Cylinder Head Assembly: Service and Repair
CYLINDER HEAD GASKET REPLACEMENT [LF]Warning:
^ Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
^ Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the Fuel Line Safety Procedure.
1. Perform Fuel Line Safety Procedures. Leave the fuel pump relay removed.
2. Remove the battery and battery tray.
3. Drain the engine coolant.
4. Remove the front suspension tower bar (joint, right side, left side). .)
5. Remove the air cleaner.
6. Remove the dynamic chamber.
7. Remove the ignition coil.
8. Remove the drive belt.
9. Remove the CKP sensor.
10. Remove the P/S oil pump with the oil hose still connected and position the P/S oil pump so that it is out of the way.
11. Remove the timing chain.
12. Remove the wiper arm.
13. Remove the cowl grille.
14. Remove the side cowl grille.
15. Remove the service hole cover.
16. Disconnect the generator, but do not remove it from the vehicle. Fix the generator using a rope to prevent it from failing.
17. Remove the exhaust manifold.
18. Remove in the order indicated in the table.
19. Install in the reverse order of removal.
20. Inspect the compression.
21. Start the engine and:
^ Inspect for the engine coolant leakage.
^ Verify the ignition timing, idle speed and idle mixture.
Camshaft Removal Note
Note: The cylinder head and the camshaft caps are numbered to make sure they are reassembled in their original position. Do not mix the caps.
1. Loosen the camshaft cap bolts in several passes in the order shown.
Cylinder Head Removal Note
1. Loosen the cylinder head bolts in two or three steps in the order shown.
Cylinder Head Installation Note
1. Measure the length of each cylinder head bolt. Replace any that exceed the maximum length.
Cylinder Head Bolt Length L: 145.2 - 145.8 mm (5.72 - 5.74 inch)
Cylinder Head Bolt Maximum: 146.5 mm (5.77 inch)
2. Tighten the cylinder head bolts in the order shown with the following 5 steps using the SST (49 D032 316).
1. Tighten to 5.0 Nm 151.0 kgf-cm, 44.3 inch lbs.)
2. Tighten 13 - 17 Nm (1.4 - 1.7 kgf-m, 10.0 - 12.5 ft. lbs.)
3. Tighten 44 - 46 Nm (4.5 - 4.6 kgf-m, 32.5 - 33.9 ft. lbs.)
4. Tighten 88°-92°
5. Tighten 88°-92°
Camshaft Installation Note
1. Set the cam position of No.1 cylinder at the top dead center (TDC) and install the camshaft.
2. Temporarily tighten the camshaft bearing caps evenly in two or three steps.
3. Tighten the camshaft cap bolts in the order shown with the following two steps.
1. Tighten to 5.0 - 9.0 Nm (51.0 - 91.7 kgf-cm, 44.3 - 79.6 inch lbs.).
2. Tighten to 14.0 - 17.0 Nm (1.5 - 1.7 kgf-m, 10.4 - 12.5 ft. lbs.)