Cylinder Head Gasket No. 1
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 PROPELLER SHAFT ASSY (4WD DRIVE TYPE) [37110]
SST 09325-20010
5. REMOVE EXHAUST PIPE ASSY FRONT [17410 / 98-28]
6. REMOVE MANIFOLD STAY [17118 / 98-26]
7. REMOVE EXHAUST MANIFOLD SUB-ASSY RH [17104 / 98-26]
8. REMOVE V-BANK COVER [11259 / 98-5]
9. REMOVE FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER [53607A]
10. REMOVE AIR CLEANER ASSEMBLY WITH HOSE
11. REMOVE INTAKE AIR SURGE TANK [17129 / 98-26]
12. SEPARATE FUEL PIPE SUB-ASSY NO.1 [23801P / 98-40]
13. SEPARATE HEATER INLET WATER HOSE [87245 / 98-190]
14. REMOVE INTAKE MANIFOLD [17111/ 98-26]
a. Disconnect the injector connectors.
b. Remove the 9 bolts, 2 nuts and intake manifold with delivery pipe.
15. SEPARATE RADIATOR HOSE INLET [16571 / 98-20]
16. REMOVE WATER OUTLET [16331 / 98-20]
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.
17. REMOVE FRONT WHEEL RH
18. REMOVE FRONT FENDER APRON SEAL RH [53736]
19. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 [88310A / 98-25]
20. REMOVE VANE PUMP V BELT [44310A / 98-25]
21. REMOVE ENGINE MOVING CONTROL ROD [2363A / 98-10]
22. REMOVE ENGINE MOUNTING STAY NO.2 RH [12327A / 98-10]
23. REMOVE GENERATOR BRACKET NO.2 [12512A / 98-10]
24. REMOVE CRANKSHAFT PULLEY [13471 / 98-13]
SST 09213-54015 (91651-60855), 09330-00021, 09950-50012 (09951-05010, 09952-05010, 09953-05010, 09954-05030)
25. REMOVE TIMING BELT NO.1 COVER [11322A / 98-9]
26. REMOVE TIMING BELT NO.2 COVER [11322B / 98-9]
27. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET [12315A / 98-10]
28. REMOVE TIMING BELT GUIDE NO.2 [13567 / 98-13]
29. REMOVE TIMING BELT [13568 / 98-14]
30. REMOVE TIMING BELT IDLER SUB-ASSY NO.2 [13502 / 98-14]
31. REMOVE CAMSHAFT TIMING PULLEY [13523P / 98-14]
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
32. REMOVE TIMING BELT NO.3 COVER [11322C / 98-9]
33. REMOVE VANE PUMP ASSY [44320 / 98-73]
34. REMOVE IGNITION COIL ASSY [19500 / 98-34]
35. REMOVE CYLINDER HEAD COVER SUB-ASSY [11201 / 98-5]
36. REMOVE CAMSHAFT [13511 / 98-14]
37. REMOVE NO.2 CAMSHAFT [13512 / 98-14]
38. REMOVE CYLINDER HEAD SUB-ASSY [11101 / 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.
39. REMOVE CYLINDER HEAD GASKET [11115 / 98-5]
40. INSPECT CYLINDER HEAD SET BOLT [11101A / 98-5]
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.
41. INSTALL CYLINDER HEAD GASKET [11115 / 98-5]
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.
42. INSTALL CYLINDER HEAD SUB-ASSY [11101 / 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.)
43. INSTALL NO.2 CAMSHAFT [13512 / 98-14]
44. INSTALL CAMSHAFT [13511 / 98-14]
45. INSTALL CYLINDER HEAD COVER SUB-ASSY [11201 / 98-5]
46. INSTALL IGNITION COIL ASSY [19500 / 98-34]
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
47. INSTALL VANE PUMP ASSY [44320 / 98-73]
48. INSTALL TIMING BELT NO.3 COVER [11322C / 98-9]
49. INSTALL CAMSHAFT TIMING PULLEY [13523P / 98-14]
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
50. INSTALL TIMING BELT IDLER SUB-ASSY NO.2 [13502 / 98-14]
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
51. INSPECT TIMING BELT [13568 / 98-14]
52. INSTALL TIMING BELT [13568 / 98-14]
SST 09960-10010 (09962-01000, 09963-01000)
53. INSTALL CHAIN TENSIONER ASSY NO.1 [13540 / 98-14]
54. INSTALL TIMING BELT GUIDE NO.2 [13567 / 98-13]
55. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET [12315A / 98-10]
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
56. INSTALL TIMING BELT NO.2 COVER [11322B / 98-9]
57. INSTALL TIMING BELT NO.1 COVER [11322A / 98-9]
58. INSTALL CRANKSHAFT PULLEY [13471 / 98-13]
SST 09213-54015 (91651-60855), 09330-00021
59. INSTALL GENERATOR BRACKET NO.2 [12512A / 98-10]
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
60. INSTALL ENGINE MOUNTING STAY NO.2 RH [12327A / 98-10]
61. INSTALL ENGINE MOVING CONTROL ROD [12363A / 98-10]
62. INSTALL VANE PUMP V BELT [44310A / 98-25]
63. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1 [88310A / 98-25]
64. INSPECT DRIVE BELT DEFLECTION AND TENSION (REFERENCE)
65. INSTALL WATER OUTLET [16331/ 98-20]
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.
Installation Sequence:
66. INSTALL INTAKE MANIFOLD [17111 / 98-26]
a. Install the intake manifold with the 9 bolts, 2 plate washers and 2 nuts. Uniformly tighten the bolts and nuts, in several passes, in the sequence shown.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
b. Retighter the water outlet mounting bolts and nuts.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
67. CONNECT FUEL PIPE SUB-ASSY NO.1 [23801P / 98-40]
68. INSTALL INTAKE AIR SURGE TANK [17129 / 98-26]
69. INSTALL AIR CLEANER ASSEMBLY WITH HOSE
70. CONNECT VACUUM HOSE
71. INSTALL FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER [53607A]
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)
72. INSTALL V-BANK COVER [11259 / 98-5]
73. INSTALL EXHAUST MANIFOLD SUB-ASSY RH [17104 / 98-26]
74. INSTALL MANIFOLD STAY [17118 / 98-26]
Torque: 34 Nm (347 kgf-cm, 25 ft. lbs.)
75. INSTALL EXHAUST PIPE ASSY FRONT [17410 / 98-28]
76. INSTALL PROPELLER SHAFT ASSY (4WD DRIVE TYPE) [37110]
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. INSPECT COOLANT LEAKS
82. INSPECT FUEL LEAK
83. CHECK GAS LEAKAGE ON EXHAUST SYSTEM
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