Cylinder head removal (RZ4E-TC)

1. Inlet cover removal

Refer to "1.Engine 1B.Mechanical(RZ4E-TC) inlet cover removal".

2. Injection pipe removal

1) Clean the injector and injector bracket using an air blower.

2) Remove the injection pipes from the injector and common rail (fuel rail).

Caution

  • Do not reuse the injection pipe.

3. Injector removal

1) Disconnect the connector from the injector.

2) Remove the injector leak-off hose from the injector leak-off pipe and fuel leak-off pipe.

Legend

  1. Injector leak-off hose

3) Remove the clip from the injector.

4) Remove the injector leak-off pipe from the injector.

Caution

  • Do not reuse the injector leak-off pipe or clip.

Legend

  1. Clip
  2. Injector leak-off pipe
  3. Injector

5) Remove the injector clamp from the injector.

Legend

  1. Washer
  2. Injector clamp

6) Clean the injector clamp bolt hole using an air blower.

Caution

  • Do not to allow the intrusion of foreign material.

7) Remove the injector from the cylinder head.

Note

  • Store the removed injectors with the cylinder numbers attached.

Caution

  • Cover the exposed portion to prevent foreign material from getting into the fuel system.
  • Do not damage the injector nozzle.
  • Never touch the electromagnetic section of the injector because it causes performance reduction and breakage.

8) Remove the gasket from the injector.

Caution

  • Do not reuse the gasket.

Legend

  1. Injector
  2. Gasket

4. Air duct removal

1) Remove the intake air duct from the air cleaner and radiator core support.

Legend

  1. Intake air duct
  2. Clip

2) Remove the PCV hose from the cylinder head cover and air duct.

Legend

  1. PCV hose
  2. Clamp

3) Remove the air duct from the air cleaner and turbocharger.

Legend

  1. Air duct

5. Cylinder head cover removal

1) Disconnect the blow-by hose from the cylinder head cover.

2) Disconnect the harness clip from the cylinder head cover.

3) Remove the cylinder head cover and gasket from the cylinder head.

Caution

  • Do not reuse the O-ring or gasket.

4) Remove the oil seal from the cylinder head cover.

6. Air cleaner removal

1) Disconnect the connector from the MAF and IAT sensor.

2) Disconnect the connector from the barometric pressure sensor.

3) Remove the air cleaner from the vehicle.

Legend

  1. Air cleaner
  2. MAF and IAT sensor
  3. Barometric pressure sensor

7. Vacuum hose removal

1) Disconnect the vacuum hose from the turbocharger control solenoid valve.

2) Remove the vacuum hose from the turbocharger and vacuum pipe.

8. Catalytic converter removal

Refer to "1.Engine 1G.Exhaust(RZ4E-TC) catalytic converter removal".

9. Turbocharger water hose disconnect

1) Disconnect the turbocharger water feed hose from the water feed pipe and return pipe.

2) Disconnect the turbocharger water return hose from the water feed pipe and return pipe.

Legend

  1. Turbocharger water feed hose
  2. Turbocharger water return hose

10. Turbocharger oil pipe removal

1) Remove the turbocharger oil pipe and gasket from the turbocharger and cylinder block.

Caution

  • To prevent the intrusion of foreign material, seal the connections.
  • Do not reuse the gasket.

Legend

  1. Turbocharger oil pipe
  2. Gasket

11. Turbocharger bracket removal

1) Remove the turbocharger bracket from the turbocharger and cylinder block.

12. Turbocharger heat protector removal

1) Remove the turbocharger heat protector from the turbocharger.

13. Turbocharger removal

1) Remove the turbocharger and gasket from the exhaust manifold.

Caution

  • To prevent the intrusion of foreign material, seal the connections.
  • Do not reuse the gasket.

2) Remove the water feed and return pipe, as well as the gasket from the turbocharger.

Caution

  • Do not reuse the gasket.

14. Exhaust manifold removal

1) Remove the heat protector from the exhaust manifold.

2) Remove the exhaust manifold and gasket from the cylinder head.

Caution

  • Do not reuse the gasket.

15. Fuel leak-off pipe removal

1) Disconnect the fuel leak-off hose from the fuel leak-off pipe.

2) Remove the fuel leak-off pipe from the common rail (fuel rail) and flywheel housing.

Caution

  • Cover the exposed section to prevent the intrusion of foreign material.

Legend

  1. Fuel leak-off pipe

16. Fuel feed pipe removal

1) Remove the clip from the fuel feed pipe.

2) Remove the fuel feed pipe from the fuel supply pump and common rail (fuel rail).

Caution

  • Do not reuse the fuel feed pipe.
  • Cover the exposed section to prevent the intrusion of foreign material.

Legend

  1. Fuel feed pipe

17. Common rail (fuel rail) removal

1) Remove the bracket from the cylinder head.

2) Disconnect the connector from the FRP sensor.

3) Remove the common rail (fuel rail) from the cylinder head.

Caution

  • Do not hold the FRP sensor.
  • Take care not to damage the connector section of the FRP sensor.

18. Turbocharger control solenoid valve removal

1) Disconnect the vacuum hose from the turbocharger control solenoid valve.

2) Remove the connector from the turbocharger control solenoid valve.

3) Remove the turbocharger control solenoid valve from the bracket.

4) Remove the bracket from the cylinder head.

19. Thermostat housing removal

1) Disconnect the connector from the engine coolant temperature sensor.

2) Remove the thermostat housing from the cylinder head and front cover.

20. Camshaft carrier removal

1) Remove the cam angle sensor rotor from the inlet camshaft.

Note

  • Referring to the diagram, secure the section indicated by the arrow.

Fixing position

2) Turn the crankshaft in the forward direction (clockwise) to align the inlet camshaft and the exhaust camshaft notches to the camshaft cap alignment marks.

Caution

  • Do not rotate the crankshaft until the camshaft carrier is reinstalled.

Legend

  1. Alignment mark
  2. Notch

3) Place the paint marking to the timing chain and camshaft sprocket.

Legend

  1. Camshaft sprocket
  2. Timing chain
  3. Paint marking

4) Remove the timing chain tensioner and gasket from the flywheel housing.

Caution

  • Do not reuse the gasket.

Legend

  1. Timing chain tensioner
  2. Gasket

5) Remove the timing chain from the camshaft sprocket.

6) Disconnect the vacuum hose from the vacuum pump.

7) Remove the camshaft carrier and gasket from the cylinder head.

Caution

  • Do not reuse the gasket.

8) Remove the dowel pin from the cylinder head.

21. Cylinder head removal

1) Disconnect the connector from the CMP sensor.

2) Remove the plug from the cylinder head.

3) Remove the following parts from the cylinder head.

  • Timing chain tension lever
  • Timing chain guide bolt
  • Timing chain lever pivot

Legend

  1. Timing chain tension lever
  2. Timing chain guide bolt
  3. Timing chain lever pivot

4) Remove the cylinder head outside bolts from the cylinder head.

5) Loosen the cylinder head bolts in the order shown in the diagram.

Caution

  • Do not reuse the cylinder head bolts.

6) Remove the cylinder head gasket from the cylinder head.

Caution

  • Do not reuse the cylinder head gasket.
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