Bolt s Outer Diameter
Cylinder head bolts are tightened by plastic zone tightening
method. Whenever the size difference between “d1” and “d2”
exceeds the limit, replace them with new one.
If reduction of outer diameter appear s in a position other than “d2”,
use it as “d2” point.
Cylinder Head Distortion
NOTE:
When performing this inspection, cylinder block distortion should be also checking. Refer to EM-256, "
Inspec-
tion After Disassembly".
1. Using scraper, wipe off oil, scale, gasket, s ealant and carbon deposits from surface of cylinder head.
CAUTION:
Do not allow gasket fragme nts to enter engine oil or engine coolant passages.
2. At each of several locations on bottom surface of cylinder head, measure the distortion in six directions.
If it exceeds the limit, replace cylinder head.
INSTALLATION
1. Install new cylinder head gasket.
2. Turn crankshaft until No. 1 piston is set at TDC.
PBIC0068E
Limit (“d1” – “d2”) : 0.18 mm (0.0071 in)
PBIC2361E
Limit : 0.1 mm (0.004 in)
PBIC0075E
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CYLINDER HEADEM-229
< SERVICE INFORMATION > [VK45DE]
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Crankshaft key should line up with the left bank cylinder center
line as shown in the figure.
3. Install cylinder head follow the steps below to tighten cylinder head bolts in numerical order as shown in the figure with cylin-
der head bolt wrench (commercial service tool).
CAUTION:
If cylinder head bolts are re -used, check their outer diame-
ters before installation. Refer to "Cylinder Head Bolts Outer
Diameter".
a. Apply new engine oil to threads and seating surface of cylinder head bolts.
b. Tighten all cylinder head bolts.
c. Completely loosen all cylinder head bolts.
CAUTION:
In step “c”, loosen cylinder head bolts in reverse order of that indicated in the figure.
d. Tighten all cylinder head bolts.
e. Turn all cylinder head bolts 60 degrees clockwise. (Angle tight- ening)
CAUTION:
Check the tightening angle by using angle wrench (SST).
Avoid judgment by visual inspection without SST.
Check tightening angle indicated on angle wrench indicator plate.
f. Turn all cylinder head bolts 60 degrees clockwise again. (Angle tightening)
4. Install in the reverse order of removal.
Disassembly and AssemblyINFOID:0000000001325799
COMPONENTS
PBIC2389E
: 98.1 N·m (10 kg-m, 72 ft-lb)
: 0 N·m (0 kg-m, 0 ft-lb)
: 44 N·m (4.5 kg-m, 32 ft-lb)
PBIC0068E
PBIC0069E
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EM-234
< SERVICE INFORMATION >[VK45DE]
CYLINDER HEAD
3. Using valve guide reamer (commercial service tool), ream cylin-
der head valve guide hole.
4. Heat cylinder head to 110 to 130 °C (230 to 266 °F) by soaking in
heated oil.
5. Using valve guide drift (commercial service tool), press valve guide from camshaft side to the dimensions as in the figure.
CAUTION:
Cylinder head contains heat . When working, wear protec-
tive equipment to avo id getting burned.
6. Using valve guide reamer (commercial service tool), apply reamer finish to valve guide.
VALVE SEAT CONTACT
After confirming that the dimensi ons of valve guides and valves are
within the specifications, perform this procedure.
Apply prussian blue (or white lead) onto contacting surface of valve
seat to check the condition of the valve contact on the surface.
Check if the contact area band is continuous all around the circum- ference.
If not, grind to adjust valve fitting and check again. If the contacting surface still has “NG” conditions even after the re-check, replace
valve seat. Refer to "VALVE SEAT REPLACEMENT". Valve guide hole diameter (for service parts):
Intake and exhaust: 10.175 - 10.196 mm (0.4006 - 0.4014 in)
SEM932C
SEM008A
PBIC0078E
Standard: Intake and exhaust: 6.000 - 6.018 mm (0.2362 - 0.2369 in)
SEM932C
SBIA0322E
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CYLINDER HEADEM-235
< SERVICE INFORMATION > [VK45DE]
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VALVE SEAT REPLACEMENT
When valve seat is removed, replace with
oversized [0.5 mm (0.020 in)] valve seat.
1. Bore out old seat until it collapses. Boring shoul d not continue beyond the bottom face of the seat recess
in cylinder head. Set the machine depth stop to ensure this. Refer to EM-266, "
Standard and Limit".
CAUTION:
Prevent to scratch cylinder head by excessive boring.
2. Ream cylinder head recess diameter for service valve seat.
Be sure to ream in circles concentric to valve guide center.This will enable valve to fit correctly.
3. Heat cylinder head to 110 to 130 °C (230 to 266 °F) by soaking in
heated oil.
4. Provide valve seats cooled well with dry ice. Force fit valve seat into cylinder head. CAUTION:
Avoid directly touching cold valve seats.
Cylinder head contains heat. Wh en working, wear protective equipment to avoid getting burned.
5. Using valve seat cutter set (commercial service tool) or valve seat grinder, finish seat to the specified dimensions. Refer to
EM-266, "
Standard and Limit".
CAUTION:
When using valve seat cutter, firmly grip cutter handle with
both hands. Then, press on the contacting surface all
around the circumference to cu t in a single drive. Improper
pressure on with cutter or cu tting many different times may
result in stage valve seat.
6. Using compound, grind to adjust valve fitting.
7. Check again for normal contact. Refer to "VALVE SEAT CONTACT".
VALVE SPRING SQUARENESS
Oversize (Service) [0.5 mm (0.020 in)] Intake : 37.500 - 37.516 mm (1.4764 - 1.4770 in)
Exhaust : 32.700 - 32.716 mm (1.2874 - 1.2880 in)
SEM795A
SEM008A
SEM934C
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EM-238
< SERVICE INFORMATION >[VK45DE]
ENGINE ASSEMBLY
1. Release fuel pressure. Refer to
EC-665, "Fuel Pressure Check".
2. Drain engine coolant from radiator. Refer to CO-37, "
Changing Engine Coolant".
CAUTION:
Perform this step when engine is cold.
Do not spill engine coolant on drive belts.
3. Disconnect both battery terminal. Refer to SC-4, "
How to Handle Battery".
4. Remove crankshaft position sensor (POS) from transmission. CAUTION:
Handle carefully to avoid dropping and shocks.
Do not disassemble.
Do not allow metal powder to adhere to magnetic part at sensor tip.
Do not place sensors in a location wh ere they are exposed to magnetism.
5. Remove the following parts: Hood assembly: Refer to BL-13, "
Fitting Adjustment".
Engine cover: Refer to EM-169
.
Front and rear engine undercover
Air duct (inlet), air duct and air cleaner case assembly: Refer to EM-173, "
Component".
Drive belts: Refer to EM-170, "
Component".
Radiator and radiator hoses (upper and lower): Refer to CO-40, "
Component".
Front road wheels and tires
Engine Room LH
1. Disconnect engine room harness from the engine side and set it aside for easier work.
2. Disconnect heater hoses, and install plugs to avoid leakage of engine coolant.
3. Disconnect ground cable from exhaust manifold cover to vehicle.
4. Disconnect vacuum hose between vehicle and engine and set it aside.
5. Discharge refrigerant from A/C circuit. Refer to ATC-120, "
HFC-134a (R-134a) Service Procedure".
6. Remove A/C piping from A/C compressor, and temporarily fasten it on vehicle with a rope. Refer to AT C -
121, "Component".
Engine Room RH
1. Disconnect fuel feed hose and EVAP hose. Refer to EM-190, "Component".
CAUTION:
Fit plugs onto disconnected hose to prevent fuel leak.
2. Disconnect engine room harness from the engine side and set it aside for easier work.
3. Disconnect ground cable from exhaust manifold cover to vehicle.
4. Disconnect vacuum hose between vehicle and engine and set it aside.
5. Disconnect reservoir tank of power steering oil pum p from engine, and move it aside for easier work.
CAUTION:
When temporarily securing, keep reservoir tank upright to avoid a fluid leak.
Vehicle Underbody
1. Remove front cross bar. Refer to FSU-5, "On-Vehicle Inspection and Service".
2. Disconnect power steering oil pump from engine. Move it from its location and secure with a rope for eas-
ier work. Refer to PS-29, "
Removal and Installation (VK45DE Models)".
3. Remove A/T fluid cooler tube. Refer to AT-241, "
Removal and Installation (2WD Models)".
4. Remove exhaust front tube and center muffler with power tool. Refer to EX-3, "
Checking Exhaust Sys-
tem".
5. Remove RH and LH transverse link mounting bolts and nuts. Refer to FSU-13, "
Removal and Installation".
6. Disconnect stabilizer connecting rod lower. Refer to FSU-5, "
On-Vehicle Inspection and Service".
7. Remove A/T control rod at control device assembly side. Then temporarily secure it on transmission, so
that it does not sag. Refer to AT-205, "
Control Device Removal and Installation".
8. Remove rear plate cover from oil pan. Then remove bolts fixing drive plate to torque converter. Refer to EM-183, "
Component" and AT-241, "Removal and Installation (2WD Models)".
9. Remove transmission joint bolts which pierce at oil pan lower rear side. Refer to AT-241, "
Removal and
Installation (2WD Models)".
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EM-240
< SERVICE INFORMATION >[VK45DE]
ENGINE ASSEMBLY
Avoid damage to and oil/grease smearing or
spills onto engine mounting insulator.
4. Remove alternator. Refer to SC-19, "
System Description".
5. Remove starter motor. Refer to SC-8, "
System Description".
6. Separate engine from transmission assembly. Refer to AT-243, "
Removal and Installation (AWD Models)".
7. Remove front final drive from engine. Refer to FFD-14, "
Removal and Installation (VQ35DE Models)".
8. Remove engine mounting insulators (RH and LH) and brackets (RH and LH) from engine with power tool.
9. Remove engine rear member and engine mounting insulator (rear) from transmission.
INSTALLATION
Note the following, and install in the reverse order of removal.
Do not allow engine mounting insulator to be damage and careful no engine oil gets on it.
For a location with a positioning pin, insert it securely into hole of mating part.
For a part with a specified installation orientation, refer to component figure in "Removal and Installation".
When installing engine mounting brackets (RH and LH) on cylinder
block, tighten two upper bolts (show n as “A” in the figure) first.
Then tighten two lower bolts (shown as “B” in the figure).
INSPECTION AFTER INSTALLATION
Inspection for Leaks
The followings are procedures for checking fluids leak, lubricates leak and exhaust gases leak.
Before starting engine, check oil/fluid levels incl uding engine coolant and engine oil. If less than required
quantity, fill to the specified level. Refer to MA-9, "
Fluids and Lubricants".
Use procedure below to check for fuel leakage.
- Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leak-
age at connection points.
- Start engine. With engine speed increased, che ck again for fuel leakage at connection points.
Run engine to check for unusual noise and vibration.
Warm up engine thoroughly to make sure there is no leak age of fuel, exhaust gases, or any oil/fluids includ-
ing engine oil and engine coolant.
Bleed air from lines and hoses of applic able lines, such as in cooling system.
After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary.
Summary of the inspection items:
*: Transmission/transaxle/CVT fluid. power steering fluid, brake fluid, etc.
PBIC2365E
Items Before starting engine Engine running After engine stopped
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Other oils and fluid* Level Leakage Level
Fuel Leakage Leakage Leakage
Exhaust gases — Leakage —
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