Removal and Replacement
CYLINDER HEAD GASKETREPLACEMENT
1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
2. REMOVE FRONT SUSPENSION BRACE SUB-ASSEMBLY UPPER CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER)
3. DRAIN COOLANT
4. DRAIN TRANSFER OIL (4WD TYPE)
5. DISCONNECT RADIATOR HOSE OUTLET
6. DISCONNECT UNION TO CONNECTOR TUBE HOSE
7. DISCONNECT HEATER INLET WATER HOSE
8. DISCONNECT FUEL TUBE SUB-ASSEMBLY
9. SEPARATE FRONT DRIVE SHAFT ASSEMBLY RH (4WD TYPE)
10. SEPARATE ENGINE MOUNTING INSULATOR ASSEMBLY RR (4WD TYPE)
a. Remove the 2 bolts and disconnect the engine mounting insulator.
11. REMOVE ENGINE MOUNTING BRACKET RR (4WD TYPE)
12. REMOVE INTAKE MANIFOLD
13. DISCONNECT ENGINE WIRE
14. REMOVE INTAKE MANIFOLD INSULATOR NO.1
15. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1
16. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
17. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
18. REMOVE CHAIN SUB-ASSEMBLY
19. REMOVE NO.2 CAMSHAFT
20. REMOVE CAMSHAFT
21. REMOVE CAMSHAFT BEARING NO.2
22. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
23. REMOVE CYLINDER HEAD SUB-ASSEMBLY
a. Using a 10 mm Bi-hexagon wrench, uniformly loosen the 10 bolts in the sequence shown in the illustration. 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 in an incorrect order.
24. REMOVE CYLINDER HEAD GASKET
25. INSPECT CYLINDER HEAD SET BOLT
26. INSTALL CYLINDER HEAD GASKET
a. Place a new 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.
^ To avoid damage to the gasket, place the cylinder head on the gasket carefully.
27. INSTALL CYLINDER HEAD SUB-ASSEMBLY
HINT: The cylinder head bolts are tightened in 2 progressive steps.
a. Apply a light coat of engine oil to the bolt threads and the area beneath the bolt heads that come in contact with the washers.
b. Install the bolts and plate washers to the cylinder head.
NOTICE: Do not drop the washers into the cylinder head.
c. Using a 10 mm bi-hexagon wrench, uniformly tighten the 10 bolts in the sequence shown in the illustration.
Torque: 79 Nm (806 kgf-cm, 58 ft. lbs.)
d. Mark the front side of the cylinder head bolt with paint.
e. Retighten the cylinder head bolts 90° in the sequence shown in the illustration. Check that the painted mark is now at a 90° angle to the front.
28. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
29. INSTALL CAMSHAFT BEARING NO.2
30. INSTALL CAMSHAFT
31. INSTALL NO. 2 CAMSHAFT
32. INSTALL CHAIN SUB-ASSEMBLY
33. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
34. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
a. Install a new gasket and the exhaust manifold convert with the 5 nuts. Uniformly tighten the nuts in the sequence shown in the illustration.
Torque: 37 Nm (337 kgf-cm, 27 ft. lbs.)
b. Install the No.1 and No.2 exhaust manifold stays with the 2 bolts and 2 nuts.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)
35. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
36. INSTALL INTAKE MANIFOLD INSULATOR NO.1
37. INSTALL ENGINE WIRE
38. INSTALL INTAKE MANIFOLD
39. INSTALL ENGINE MOUNTING BRACKET RR (4WD TYPE)
40. INSTALL ENGINE MOUNTING INSULATOR ASSEMBLY RR (4WD TYPE)
a. Install the mounting insulator with bolts.
Torque: 75 Nm (765 kgf-cm, 55 ft. lbs.)
41. INSTALL FRONT DRIVE SHAFT ASSEMBLY RH (4WD TYPE)
42. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
43. CONNECT FUEL TUBE SUB-ASSEMBLY
44. INSTALL FRONT SUSPENSION BRACE SUB-ASSEMBLY UPPER CENTER
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)
45. ADD ENGINE OIL
46. ADD COOLANT
47. ADD TRANSFER OIL (4WD TYPE)
a. Install a new gasket and the filler plug.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
48. CHECK FOR OIL LEAKS
49. CHECK FOR ENGINE COOLANT LEAKS
50. INSPECT FOR FUEL LEAKS
51. CHECK IDLE SPEED AND IGNITION TIMING
52. INSPECT CO/HC
53. CHECK ABS SPEED SENSOR SIGNAL
54. INSPECT FRONT WHEEL ALIGNMENT