Cylinder Head Gasket No. 2

REPLACEMENT
1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
2. DRAIN COOLANT
3. DRAIN ENGINE OIL
4. REMOVE MANIFOLD STAY NO.2
5. SEPARATE EXHAUST MANIFOLD CONVERTER SUB-ASSY NO.2
a. Remove the 2 nuts, and separate the exhaust manifold converter from the front exhaust pipe.
6. REMOVE V-BANK COVER SUB-ASSY
7. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER)
8. REMOVE AIR CLEANER ASSEMBLY WITH HOSE
9. REMOVE INTAKE AIR SURGE TANK
10. DISCONNECT FUEL PIPE SUB-ASSY NO.1
11. DISCONNECT HEATER INLET WATER HOSE
12. REMOVE INTAKE MANIFOLD
13. REMOVE RADIATOR HOSE INLET
14. REMOVE WATER OUTLET
15. DISCONNECT RADIATOR HOSE OUTLET
16. REMOVE WATER INLET PIPE
17. REMOVE OIL LEVEL GAGE SUB-ASSY
18. REMOVE OIL LEVEL GAGE GUIDE
19. REMOVE FRONT WHEEL RH
20. REMOVE FRONT FENDER APRON SEAL RH
21. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
22. REMOVE VANE PUMP V BELT
23. REMOVE ENGINE MOVING CONTROL ROD
24. REMOVE ENGINE MOUNTING STAY NO.2 RH
25. REMOVE GENERATOR BRACKET NO.2
26. REMOVE CRANKSHAFT PULLEY
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09954-05030)
27. REMOVE TIMING BELT NO.1 COVER
28. REMOVE TIMING BELT NO.2 COVER
29. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
30. REMOVE TIMING BELT GUIDE NO.2
31. REMOVE TIMING BELT
32. REMOVE TIMING BELT IDLER SUB-ASSY NO.2
33. REMOVE CAMSHAFT TIMING PULLEY
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
34. REMOVE TIMING BELT NO.3 COVER
35. REMOVE IGNITION COIL ASSY
36. REMOVE CYLINDER HEAD COVER SUB-ASSY LH
37. REMOVE NO.3 CAMSHAFT SUB-ASSY
38. REMOVE NO.4 CAMSHAFT SUB-ASSY
39. REMOVE CYLINDER HEAD LH





a. Using an 8 mm hexagon wrench, remove the hexagon bolt.





b. Uniformly loosen the 8 cylinder head bolts, in several passes, in the sequence shown. Remove the 8 cylinder head bolts and plate washers.

NOTICE:
- Be careful not to drop washers into the cylinder head.
- Head warpage or cracking could result from removing bolts in an incorrect order.

40. REMOVE CYLINDER HEAD GASKET NO.2
41. INSPECT CYLINDER HEAD SET BOLT





42. INSTALL CYLINDER HEAD GASKET NO.2
a. Place a new cylinder head gasket on the cylinder block surface with the L mark upward.

NOTICE:
- Remove any oil from the contact surface.
- Be careful of the installation direction.
- Place the cylinder head quietly in order not to damage the gasket at the bottom part of the head.

43. INSTALL CYLINDER HEAD LH

NOTICE: The cylinder head bolts are tightened in 2 progressive steps.

a. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
b. Install the plate washer to the cylinder head bolt.





c. Install and uniformly tighten the 8 cylinder head bolts, in several passes, in the sequence shown.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)





d. Mark the front side of each cylinder head bolt head with paint.
e. Retighten the cylinder head bolts by 90° in the sequence shown.
f. Check that the painted mark is now at a 90° angle to the front.





g. Using an 8 mm socket hexagon wrench, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)
44. INSTALL NO.4 CAMSHAFT SUB-ASSY
45. INSTALL NO.3 CAMSHAFT SUB-ASSY
46. INSTALL CYLINDER HEAD COVER SUB-ASSY LH
47. INSTALL IGNITION COIL ASSY
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
48. INSTALL TIMING BELT NO.3 COVER
49. INSTALL CAMSHAFT TIMING PULLEY
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
50. INSTALL TIMING BELT IDLER SUB-ASSY NO.2
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
51. INSPECT TIMING BELT
52. INSTALL TIMING BELT
SST 09960-10010 (09962-01000, 09963-01000)
53. INSTALL CHAIN TENSIONER ASSY NO.1
54. INSTALL TIMING BELT GUIDE NO.2
55. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
56. INSTALL TIMING BELT NO.2 COVER
57. INSTALL TIMING BELT NO.1 COVER
58. INSTALL CRANKSHAFT PULLEY
SST 09213-54015 (91651-60855), 09330-00021
59. INSTALL GENERATOR BRACKET NO.2
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
60. INSTALL ENGINE MOUNTING STAY NO.2 RH
61. INSTALL ENGINE MOVING CONTROL ROD
62. INSTALL VANE PUMP V BELT
63. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
64. INSPECT DRIVE BELT DEFLECTION AND TENSION (REFERENCE)
65. INSTALL OIL LEVEL GAGE GUIDE
66. INSTALL WATER INLET PIPE
67. INSTALL WATER OUTLET
68. INSTALL INTAKE MANIFOLD
69. CONNECT FUEL PIPE SUB-ASSY NO.1
70. INSTALL INTAKE AIR SURGE TANK
71. INSTALL AIR CLEANER ASSEMBLY WITH HOSE
72. CONNECT VACUUM HOSE
73. INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER)
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)
74. INSTALL V-BANK COVER SUB-ASSY
75. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSY NO.2
a. Install a new gasket and the exhaust manifold converter to the front exhaust pipe.
Torque: 62 Nm (633 kgf-cm, 46 ft. lbs.)
76. INSTALL MANIFOLD STAY NO.2
77. INSTALL FRONT WHEEL RH
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
78. ADD ENGINE OIL
79. ADD COOLANT
80. INSPECT OIL LEAK
81. CHECK ENGINE COOLANT LEAK
82. INSPECT FUEL LEAK
83. CHECK EXHAUST GAS LEAK
84. INSPECT IGNITION TIMING
SST 09843-18040, 09843-18020
85. INSPECT ENGINE IDLE SPEED
SST 09843-18040
86. INSPECT COMPRESSION
SST 09992-00500
87. INSPECT CO/HC