Cylinder Head Gasket No. 1 (RH)
Part 1:
Part 2:
Part 3:
Part 4:
Part 5:
Part 6:
Part 7:
Part 8:
CYLINDER HEAD GASKET
REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. DRAIN ENGINE COOLANT
4. DRAIN ENGINE OIL
5. REMOVE FRONT WHEEL RH
6. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS)
7. REMOVE V-BANK COVER SUB-ASSEMBLY
8. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
9. REMOVE EMISSION CONTROL VALVE SET
10. REMOVE INTAKE AIR SURGE TANK
11. REMOVE INTAKE MANIFOLD
12. REMOVE WATER OUTLET
13. REMOVE FRONT FENDER APRON SEAL RH
14. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
15. REMOVE VANE PUMP V BELT
16. REMOVE ENGINE MOVING CONTROL ROD
17. REMOVE ENGINE MOUNTING STAY NO.2 RH
18. REMOVE GENERATOR BRACKET NO.2
19. REMOVE CRANKSHAFT PULLEY
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05031)
20. REMOVE TIMING BELT NO.1 COVER
21. REMOVE TIMING BELT NO.2 COVER
22. REMOVE ENGINE MOUNTING BRACKET RH
23. REMOVE TIMING BELT GUIDE NO.2
24. REMOVE TIMING BELT
25. REMOVE TIMING BELT IDLER SUB-ASSEMBLY NO.2
26. REMOVE CAMSHAFT TIMING PULLEY
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
27. REMOVE TIMING BELT NO.3 COVER
28. SEPARATE VANE PUMP ASSEMBLY
29. REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT
30. REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET REAR
31. REMOVE EXHAUST PIPE ASSEMBLY FRONT
32. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1
a. Disconnect the air fuel ratio sensor connector.
b. Remove the 3 bolts and exhaust manifold heat insulator.
33. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Using several steps, loosen and remove the 6 nuts in the sequence shown in the illustration.
b. Remove the exhaust manifold RH and gasket from the cylinder head RH.
34. REMOVE IGNITION COIL ASSEMBLY
35. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
36. REMOVE CAMSHAFT
37. REMOVE NO.2 CAMSHAFT
38. REMOVE CYLINDER HEAD SUB-ASSEMBLY
a. Disconnect the VVT sensor connector.
b. Disconnect the camshaft timing oil control valve connector.
c. Remove the nut, then disconnect the engine wire harness clamp.
d. Using a socket hexagon wrench 8, remove the hexagon bolt.
e. Using several steps, loosen the 8 cylinder head bolts uniformly in the sequence shown in the illustration.
Remove the 8 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 the bolts in an incorrect order.
39. REMOVE CYLINDER HEAD GASKET
40. INSPECT CYLINDER HEAD SET BOLT
a. Using vernier calipers, measure the tension portion diameter of the bolt.
Standard outside diameter: 8.95 to 9.05 mm (0.3524 to 0.3563 inch)
Minimum outside diameter: 8.75 mm (0.3445 inch)
If the diameter is less than minimum, replace the bolt.
41. INSTALL CYLINDER HEAD GASKET
a. Place a new cylinder head gasket on the cylinder block with the R mark upward.
NOTICE:
^ Remove any oil from the contact surface.
^ Be careful of the installing orientation.
^ Place the cylinder head on the gasket carefully in or der not to damage the gasket at the bottom part of the head.
42. INSTALL CYLINDER HEAD SUB-ASSEMBLY
NOTICE: The cylinder head bolts are tightened in 2 successive steps.
a. Apply a light coat of engine oil to the threads of the cylinder head bolts.
b. Install the plate washers to the cylinder head bolts.
c. Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration.
Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.)
d. Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
e. Retighten the cylinder head bolts by 90° in the same sequence as step (c).
f. Check that each painted mark is now at a 90° angle to the front.
g. Using a socket hexagon wrench 8, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)
h. Connect the engine wire harness clamp with the nut.
Torque: 8.4 Nm (85 kgf-cm, 74 inch lbs.)
43. INSTALL NO.2 CAMSHAFT
44. INSTALL CAMSHAFT
45. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
46. INSTALL IGNITION COIL ASSEMBLY
47. INSTALL EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Install a new gasket and the exhaust manifold RH with the 6 nuts. Using several steps, tighten the nuts uniformly in the sequence shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
b. Retighten nuts 1 and 2 shown in the illustration.
48. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
Torque: 8.5 Nm (87 kgf-cm, 75 ft. lbs.)
49. INSTALL EXHAUST PIPE ASSEMBLY FRONT
50. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET REAR
51. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET FRONT
52. INSTALL VANE PUMP ASSEMBLY
53. INSTALL TIMING BELT NO.3 COVER
54. INSTALL CAMSHAFT TIMING PULLEY
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
55. INSTALL TIMING BELT IDLER SUB-ASSEMBLY NO.2
56. INSPECT TIMING BELT
57. INSTALL TIMING BELT
SST 09960-10010 (09962-01000, 09963-01000)
58. INSTALL TIMING BELT TENSIONER ASSEMBLY
59. INSTALL TIMING BELT GUIDE NO.2
60. INSTALL ENGINE MOUNTING BRACKET RH
61. INSTALL TIMING BELT NO.2 COVER
62. INSTALL TIMING BELT NO.1 COVER
63. INSTALL CRANKSHAFT PULLEY
SST 09213-54015 (91651-60855), 09330-00021
64. INSTALL GENERATOR BRACKET NO.2
65. INSTALL ENGINE MOUNTING STAY NO.2 RH
66. INSTALL ENGINE MOVING CONTROL ROD
67. INSTALL VANE PUMP V BELT
68. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
69. INSPECT DRIVE BELT DEFLECTION AND TENSION
70. INSTALL WATER OUTLET
71. INSTALL INTAKE MANIFOLD
72. INSTALL INTAKE AIR SURGE TANK
73. INSTALL EMISSION CONTROL VALVE SET
74. INSTALL AIR CLEANER CAP SUB-ASSEMBLY
75. CHECK CONNECTION OF VACUUM HOSE
76. INSTALL V-BANK COVER SUB-ASSEMBLY
77. INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/O TEMS)
78. INSTALL FRONT WHEEL RH
79. ADD ENGINE OIL
80. ADD ENGINE COOLANT
81. CHECK FOR ENGINE OIL LEAKS
82. CHECK FOR ENGINE COOLANT LEAKS
83. INSPECT FOR FUEL LEAKS
84. CHECK FOR EXHAUST GAS LEAKS
85. INSPECT IGNITION TIMING
SST 09843-18040
86. INSPECT ENGINE IDLE SPEED
87. INSPECT COMPRESSION
SST 09992-00500
88. INSPECT CO/HC
89. SYSTEM INITIALIZATION