Cylinder Head Gasket No. 2
REPLACEMENT1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT.
a. Disconnect the fuel pump connector.
b. Start the engine. After the engine has stopped on its own, turn the ignition switch to LOCK (OFF).
c. Disconnect negative (-) terminal cable from battery.
d. Connect the fuel pump connector.
2. DRAIN COOLANT
3. DRAIN ENGINE OIL
4. REMOVE MANIFOLD STAY NO.2 [17139 / 98-26]
5. SEPARATE EXHAUST MANIFOLD SUB-ASSY LH [17105 / 98-26]
a. Remove the 2 bolts, and disconnect the exhaust manifold LH from the catalytic converter.
6. REMOVE V-BANK COVER [11259 / 98-5]
7. REMOVE FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER [53607A]
8. REMOVE AIR CLEANER ASSEMBLY WITH HOSE.
9. REMOVE INTAKE AIR SURGE TANK [17129 / 98-26]
10. SEPARATE FUEL PIPE SUB-ASSY NO.1 [23801P / 98-40]
11. SEPARATE HEATER INLET WATER HOSE [87245 / 98-190]
12. REMOVE INTAKE MANIFOLD [17111 / 98-26]
13. REMOVE RADIATOR HOSE INLET [16571 / 98-20]
14. REMOVE WATER OUTLET [16331 / 98-20]
15. SEPARATE RADIATOR HOSE OUTLET [16572 / 98-20]
16. REMOVE WATER INLET PIPE [16322 / 98-20]
17. REMOVE OIL LEVEL GAGE SUB-ASSY [15301 /98-7]
18. REMOVE OIL LEVEL GAGE GUIDE [11452 / 98-7]
19. REMOVE CYLINDER HEAD PLATE REAR [11181/ 98-5]
a. Disconnect the A/F sensor connector.
b. Remove the 2 bolts and cylinder head rear plate.
20. REMOVE FRONT WHEEL RH
21. REMOVE FRONT FENDER APRON SEAL RH [53736]
22. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 [88310A / 98-25]
23. REMOVE VANE PUMP V BELT [44310A / 98-25]
24. REMOVE ENGINE MOVING CONTROL ROD [12363A / 98-10]
25. REMOVE ENGINE MOUNTING STAY NO.2 RH [12327A / 98-10]
26. REMOVE GENERATOR BRACKET NO.2 [12512A / 98-10]
27. REMOVE CRANKSHAFT PULLEY [13471 / 98-13]
SST 09213-54015 (91651-60855), 09330-00021, 09950-50012 (09951-05010, 09952-05010, 09953-05010, 09954-05030)
28. REMOVE TIMING BELT NO.1 COVER [11322A / 98-9]
29. REMOVE TIMING BELT NO.2 COVER [11322B / 98-9]
30. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET [12315A / 98-10]
31. REMOVE TIMING BELT GUIDE NO.2 [13567 / 98-13]
32. REMOVE TIMING BELT [13568 / 98-14]
33. REMOVE TIMING BELT IDLER SUB-ASSY NO.2 [13502 / 98-14]
34. REMOVE CAMSHAFT TIMING PULLEY [13523P / 98-14]
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
35. REMOVE TIMING BELT NO.3 COVER [11322C / 98-9]
36. REMOVE IGNITION COIL ASSY [19500 / 98-34]
37. REMOVE CYLINDER HEAD COVER SUB-ASSY LH [11202 / 98-5]
38. REMOVE NO.3 CAMSHAFT SUB-ASSY [13053 / 98-14]
39. REMOVE NO.4 CAMSHAFT SUB-ASSY [13054 / 98-14]
40. REMOVE CYLINDER HEAD LH [11102 / 98-5]
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.
41. REMOVE CYLINDER HEAD GASKET NO.2 [11116 / 98-5]
42. INSPECT CYLINDER HEAD SET BOLT [11101A / 98-5]
43. INSTALL CYLINDER HEAD GASKET NO.2 [11116 / 98-5]
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.
44. INSTALL CYLINDER HEAD LH [11102 / 98-5]
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.)
45. INSTALL NO.4 CAMSHAFT SUB-ASSY [13054 / 98-14]
46. INSTALL NO.3 CAMSHAFT SUB-ASSY [13053 / 98-14]
47. INSTALL CYLINDER HEAD COVER SUB-ASSY LH [11202 / 98-5]
48. INSTALL IGNITION COIL ASSY [19500 / 98-34]
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
49. INSTALL TIMING BELT NO.3 COVER [11322C / 98-9]
50. INSTALL CAMSHAFT TIMING PULLEY [13523P / 98-14]
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
51. INSTALL TIMING BELT IDLER SUB-ASSY NO.2 [13502 / 98-14]
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
52. INSPECT TIMING BELT [13568 / 98-14]
53. INSTALL TIMING BELT [13568 / 98-14]
SST 09960-10010 (09962-01000, 09963-01000)
54. INSTALL CHAIN TENSIONER ASSY NO.1 [13540 / 98-14]
55. INSTALL TIMING BELT GUIDE NO.2 [13567 / 98-13]
56. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET [12315A / 98-10]
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
57. INSTALL TIMING BELT NO.2 COVER [11322B / 98-9]
58. INSTALL TIMING BELT NO.1 COVER [11322A / 98-9]
59. INSTALL CRANKSHAFT PULLEY [13471 / 98-13]
SST 09213-54015 (91651-60855), 09330-00021
60. INSTALL GENERATOR BRACKET NO.2 [12512A / 98-10]
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
61. INSTALL ENGINE MOUNTING STAY NO.2 RH [12327A / 98-10]
62. INSTALL ENGINE MOVING CONTROL ROD [12363A / 98-10]
63. INSTALL VANE PUMP V BELT [44310A / 98-25]
64. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 [88310A / 98-25]
65. INSPECT DRIVE BELT DEFLECTION AND TENSION(REFERENCE)
66. INSTALL CYLINDER HEAD PLATE REAR [11181/ 98-5]
a. Install the cylinder head rear plate with the 2 bolts.
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
67. INSTALL OIL LEVEL GAGE GUIDE [11452 / 98-7]
68. INSTALL WATER INLET PIPE [16322 / 98-20]
69. INSTALL WATER OUTLET [16331 / 98-20]
70. INSTALL INTAKE MANIFOLD [17111 / 98-26]
71. CONNECT FUEL PIPE SUB-ASSY NO.1 [23801P / 98-40]
72. INSTALL INTAKE AIR SURGE TANK [17129 / 98-26]
73. INSTALL AIR CLEANER ASSEMBLY WITH HOSE
74. CONNECT VACUUM HOSE
75. INSTALL FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER [53607A]
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)
76. INSTALL V-BANK COVER [11259 / 98-5]
77. INSTALL EXHAUST MANIFOLD SUB-ASSY LH [17105 / 98-26]
a. Install a new gasket and the exhaust manifold to the catalytic converter.
Torque: 56 Nm (571 kgf-cm, 41 ft. lbs.)
78. INSTALL MANIFOLD STAY NO.2 [17139 / 98-26]
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
79. INSTALL FRONT WHEEL RH
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
80. ADD ENGINE OIL
81. ADD COOLANT
82. INSPECT OIL LEAK
83. INSPECT COOLANT LEAKS
84. INSPECT FUEL LEAK
85. CHECK GAS LEAKAGE ON EXHAUST SYSTEM
86. INSPECT IGNITION TIMING
SST 09843-18040, 09843-18020
87. INSPECT ENGINE IDLE SPEED
SST 09843-18040
88. INSPECT COMPRESSION
SST 09992-00500
89. INSPECT CO/HC