Removal and Replacement
CYLINDER HEAD GASKET (1MZ-FE - 2003 MY) REPLACEMENT1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
2. DRAIN COOLANT
3. DRAIN ENGINE OIL
4. REMOVE PROPELLER W/CENTER BEARING SHAFT ASSY (4WD DRIVE TYPE)
SST 0932-20010
5. REMOVE EXHAUST PIPE ASSY FRONT
6. REMOVE MANIFOLD STAY
7. REMOVE EXHAUST MANIFOLD SUB-ASSY RH
8. REMOVE V-BANK COVER
9. REMOVE FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER
10. REMOVE AIR CLEANER ASSEMBLY WITH HOSE
11. REMOVE INTAKE AIR SURGE TANK
12. SEPARATE FUEL PIPE SUB-ASSY NO.1
13. SEPARATE HEATER INLET WATER HOSE
14. REMOVE INTAKE MANIFOLD
a. Disconnect the injector connectors.
b. Remove the 9 bolts, 2 nuts and intake manifold with delivery pipe.
15. SEPARATE RADIATOR HOSE INLET
16. REMOVE WATER OUTLET
a. Disconnect the water temperature sensor connector and grand cable.
b. Remove the 2 bolts and 2 nuts.
c. Disconnect the water bypass hose, and remove the water outlet.
d. Remove the 2 gaskets.
17. REMOVE FRONT WHEEL RH
18. REMOVE FRONT FENDER APRON SEAL RH
19. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
20. REMOVE VANE PUMP V BELT
21. REMOVE ENGINE MOVING CONTROL ROD
22. REMOVE ENGINE MOUNTING STAY NO.2 RH
23. REMOVE GENERATOR BRACKET NO.2
24. REMOVE CRANKSHAFT PULLEY
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010, 09953-05010, 09954-05030)
25. REMOVE TIMING BELT NO.1 COVER
26. REMOVE TIMING BELT NO.2 COVER
27. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
28. REMOVE TIMING BELT GUIDE NO.2
29. REMOVE TIMING BELT
30. REMOVE TIMING BELT IDLER SUB-ASSY NO.2
31. REMOVE CAMSHAFT TIMING PULLEY
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
32. REMOVE TIMING BELT NO.3 COVER
33. REMOVE VANE PUMP ASSY
34. REMOVE IGNITION COIL ASSY
35. REMOVE CYLINDER HEAD COVER SUB-ASSY
36. REMOVE CAMSHAFT
37. REMOVE NO.2 CAMSHAFT
38. REMOVE CYLINDER HEAD SUB-ASSY
a. Using an 8 mm hexagon wrench, remove the hexagon bolt.
b. Uniformly loosen the 8 cylinder head bolts, in several passes, in the sequence shown. Remove the 8 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 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 - 9.05 mm (0.3524 - 0.3563 inch)
Minimum outside diameter: 8.75 mm (0.3775 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 surface with the R mark upward.
NOTICE:
- Remove any oil from the contact surface.
- Be careful of the installation direction.
- Place the cylinder head quietly in order not to damage the gasket at the bottom part of the head.
42. INSTALL CYLINDER HEAD SUB-ASSY
NOTICE: The cylinder head bolts are tightened in 2 progressive steps.
a. Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
b. Install the plate washer to the cylinder head bolt.
c. Install and uniformly tighten the 8 cylinder head bolts, in several passes, in the sequence shown.
Torque: 54 Nm (551 kgf-cm, 40 ft. lbs.)
d. Mark the front side of each cylinder head bolt head with paint.
e. Retighten the cylinder head bolts by 90° in the sequence shown.
f. Check that the painted mark is now at a 90° angle to the front.
g. Using an 8 mm socket hexagon wrench, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)
43. INSTALL NO.2 CAMSHAFT
44. INSTALL CAMSHAFT
45. INSTALL CYLINDER HEAD COVER SUB-ASSY
46. INSTALL IGNITION COIL ASSY
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
47. INSTALL VANE PUMP ASSY
48. INSTALL TIMING BELT NO.3 COVER
49. INSTALL CAMSHAFT TIMING PULLEY
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
50. INSTALL TIMING BELT IDLER SUB-ASSY NO.2
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
51. INSPECT TIMING BELT
52. INSTALL TIMING BELT
SST 09960-10010 (09962-01000, 09963-01000)
53. INSTALL CHAIN TENSIONER ASSY NO.1
54. INSTALL TIMING BELT GUIDE NO.2
55. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
56. INSTALL TIMING BELT NO.2 COVER
57. INSTALL TIMING BELT NO.1 COVER
58. INSTALL CRANKSHAFT PULLEY
SST 09213-54015 (91651-0855), 09330-00021
59. INSTALL GENERATOR BRACKET NO.2
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
60. INSTALL ENGINE MOUNTING STAY NO.2 RH
61. INSTALL ENGINE MOVING CONTROL ROD
62. INSTALL VANE PUMP V BELT
63. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
64. INSPECT DRIVE BELT DEFLECTION AND TENSION (REFERENCE)
65. INSTALL WATER OUTLET
a. Install 2 new gaskets to the cylinder head.
b. Connect the water outlet to the bypass hose.
c. Install the water outlet with the 2 bolts, 2 nuts and 2 plate washers. Alternately tighten the bolts and nuts.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
NOTICE: Do not scratch the seal surface of the water outlet with the stud bolt.
66. INSTALL INTAKE MANIFOLD
a. Install the intake manifold with the 9 bolts, 2 plate washers and 2 nuts. Uniformly tighten the bolts and nuts, in several passes, in the sequence shown.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
b. Retighter the water outlet mounting bolts and nuts.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
67. CONNECT FUEL PIPE SUB-ASSY NO.1
68. INSTALL INTAKE AIR SURGE TANK
69. INSTALL AIR CLEANER ASSEMBLY WITH HOSE
70. CONNECT VACUUM HOSE
71. INSTALL FRONT SUSPENSION BRACE SUB-ASSY UPPER CENTER
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)
72. INSTALL V-BANK COVER
73. INSTALL EXHAUST MANIFOLD SUB-ASSY RH
74. INSTALL MANIFOLD STAY
Torque: 34 Nm (347 kgf-cm, 25 ft. lbs.)
75. INSTALL EXHAUST PIPE ASSY FRONT
76. INSTALL PROPELLER W/CENTER BEARING SHAFT ASSY (4WD DRIVE TYPE)
77. INSTALL FRONT WHEEL RH
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)
78. ADD ENGINE OIL
79. ADD COOLANT
80. INSPECT FOR OIL LEAKS
81. INSPECT CHECK FOR ENGINE COOLANT LEAKS
82. INSPECT FOR FUEL LEAKS
83. CHECK FOR EXHAUST GAS LEAK
84. INSPECT IGNITION TIMING
SST 09843-18040, 09843-18020
85. INSPECT ENGINE IDLE SPEED
SST 09843-18040
86. INSPECT COMPRESSION
SST 09992-00500
87. INSPECT CO/HC