Cylinder Head Gasket No. 1 (RH)

CYLINDER HEAD GASKET
REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE
2. REMOVE ENGINE UNDER COVER ASSY (W/ ENGINE UNDER COVER ASSY)
3. REMOVE ENGINE UNDER COVER NO.1
4. REMOVE ENGINE UNDER COVER NO.2 (W/ ENGINE UNDER COVER NO.2)
5. DRAIN ENGINE COOLANT
6. DRAIN ENGINE OIL
7. REMOVE FRONT WHEEL RH
8. REMOVE FR WIPER ARM RH
9. REMOVE FR WIPER ARM LH
10. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSY
11. REMOVE WINDSHIELD WIPER LINK ASSY
12. REMOVE COWL TOP PANEL SUB-ASSY OUTER
13. REMOVE V-BANK COVER SUB-ASSY
14. REMOVE AIR CLEANER CAP SUB-ASSY
15. REMOVE EMISSION CONTROL VALVE SET
16. REMOVE INTAKE AIR SURGE TANK
17. DISCONNECT FUEL PIPE SUB-ASSY NO.1





18. DISCONNECT HEATER INLET WATER HOSE
a. Lock the hose clamp as shown in the illustration.
b. Disconnect the heater inlet water hose
19. REMOVE INTAKE MANIFOLD





a. Remove the nut and disconnect the ground cable
b. Disconnect the 6 fuel injector connectors.





c. In order to remove the intake manifold, using several steps, remove the 9 bolts and 2 nuts in the sequence shown in the illustration.
20. DISCONNECT RADIATOR HOSE INLET
21. REMOVE WATER OUTLET
a. Disconnect the radiator hose inlet.





b. Disconnect the engine coolant temperature sensor connector.
c. Remove the clamp.
d. Remove the 2 bolts, 2 nuts and 2 washers.
e. Lock the hose clamp as shown in the illustration and remove the water outlet together with water by-pass hose No.1.
f. Remove the 2 gaskets from the 2 cylinder heads.
22. REMOVE FRONT FENDER APRON SEAL RH
23. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
24. REMOVE VANE PUMP V BELT
25. REMOVE ENGINE MOVING CONTROL ROD
26. REMOVE ENGINE MOUNTING STAY NO.2 RH
27. REMOVE GENERATOR BRACKET NO.2
28. REMOVE CRANKSHAFT PULLEY
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05031)
29. REMOVE TIMING BELT NO.1 COVER
30. REMOVE TIMING BELT NO.2 COVER
31. REMOVE ENGINE MOUNTING BRACKET RH
32. REMOVE TIMING BELT GUIDE NO.2
33. REMOVE TIMING BELT
34. REMOVE TIMING BELT IDLER SUB-ASSY NO.2
35. REMOVE CAMSHAFT TIMING PULLEY
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
36. REMOVE TIMING BELT NO.3 COVER
37. SEPARATE VANE PUMP ASSY
38. REMOVE PROPELLER SHAFT (4WD DRIVE TYPE)
SST 09325-20010
39. REMOVE EXHAUST PIPE SUB-ASSY FRONT NO.3
40. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1
41. REMOVE MANIFOLD STAY
42. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSY
a. Disconnect the heated oxygen sensor connector.





b. Using several steps, loosen and remove the 6 nuts in the sequence shown in the illustration
c. Remove the exhaust manifold RH and the gasket from the cylinder head RH
43. REMOVE IGNITION COIL ASSY
44. REMOVE CYLINDER HEAD COVER SUB-ASSY
45. REMOVE CAMSHAFT
46. REMOVE NO.2 CAMSHAFT
47. REMOVE CYLINDER HEAD SUB-ASSY





a. Disconnect the VVT sensor connector.
b. Disconnect the camshaft timing oil control valve connector
c. Remove the nut and disconnect the engine wire harness clamp.





d. Using a socket hexagon wrench 8, remove the hexagon bolt.





e. Using several steps, loosen the 8 cylinder head bolts uniformly in the sequence shown in the illustration. 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.

48. REMOVE CYLINDER HEAD GASKET





49. INSPECT CYLINDER HEAD SET BOLT
a. Using vernier calipers, measure the tension portion diameter of the bolt
Standard outside diameter: 8.95 to 9.05 mm (0.3524 to 0.3563 inch)
Minimum outside diameter: 8.75 mm (0.3445 inch)
If the diameter is less than minimum, replace the bolt.





50. INSTALL CYLINDER HEAD GASKET
a. Place a new cylinder head gasket on the cylinder block with the R mark upward.

NOTICE:
^ Remove any oil from the contact surface.
^ Be careful of the installing orientation.
^ Place the cylinder head on the gasket carefully in order not to damage the gasket at the bottom part of the head.

51. INSTALL CYLINDER HEAD SUB-ASSY

NOTICE: The cylinder head bolts are tightened in 2 successive steps.

a. Apply a light coat of engine oil on the threads of the cylinder head bolts.
b. Install the plate washers to the cylinder head bolts.





c. Using several steps, install and tighten the 8 cylinder head bolts uniformly in the sequence shown in the illustration.
Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.)





d. Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
e. Retighten the cylinder head bolts by 90° in the same sequence as step c.
f. Check that each painted mark is now at a 90° angle to the front.





g. Using a socket hexagon wrench 8, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)
h. Connect the engine wire harness clamp with the nut.
Torque: 8.4 Nm (85 kgf-cm, 74 inch lbs.)
52. INSTALL NO.2 CAMSHAFT
53. INSTALL CAMSHAFT
54. INSTALL CYLINDER HEAD COVER SUB-ASSY
55. INSTALL IGNITION COIL ASSY





56. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSY
a. Install a new gasket and the exhaust manifold RH with the 6 nuts. Using several steps, tighten the nuts uniformly in the sequence shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
b. Retighten nuts 1 and 2 shown in the illustration.
57. INSTALL MANIFOLD STAY
Torque: 34 Nm (347 kgf-cm, 25 ft. lbs.)
58. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
Torque: 8.5 Nm (87 kgf-cm, 75 inch lbs.)
59. INSTALL EXHAUST PIPE SUB-ASSY FRONT NO.3
60. INSTALL PROPELLER SHAFT (4WD DRIVE TYPE)
61. INSTALL VANE PUMP ASSY
62. INSTALL TIMING BELT NO.3 COVER
63. INSTALL CAMSHAFT TIMING PULLEY
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
64. INSTALL TIMING BELT IDLER SUB-ASSY NO.2
65. INSPECT TIMING BELT
66. INSTALL TIMING BELT
SST 09960-10010 (09962-01000, 09963-01000)
67. INSTALL CHAIN TENSIONER ASSY NO.1
68. INSTALL TIMING BELT GUIDE NO.2
69. INSTALL ENGINE MOUNTING BRACKET RH
70. INSTALL TIMING BELT NO.2 COVER
71. INSTALL TIMING BELT NO.1 COVER
72. INSTALL CRANKSHAFT PULLEY
SST 09213-54015 (91651-60855), 09330-00021
73. INSTALL GENERATOR BRACKET NO.2
74. INSTALL ENGINE MOUNTING STAY NO.2 RH
75. INSTALL ENGINE MOVING CONTROL ROD
76. INSTALL VANE PUMP V BELT
77. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
78. INSPECT DRIVE BELT DEFLECTION AND TENSION (REFERENCE)
79. INSTALL WATER OUTLET
a. Install 2 new gaskets to the 2 cylinder heads.
b. Install the water outlet together with water by-pass hose No.1 and unlock the hose clamp.
c. Tighten the 2 bolts, 2 nuts and 2 washers.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
d. Install the clamp.
e. Connect the engine coolant temperature sensor connector.
f. Connect the radiator hose inlet.





80. INSTALL INTAKE MANIFOLD
a. Install the intake manifold with the 9 bolts, 2 nuts and 2 washers. Using several steps tighten the bolts and nuts uniformly in the sequence shown in the illustration.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
b. Retighten the water outlet mounting bolts and nuts.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
c. Install the ground cable with the nut.
Torque: 8.4 Nm (86 kgf-cm, 74 inch lbs.)
d. Connect the heater inlet water hose.
81. CONNECT FUEL PIPE SUB-ASSY NO.1
82. INSTALL INTAKE AIR SURGE TANK
83. INSTALL EMISSION CONTROL VALVE SET
84. INSTALL AIR CLEANER CAP SUB-ASSY
85. CONNECT VACUUM HOSE
86. INSTALL V-BANK COVER SUB-ASSY
87. INSTALL COWL TOP PANEL SUB-ASSY OUTER
88. INSTALL WINDSHIELD WIPER LINK ASSY
89. INSTALL FR WIPER ARM LH
90. INSTALL FR WIPER ARM RH
91. INSTALL FRONT WHEEL RH
92. ADD ENGINE OIL
93. ADD ENGINE COOLANT
94. CHECK FOR ENGINE OIL LEAKS
95. CHECK FOR ENGINE COOLANT LEAKS
96. INSPECT FOR FUEL LEAKS
97. CHECK FOR EXHAUST GAS LEAKS
98. INSPECT IGNITION TIMING
SST 09843-18040
99. INSPECT ENGINE IDLE SPEED
SST 09843-18040
100. INSPECT COMPRESSION
SST 09992-00500
101. INSPECT CO/HC