Cylinder Head Assembly: Service and Repair

CYLINDER HEAD GASKET REPLACEMENT [L3 WITH TC]

Warning:
- Fuel vapor is hazardous. It can very easily ignite, causing death, serious injury, or damage. Always keep sparks and flames away from fuel.
- Fuel line spills and leakage from the pressurized fuel system are dangerous. Fuel can easily ignite and cause serious injury or death and damage. Fuel can also irritate skin and eyes. To prevent this, always perform the Fuel Line Safety Procedure.

1. Remove the timing chain.
2. Remove the generator.

Note:
- Place the generator out of the way with the wiring harnesses connected.

3. Remove the exhaust manifold.
4. Remove the intake manifold.
5. Disconnect the heater, bypass, radiator hoses.





6. To firmly support the engine, first set the engine jack and attachment to the oil pan.
7. Remove in the order indicated in the figure.
8. Install in the reverse order of removal.
9. Bleed the air from the cooling system.





10. Inspect the compression pressure.

Camshaft Removal Note





Note:
- The camshaft caps are to be kept ordered for correct reassembly in their original positions.

1. Loosen the camshaft cap bolts in two or three passes in the order shown, and remove them.

Cylinder Head Removal Note





1. Loosen the cylinder head installation bolts in two to three passes in the order shown in the figure and remove them.

Cylinder Head Installation Note





1. Measure the length of each cylinder head bolt.
- Replace any cylinder head bolts that exceed the maximum length.
Cylinder head bolt length
Standard 144.7 - 145.3 mm (5.700 - 5.720 inch)
Maximum: 146 mm (5.748 inch)





Tightening procedure
(1) 3 - 11 Nm (30.6 - 112 kgf-cm, 26.6 - 97.3 inch lbs.)
(2) 13 - 17 Nm (1.4 - 1.7 kgf-m, 9.6 - 12.5 ft. lbs.)
(3) 43 - 47 Nm (4.4 - 4.7 kgf-m, 31.8 - 34.6 ft. lbs.)
(4) 88° - 92°
(5) 88° - 92°

Camshaft Installation Note





1. Install the camshaft with No.3 cylinder cam aligned at TDC of compression stroke.
2. Carefully apply adhesive agent to the area indicated in the figure so that it does not leak into the sliding part.
Thickness 1.0 mm (0.039 inch)





3. Install the camshaft caps and temporarily tighten the camshaft cap bolts evenly in two or three passes, and then tighten the camshaft cap bolts using the following two steps, in the order shown in the figure.
Tightening procedure
(1) 5.0 - 9.0 Nm (51.0 - 91.7 kgf-cm, 44.3 - 79.6 inch lbs.)
(2) 14.0 - 17.0 Nm (1.5 - 1.7 kgf-m, 10.4 - 12.5 ft. lbs.)