Removal and Replacement
CYLINDER HEAD GASKET (2AZ-FE - 2003 MY) REPLACEMENT1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
2. REMOVE FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER
3. REMOVE CHAIN SUB-ASSY
4. DRAIN COOLANT
5. DRAIN TRANSFER OIL (4WD DRIVE TYPE)
a. Install a new gasket and the drain plug after draining transfer oil.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
6. SEPARATE RADIATOR HOSE OUTLET
7. SEPARATE UNION TO CHECK VALVE HOSE
8. SEPARATE HEATER INLET WATER HOSE
9. SEPARATE FUEL TUBE SUB-ASSY
10. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY
11. REMOVE FRONT DRIVE SHAFT ASSY RH (4WD DRIVE TYPE)
SST 09520-01010, 09520-24010 (09520-32040)
12. SEPARATE ENGINE MOUNTING INSULATOR ASSY RR (4WD DRIVE TYPE)
a. Remove the 2 bolts, and disconnect engine mounting insulator.
13. SEPARATE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (4WD DRIVE TYPE)
a. Remove the 6 bolts and engine mounting bracket.
14. REMOVE INTAKE MANIFOLD
a. Disconnect the 2 water by-pass hoses of the throttle body.
b. Remove the 5 bolts, 2 nuts, intake manifold and gasket.
15. SEPARATE ENGINE WIRE
16. REMOVE INTAKE MANIFOLD INSULATOR NO.1
17. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1
18. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSY
a. Remove the 2 bolts, nuts, No.1 and No.2 exhaust manifold stay.
b. Remove the 5 nuts, exhaust manifold and gasket.
19. REMOVE NO.2 CAMSHAFT
a. Remove the No.2 and No.3 camshaft bearing cap in the sequence shown in the illustration.
b. Remove the No.2 camshaft.
20. REMOVE CAMSHAFT
a. Remove the No.1 and No.3 camshaft bearing cap in the sequence shown in the illustration.
b. Remove the No.1 camshaft.
21. REMOVE CAMSHAFT BEARING NO.2
22. REMOVE CYLINDER HEAD SUB-ASSY
a. Using a 10 mm bi-hexagon wrench, uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown. Remove the 10 cylinder head bolts and plate washers.
NOTICE:
- Be careful not to drop washers into the cylinder head.
- Head warpage or cracking could result from removing bolts and installing incorrect order.
23. REMOVE CYLINDER HEAD GASKET
24. INSPECT CYLINDER HEAD SET BOLT
a. Using a vernier calipers, measure the length of head bolts from the seat to the end.
Standard bolt length: 161.3 - 162.3 mm (6.350 - 6.390 inch)
Maximum bolt length: 164.2 mm (6.465 inch)
If the length is greater than maximum, replace the bolt.
25. INSTALL CYLINDER HEAD GASKET
a. Place a new cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.
NOTICE:
- Remove any oil from contact surface.
- Be careful of the installation direction.
- Place the cylinder head quietly in order not to damage the gasket with the bottom part of the head.
26. INSTALL CYLINDER HEAD SUB-ASSY
HINT: The cylinder head bolts are tightened in 2 progressive steps.
a. Apply seal packing in the shape of bead (Diameter 2.5 - 3mm (0.098 - 0.118 inch)) consequently as shown in the illustration.
Seal packing: Part No. 08826-00080 or equivalent
NOTICE:
- Remove any oil from contact surface.
- Install the cylinder head within 3 minutes after applying seal packing.
- After installing the cylinder head, cylinder head bolts must be tightened within 15 minutes.
b. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
c. Install bolts and plate washers to the cylinder head.
NOTICE: Do not drop the washers into the cylinder head.
d. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts and plate washers, in several passes, in the sequence shown.
Torque: 79 Nm (806 kgf-cm, 58 ft. lbs.)
e. Mark the front side of the cylinder head bolt with paint.
f. Retighten the cylinder head bolts by 90° in the sequence shown.
g. Check that the paint mark is now at a 90° angle to the front.
27. INSTALL CAMSHAFT
a. Tighten the camshaft bearing cap No.1 and No.3 as the sequence shown in the illustration.
Torque:
Bearing cap No.1 30 Nm (301 kgf-cm, 22 ft. lbs.)
Bearing cap No.3 9.0 Nm (92 kgf-cm, 80 inch lbs.)
28. INSTALL NO.2 CAMSHAFT
a. Tighten the camshaft bearing cap No.2 and No.3 as the sequence shown in the illustration.
Torque:
Bearing cap No.2 30 Nm (301 kgf-cm, 22 ft. lbs.)
Bearing cap No.3 9.0 Nm (92 kgf-cm, 80 inch lbs.)
29. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSY
a. Install a new gasket and the exhaust manifold with the 5 nuts.
Torque: 37 Nm (378 kgf-cm, 27 ft. lbs.)
b. Install the No.1 and No.2 exhaust manifold stay with the 2 bolts and 2 nuts.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)
30. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
31. INSTALL INTAKE MANIFOLD
a. Install a new gasket and the intake manifold with the 5 bolts and 2 nuts.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
32. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET (4WD DRIVE TYPE)
a. Install the mounting bracket with the 6 bolts.
Torque:
34 Nm (347 kgf-cm, 25 ft. lbs.) for Bolt A
64 Nm (653 kgf-cm, 47 ft. lbs.) for Bolt B
33. INSTALL ENGINE MOUNTING INSULATOR ASSY RR (4WD DRIVE TYPE)
a. Install the mounting insulator with bolts.
Torque: 75 Nm (765 kgf-cm, 55 ft. lbs.)
34. INSTALL FRONT DRIVE SHAFT ASSY RH (4WD DRIVE TYPE)
35. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
Torque: 9.0 Nm(92 kgf-cm, 80 inch lbs.)
36. CONNECT FUEL TUBE SUB-ASSY
37. INSTALL CHAIN SUB-ASSY
SST 09309-37010
38. INSTALL CRANKSHAFT POSITION SENSOR
39. INSTALL FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)
40. ADD ENGINE OIL
41. ADD COOLANT
42. ADD TRANSFER OIL (4WD DRIVE TYPE) (4WD DRIVE TYPE)
a. Install a new gasket and the filler plug.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
43. INSPECT FOR OIL LEAKS
44. CHECK FOR ENGINE COOLANT LEAKS
45. INSPECT FOR FUEL LEAKS
46. INSPECT CHECK IDLE SPEED AND IGNITION TIMING
47. INSPECT CO/HC
48. CHECK ABS SPEED SENSOR SIGNAL
49. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT