Cylinder Head Gasket

CYLINDER HEAD GASKET
REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE
2. REMOVE CHAIN SUB-ASSY





3. SEPARATE EXHAUST PIPE ASSY FRONT
a. Remove the 2 bolts and 2 compression springs which are installed on the front side of the exhaust pipe.
4. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1
a. Remove the 4 bolts and exhaust manifold heat insulator.





5. REMOVE MANIFOLD SUPPORT BRACKET
a. Remove the 3 bolts and manifold support bracket.
6. REMOVE AIR CLEANER ASSY
7. DISCONNECT ACCELERATOR CONTROL CABLE ASSY
8. REMOVE THROTTLE BODY ASSY
9. DISCONNECT ENGINE WIRE





10. REMOVE WATER FILLER SUB-ASSY
a. Disconnect the radiator inlet hose.
b. Disconnect the radiator hose No.3.
c. Disconnect the radiator reservoir tank hose.
d. Remove the 2 bolts and water filler.





11. REMOVE INTAKE MANIFOLD
a. Using several steps, remove the 3 bolts and 2 nuts in the sequence shown in the illustration, then remove the intake manifold.
b. Remove the gasket from the intake manifold.





12. REMOVE OIL LEVEL GAGE GUIDE
a. Remove the bolt and oil level gage guide.





13. DISCONNECT UNION TO CHECK VALVE HOSE
a. Disconnect the union to check the valve hose for the brake booster.
14. DISCONNECT RADIATOR HOSE INLET
a. Disconnect the radiator hose inlet from the union.
15. DISCONNECT FUEL TUBE SUB-ASSY
SST 09268-21010
16. DISCONNECT HEATER WATER INLET HOSE A
a. Disconnect the heater water inlet hose from the water bypass pipe No.2.





17. SEPARATE WATER BYPASS PIPE NO.1
a. Remove the set bolt of the water bypass pipe No.1.





18. REMOVE CAMSHAFT

NOTICE: When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC and align the oil jet hole with the paint mark to prevent the pistons from coming into contact with the valves.





a. Using several steps, uniformly loosen and remove the 19 bearing cap bolts in the sequence shown in the illustration, and then remove the 9 bearing caps, the No.1 and the No.2 camshafts.

NOTICE: Loosen each bolt uniformly keeping the camshaft level.





19. REMOVE CYLINDER HEAD SUB-ASSY
a. Using several steps, uniformly loosen and remove the 10 cylinder head bolts with an 8 mm bi-hexagon wrench in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

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

20. REMOVE CYLINDER HEAD GASKET





21. INSPECT CYLINDER HEAD SET BOLT
a. Using vernier calipers, measure the length of head bolts from the seat to the end.
Standard bolt length: 142.8 to 144.2 mm (5.622 to 5.677 inch)
Maximum bolt length: 147.1 mm (5.791 inch)
If the length exceeds maximum, replace the bolt.





22. INSTALL CYLINDER HEAD GASKET
a. Place a new cylinder head gasket on the cylinder block with the Lot No. stamp facing upward.

NOTICE:
^ Remove any oil from the contact surface.
^ Be careful of the mounting orientation.
^ Place the cylinder head on the gasket gently not to damage the gasket at the bottom part of the head.





23. INSTALL CYLINDER HEAD SUB-ASSY

HINT: The cylinder head bolts are tightened in 2 successive steps.

a. Apply a continuous bead of seal packing (Diameter 3.5 to 4.5 mm (0.1378 to 0.1772 inch)) as shown in the illustration.

NOTICE:
^ Remove any oil from the contact surface.
^ Install the cylinder head within 3 minutes of applying seal packing.

b. Apply a light coat of engine oil to the threads of the cylinder head bolts.





c. Using several steps, install and tighten the 10 cylinder head bolts and plate washers uniformly with an 8 mm bi-hexagon wrench in the sequence shown in the illustration.
Torque: 29 Nm (300 kgf-cm, 22 ft. lbs.)





d. Mark the front of the cylinder head bolt with paint.
e. Retighten the cylinder head bolts by additional 90° and one more additional 90° as shown in the illustration.
f. Check that the paint mark is now at 180° opposite to the front.
24. INSTALL CAMSHAFT
a. Apply a light coat of engine oil to the camshaft journals.
b. Place the camshaft on the cylinder head with the timing mark on the camshaft timing gear facing upward.





c. Examine the front marks and numbers and tighten the bolts in the sequence shown in the illustration.
Torque: 13 Nm (129 kgf-cm, 9.4 ft. lbs.)

NOTICE: Tighten each bolt uniformly keeping the camshaft level.

d. Install the bearing cap No.1.
Torque: 23 Nm (235 kgf-cm, 17 ft. lbs.)
25. INSTALL WATER BYPASS PIPE NO.1
a. Install the water bypass pipe No.1 with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
26. CONNECT FUEL TUBE SUB-ASSY
27. INSTALL OIL LEVEL GAGE GUIDE
a. Apply engine oil to a new O-ring.
b. Install oil level gauge guide with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)





28. INSTALL INTAKE MANIFOLD
a. Install a new gasket onto the intake manifold.
b. Install the intake manifold with the 3 bolts and 2 nuts. Using several steps, uniformly tighten the bolts and nuts in the sequence shown in the illustration.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)





29. INSTALL WATER FILTER SUB-ASSY
a. Install the water filler with the 2 bolts.
Torque: 7.5 Nm (76 kgf-cm, 66 inch lbs.)
b. Connect the radiator reservoir tank hose.
c. Connect the radiator hose No.3.
d. Connect the radiator inlet hose.
30. INSTALL THROTTLE BODY ASSY
31. INSTALL AIR CLEANER ASSY





32. INSTALL MANIFOLD SUPPORT BRACKET
a. Install the manifold support bracket with the 3 bolts.
Torque: 37 Nm (377 kgf-cm, 27 ft. lbs.)
33. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
a. Install the exhaust manifold heat insulator No.1 with the 4 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)





34. CONNECT EXHAUST PIPE ASSY FRONT
a. Place a new gasket on the exhaust manifold.
b. Install the 2 compression springs and 2 bolts.
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
35. INSTALL CHAIN SUB-ASSY
36. ADD ENGINE OIL
37. CHECK FOR ENGINE OIL LEAKS
38. ADD ENGINE COOLANT
39. CHECK FOR ENGINE COOLANT LEAKS
40. CHECK FOR FUEL LEAKS