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". Before Service Precaution
1. Perform "Fuel Line Safety Procedures". Leave the fuel pump relay removed. Before Service Precaution
2. Remove the battery and battery tray. Removal and Replacement
3. Drain the engine coolant. Service and Repair
4. Remove the front suspension tower bar (joint, right side, left side). Service and Repair
5. Remove the air cleaner. Service and Repair
6. Remove the dynamic chamber. Service and Repair
7. Remove the ignition coil. Service and Repair
8. Remove the drive belt. Service and Repair
9. Remove the CKP sensor. Service and Repair
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. Removal and Replacement
11. Remove the timing chain. Service and Repair
12. Remove the wiper arm and blade. Service and Repair
13. Remove the cowl grille. Cowl Grille Removal/Installation
14. Remove the side cowl grille. Side Cowl Grille Removal/Installation
15. Remove the service hole cover. Service and Repair
16. Disconnect the generator, but do not remove it from the vehicle. Fix the generator using a rope to prevent it from falling. Removal and Replacement
17. Remove the exhaust manifold. Service and Repair
18. Remove in the order indicated in the table.
19. Install in the reverse order of removal.
20. Inspect the compression. Testing and Inspection
21. Start the engine and:
- Inspect for the engine coolant leakage.
- Verify the ignition timing, idle speed and idle mixture. Service and Repair
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 Gasket Installation Note
1. Apply silicone sealant to the areas shown in the figure.
CAUTION:
- Install the cylinder head gasket and cylinder head before the applied silicone sealant starts to harden.
Thickness
- 4-7 mm {0.16-0.27 in}
2. Install the cylinder block with a new cylinder head gasket.
3. Apply silicone sealant to the areas shown in the figure.
Thickness
- 4-7 mm {0.16-0.27 in}
4. Install the cylinder head referring to the Cylinder Head Installation Note.
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 in}
Cylinder Head Bolt Maximum
- 146.5 mm {5.77 in}
2. Tighten the cylinder head bolts in the order shown with the following 5 steps using the SST (49 D032 316).
a. Tighten to 5.0 Nm {51.0 kgf-cm, 44.3 in-lbf}
b. Tighten 13-17 Nm {1.4-1.7 kgf-m, 10.0-12.5 ft-lbf}
c. Tighten 44-46 Nm {4.5-4.6 kgf-m, 32.5-33.9 ft-lbf}
d. Tighten 88°-92°
e. Tighten 88°-92°
Camshaft Installation Note
1. Apply the gear oil (SAE No. 90 or equivalent) to each journal of the cylinder head as shown in the figure.
2. Set the cam position of No.1 cylinder at the top dead center (TDC) and install the camshaft.
3. Apply the gear oil (SAE No. 90 or equivalent) to each journal of the camshaft as shown in the figure.
4. Temporarily tighten the camshaft bearing caps evenly in two or three steps.
5. Tighten the camshaft cap bolts in the order shown with the following two steps.
a. Tighten to 5.0-9.0 Nm {51.0-91.7 kgf-cm, 44.3-79.6 in-lbf}
b. Tighten to 14.0-17.0 Nm {1.5-1.7 kgf-m, 10.4-12.5 ft-lbf}
