Cylinder Head Sub-Assembly
REPLACEMENT1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
2. DRAIN COOLANT
3. DRAIN ENGINE OIL
4. REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET
5. REMOVE EXHAUST PIPE ASSY FRONT
6. REMOVE EXHAUST MANIFOLD SUB-ASSY RH
7. REMOVE V-BANK COVER SUB-ASSY
8. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER)
9. REMOVE AIR CLEANER ASSEMBLY WITH HOSE
10. REMOVE INTAKE AIR SURGE TANK
11. DISCONNECT FUEL PIPE SUB-ASSY NO.1
12. DISCONNECT HEATER INLET WATER HOSE
13. REMOVE INTAKE MANIFOLD
a. Disconnect the injector connectors.
b. Remove the 9 bolts, 2 nuts and intake manifold with delivery pipe.
14. DISCONNECT RADIATOR HOSE INLET
15. REMOVE WATER OUTLET
a. Disconnect the water temperature sensor connector and grand cable.
b. Remove the 2 bolts and 2 nuts.
c. Disconnect the water bypass hose, and remove the water outlet.
d. Remove the 2 gaskets.
16. REMOVE FRONT WHEEL RH
17. REMOVE FRONT FENDER APRON SEAL RH
18. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
19. REMOVE VANE PUMP V BELT
20. REMOVE ENGINE MOVING CONTROL ROD
21. REMOVE ENGINE MOUNTING STAY NO.2 RH
22. REMOVE GENERATOR BRACKET NO.2
23. REMOVE CRANKSHAFT PULLEY
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09954-05030)
24. REMOVE TIMING BELT NO.1 COVER
25. REMOVE TIMING BELT NO.2 COVER
26. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
27. REMOVE TIMING BELT GUIDE NO.2
28. REMOVE TIMING BELT
29. REMOVE TIMING BELT IDLER SUB-ASSY NO.2
30. REMOVE CAMSHAFT TIMING PULLEY
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
31. REMOVE TIMING BELT NO.3 COVER
32. REMOVE VANE PUMP ASSY
33. REMOVE IGNITION COIL ASSY
34. REMOVE CYLINDER HEAD COVER SUB-ASSY
35. REMOVE CAMSHAFT
36. REMOVE NO.2 CAMSHAFT
37. REMOVE CYLINDER HEAD SUB-ASSY
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 no to drop washers into the cylinder head.
- Head warpage or cracking could result from removing bolts in an incorrect order.
38. REMOVE CYLINDER HEAD GASKET
39. INSPECT CYLINDER HEAD SET BOLT
a. Using vernier calipers, measure the tension portion diameter of the bolt.
Standard outside diameter: 8.95 - 9.05 mm (0.3524 - 0.3563 inch)
Minimum outside diameter: 8.75 mm (0.3775 inch)
If the diameter is less than minimum, replace the bolt.
40. INSTALL CYLINDER HEAD GASKET
a. Place a new cylinder head gasket on the cylinder block surface with the R 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.
41. INSTALL CYLINDER HEAD SUB-ASSY
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.)
42. INSTALL NO.2 CAMSHAFT
43. INSTALL CAMSHAFT
44. INSTALL CYLINDER HEAD COVER SUB-ASSY
45. INSTALL IGNITION COIL ASSY
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
46. INSTALL VANE PUMP ASSY
47. INSTALL TIMING BELT NO.3 COVER
48. INSTALL CAMSHAFT TIMING PULLEY
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
49. INSTALL TIMING BELT IDLER SUB-ASSY NO.2
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
50. INSPECT TIMING BELT
51. INSTALL TIMING BELT
SST 09960-10010 (09962-01000, 09963-01000)
52. INSTALL CHAIN TENSIONER ASSY NO.1
53. INSTALL TIMING BELT GUIDE NO.2
54. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
55. INSTALL TIMING BELT NO.2 COVER
56. INSTALL TIMING BELT NO.1 COVER
57. INSTALL CRANKSHAFT PULLEY
SST 0921-54015 (91651-60855), 09330-00021
58. INSTALL GENERATOR BRACKET NO.2
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
59. INSTALL ENGINE MOUNTING STAY NO.2 RH
60. INSTALL ENGINE MOVING CONTROL ROD
61. INSTALL VANE PUMP V BELT
62. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
63. INSPECT DRIVE BELT DEFLECTION AND TENSION (REFERENCE)
64. INSTALL WATER OUTLET
a. Install 2 new gaskets to the cylinder head.
b. Connect the water outlet to the bypass hose.
c. Install the water outlet with the 2 bolts, 2 nuts and 2 plate washers, Alternately tighten the bolts and nuts.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
NOTICE: Do not scratch the seal surface of the water outlet with the stud bolt.
65. INSTALL INTAKE MANIFOLD
a. Install the intake manifold with the 9 bolts, 2 plate washers and 2 nuts.
b. Uniformly tighten the bolts and nuts, in several passes, in the sequence shown.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
c. Retighten the water outlet mounting bolts and nuts.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
66. CONNECT FUEL PIPE SUB-ASSY NO.1
67. INSTALL INTAKE AIR SURGE TANK
68. INSTALL AIR CLEANER ASSEMBLY WITH HOSE
69. CONNECT VACUUM HOSE
70. INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER)
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)
71. INSTALL V-BANK COVER SUB-ASSY
72. INSTALL EXHAUST MANIFOLD SUB-ASSY RH
73. INSTALL EXHAUST PIPE ASSY FRONT
74. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET
75. INSTALL FRONT WHEEL RH
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
76. ADD ENGINE OIL
77. ADD COOLANT
78. INSPECT OIL LEAK
79. CHECK ENGINE COOLANT LEAK
80. INSPECT FUEL LEAK
81. CHECK EXHAUST GAS LEAK
82. INSPECT IGNITION TIMING
SST 09843-18040, 09843-18020
83. INSPECT ENGINE IDLE SPEED
SST 09843-18040
84. INSPECT COMPRESSION
SST 09992-00500
85. INSPECT CO/HC