4.
Disconnect the wiring connectors and harness clamps and remove the wiring protector around the intake manifold and cylinder head cover.
Use fender covers to avoid damaging painted surfaces.
To avoid damage, unplug the wiring connectors carefully while holding the connector portion.
Mark all wiring and hoses to avoid misconnection.
Disconnect the battery negative terminal.
Remove the air cleaner assembly.
(Refer to Intake and Exhaust System - "Air Cleaner")
Drain the engine coolant.
(Refer to Cooling System - "Coolant")
Disconnect the wiring connectors and harness clamps and remove the wiring protector around the intake manifold and cylinder head cover.
Disconnect the brake booster vacuum hose (A).
Disconnect the positive crankcase ventilation (PSV) hose (A) and then remove the brake vacuum pipe (B).
Remove the heated oxygen sensor (HO2S).
(Refer to Engine Control / Fuel System - "Heated Oxygen Sensor (HO2S)")
Disconnect the coolant hose (A).
Remove the turbo manifold module heat protector (A).
Tightening torque :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
Remove the turbo charger water pipe (B).
Tightening torque
Water pipe mounting bolt :
9.8 ~ 11.8 N.m (1.0 ~ 1.2 kgf.m, 7.2 ~ 8.7 lb-ft)
Eye bolt :
26.5 ~ 32.4 N.m (2.7 ~ 3.3 kgf.m, 19.5 ~ 23.9 lb-ft)
Remove the heat protector (A) and engine hanger (B).
Tightening torque :
18.6 ~ 23.5 N.m (1.9 ~ 2.4 kgf.m, 13.7 ~ 17.4 lb-ft)
Remove the high pressure fuel pump.
(Refer to Engine Control / Fuel System - "High Pressure Fuel Pump")
Remove the ignition coil.
(Refer to Engine Electrical System - "Ignition Coil")
Remove the cylinder head cover (A) with gasket.
The hardening sealant on the upper area between timing chain cover and cylinder head should be removed before assembling cylinder head cover.
Assemble within 5 minutes of applying sealant.
Bead width : 2.0 ~ 3.0 mm (0.08 ~ 0.12 in.)
Install the cylinder head cover (A) with new head cover gasket.
Do not reuse the cylinder head cover gasket.
Install the cylinder head cover bolts in the following two step method.
Tightening torque
Step 1:
3.9 ~ 5.9 N.m (0.4 ~ 0.6 kgf.m, 2.9 ~ 4.3 lb-ft)
Step 2:
7.8 ~ 9.8 N.m (0.8 ~ 1.0 kgf.m, 5.8 ~ 7.2 lb-ft)
Do not reuse cylinder head cover gasket.
The firing and/or blow out test should not be performed within 30 minutes of assembling the cylinder head cover.
Install the remaining parts in the reverse order of removal.
