Cylinder Head Gasket No. 1 (RH)
REPLACEMENT1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
2. REMOVE TIMING BELT
3. REMOVE CAMSHAFT (RH BANK)
4. REMOVE TRANSMISSION OIL FILLER TUBE SUB-ASSY
a. Remove the bolt and transmission oil filler tube.
5. REMOVE OIL LEVEL GAGE GUIDE
a. Remove the bolt and oil level gage guide.
6. DISCONNECT FUEL HOSE
7. DISCONNECT FUEL HOSE NO.2
8. DISCONNECT FUEL VAPOR FEED HOSE ASSY
9. SEPARATE ENGINE WIRE
a. Disconnect the 8 fuel injector connectors.
b. Remove the 3 bolts and separate engine wire harness.
10. DISCONNECT WATER BY-PASS HOSE NO.7
11. DISCONNECT WATER BY-PASS HOSE
12. REMOVE INTAKE MANIFOLD ASSY
a. Remove the 6 bolts and 4 nuts.
b. Remove the intake manifold assy and 2 gaskets.
13. REMOVE WATER INLET HOUSING
a. Remove the 2 bolts.
b. Remove the water inlet housing and gasket from the engine.
14. REMOVE WATER BY-PASS JOINT FR
a. Remove the 4 nuts.
b. Remove the water by-pass joint and 2 gaskets.
15. REMOVE WATER BY-PASS PIPE SUB-ASSY
a. Remove the bolt and water by-pass.
16. REMOVE WATER BY-PASS JOINT RR
a. Remove the 4 nuts, water by-pass joint and 2 gaskets.
17. DISCONNECT ENGINE WIRE
a. Remove the 2 bolts as shown in the illustration.
18. SEPARATE FRONT EXHAUST PIPE
a. Remove the 2 bolts and separate the front exhaust pipe.
19. REMOVE CYLINDER HEAD SUB-ASSY
a. Uniformly loosen in sequence as shown. Remove the 10 cylinder head bolts and plate washers
NOTICE:
^ Cylinder head warpage or cracking could result from removing bolts in incorrect order.
^ Do not drop the plate washer for cylinder head bolt into portion A as shown in the illustration. If dropped into the portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.
b. Remove the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench
HINT: If the cylinder head is lifted off, pry off between the cylinder head and cylinder block with a screwdriver
NOTICE:
^ Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
^ The cylinder head should not be tilted so as to secure the valve lifter. If the cylinder head is tilted, remove the valve lifter and check that the adjusting shim is set correctly.
20. REMOVE CYLINDER HEAD GASKET
21. CLEAN CYLINDER BLOCK SUB-ASSY
a. Turn the crankshaft, and bring each piston to Top Dead Center (TDC) Using a gasket scraper, remove all the carbon from the piston top surface
b. Using a gasket scraper, remove all the gasket material from the cylinder block surface.
c. Using compressed air, blow carbon and oil from the bolt holes.
CAUTION: Protect your eyes when using high pressure compressed air.
22. INSPECT CYLINDER BLOCK FOR FLATNESS
a. Inspect for flatness. Using a precision-straight edge and feeler gauge, check for warpage by measuring.
Maximum warpage: 0.07 mm (0.0028 inch)
If warpage is greater than maximum, replace the cylinder block.
23. CLEAN CYLINDER HEAD SUB-ASSY
a. Using a gasket scraper, remove all the gasket material form the cylinder block contact surface.
NOTICE: Be careful not to scratch the cylinder block contact surface.
24. INSPECT CYLINDER HEAD FOR FLATNESS
a. Using a precision straight edge and feeler gauge, measure the surfaces contacting the cylinder block and the manifolds for warpage.
Maximum warpage: 0.10 mm (0.0039 inch)
If warpage is greater than maximum, replace the cylinder head.
25. INSPECT CYLINDER HEAD SET BOLT
a. Using vernier calipers, measure the thread outside diameter of the bolt.
Standard outside diameter: 9.810 - 9.960 mm (0.3862 - 0.3921 inch)
Minimum outside diameter: 9.700 mm (0.3819 inch)
If the diameter is less than minimum, replace the bolt.
26. INSTALL CYLINDER HEAD GASKET
a. Place new cylinder head gasket in position on the cylinder block.
HINT: On the rear side of the cylinder head gasket are marks to distinguish the LH and RH banks, a "2UR" mark for the RH bank and a "2UL" mark for the LH bank.
NOTICE: Be careful of the installation direction.
b. Place the cylinder head in position on the cylinder head gasket.
27. INSTALL CYLINDER HEAD SUB-ASSY
HINT:
^ The cylinder head bolts are tightened in 3 progressive steps.
^ If any cylinder head bolt is broken or deformed, replace it.
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 10 cylinder head bolts, and plate washers, in the sequence shown.
Torque: 32 Nm (325 kgf-cm, 24 ft. lbs.)
If any one of the cylinder head bolts does not meet the torque specification, replace the cylinder head bolt.
NOTICE: Do not drop the plate washer for cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.
d. Mark the front of the cylinder head bolt head with paint.
e. Retighten the cylinder head bolts by 90° in the numerical order shown.
f. Retighten the cylinder head bolts by an additional 90°.
g. Check that the painted mark is now at a 180° angle to front.
28. INSTALL FRONT EXHAUST PIPE
a. Place the new gasket to the front exhaust pipe.
b. Install the 2 nuts and front exhaust pipe.
Torque: 62 Nm (632 kgf-cm, 46 ft. lbs.)
29. CONNECT ENGINE WIRE
a. Connect the engine wire with bolt as shown in the illustration.
30. INSTALL WATER BY-PASS JOINT RR
31. INSTALL WATER BY-PASS JOINT FR
32. INSTALL WATER INLET HOUSING
a. Install the new gasket and water inlet housing with 2 bolts.
Torque: 18 Nm (185 kgf-cm, 13 inch lbs.)
33. INSTALL WATER BY-PASS PIPE SUB-ASSY
a. Install a new O-ring to the water by-pass pipe.
b. Apply soapy water to the O-ring
c. Push in the water by-pass pipe end into the pipe hole of the water pump.
d. Install the water by-pass pipe with the bolt
Torque: 18 Nm (185 kgf-cm, 13 ft. lbs.)
34. INSTALL INTAKE MANIFOLD ASSY
a. Install the 2 new gaskets to cylinder head
b. Install the intake manifold assy with the 6 bolts and 2 nuts.
Torque:
Bolt 18 Nm (185 kgf-cm, 13 ft. lbs.)
Nut 18 Nm (185 kgf-cm, 13 ft. lbs.)
35. CONNECT WATER BY-PASS HOSE
36. CONNECT WATER BY-PASS HOSE NO.7
37. INSTALL ENGINE WIRE
Torque: 8.2 Nm (83 kgf-cm, 72 inch lbs.)
38. CONNECT FUEL VAPOR FEED HOSE ASSY
39. CONNECT FUEL HOSE NO.2
40. CONNECT FUEL HOSE
41. INSTALL OIL LEVEL GAGE GUIDE
a. Install a new O-ring to the oil level gage guide
b. Install the oil level gage guide with the bolt.
Torque: 15 Nm (155 kgf-cm, 11 ft. lbs.)
42. INSTALL TRANSMISSION OIL FILLER TUBE SUB-ASSY
a. Install the transmission oil filler tube sub-assy with the bolt
43. INSTALL CAMSHAFT (RH BANK)
44. INSTALL TIMING BELT