Cylinder Head Gasket No. 2

REPLACEMENT
1. PREVENT GASOLINE FROM SPILLING OUT
2. REMOVE TIMING BELT
3. REMOVE CAMSHAFT (LH BANK)
4. REMOVE INTAKE MANIFOLD ASSEMBLY
5. REMOVE WATER INLET HOUSING
a. Remove the 2 bolts.
b. Remove the water inlet housing and O-ring from the engine.
6. REMOVE WATER BY-PASS JOINT FR
a. Remove the 4 nuts.
b. Remove the water by-pass joint and 2 gaskets.
7. REMOVE WATER BY-PASS PIPE SUB-ASSEMBLY
a. Remove the bolt and water by-pass pipe.
8. REMOVE AIR SWITCHING VALVE NO.2
9. REMOVE WATER BY-PASS JOINT RR
a. Remove the 4 nuts, water by-pass joint and 2 gaskets.
10. DISCONNECT ENGINE WIRE
11. REMOVE REAR TIMING BELT PLATE LH NO. 2
a. Remove the 2 bolts and rear timing belt plate LH No.2.
12. REMOVE REAR TIMING BELT PLATE LH
a. Remove the bolt and rear timing belt plate LH.
13. SEPARATE FRONT EXHAUST PIPE
a. Remove the 2 bolts and separate the front exhaust pipe.
14. REMOVE CYLINDER HEAD LH





a. Uniformly loosen the 10 cylinder head bolts in the order shown in the illustration. Remove the 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 the 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.





b. Lift 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 cannot be lifted easily, pry 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.

15. REMOVE CYLINDER HEAD GASKET NO.2
16. CLEAN CYLINDER BLOCK SUB-ASSEMBLY





a. Turn the crankshaft, and bring each piston to the 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 compressed air.

17. CHECK CYLINDER BLOCK FOR WARPAGE





a. Inspect for warpage.
1 Using a precision straight edge and feeler gauge, measure the warpage of the contact surfaces of the cylinder head and crankshaft bearing cap.
Maximum warpage: 0.07 mm (0.0028 inch)
If warpage is greater than the maximum, replace the cylinder block sub-assembly.





b. Visually check the cylinder for vertical scratches. If deep scratches are present, rebore all the 8 cylinders and replace all the 8 pistons. If necessary, replace the cylinder block.
18. CLEAN CYLINDER HEAD LH





a. Clean the cylinder head.
1 Using a gasket scraper, remove all the gasket material from the cylinder block contact surface.

NOTICE: Be careful not to scratch the cylinder block contact surface.





2 Using a wire brush, remove all the carbon from the combustion chambers.

NOTICE: Be careful not to scratch the cylinder block contact surface.





3 Using a valve guide bushing brush and solvent, clean all the guide bushes.





4 Using a soft brush and solvent, thoroughly clean the cylinder head.
19. INSPECT CHECK CYLINDER HEAD FOR WARPAGE





a. Inspect for warpage.
1 Using a precision straight edge and feeler gauge, measure the warpage of the contact surfaces of the cylinder block and the manifolds.
Maximum warpage: 0.10 mm (0.0039 inch)
If warpage is greater than the maximum, replace the cylinder head.





b. Inspect for cracks.
1 Using a dye penetrant, check the combustion chamber, intake ports, exhaust ports and cylinder block surface for cracks.
If cracked, replace the cylinder head.





20. INSPECT CYLINDER HEAD SET BOLT
a. Using vernier calipers, measure the thread outside diameter of the bolt.
Standard outside diameter: 9.810 to 9.960 mm (0.3862 to 0.3921 inch)
Minimum outside diameter: 9.700 mm (0.3819 inch)
If the diameter is less than the minimum, replace the bolt.





21. INSTALL CYLINDER HEAD GASKET NO.2
a. Place a new cylinder head gasket in position on the cylinder block.

HINT: A mark is placed on the rear side of the cylinder head gasket to distinguish the LH and RH banks, a 2R mark for the RH bank and a 2L mark for the LH bank.

NOTICE: Be careful of the installation direction.

b. Place the cylinder head in position on the cylinder head gasket.
22. INSTALL CYLINDER HEAD LH





a. Check that the timing mark of the crankshaft timing pulley is in the position shown in the illustration, and that the piston is below the TDC of compression.
b. Install the cylinder head with the exhaust manifold to the cylinder block.

HINT:
^ The cylinder head bolts are tightened in 3 progressive steps.
^ If any cylinder head bolt is broken or deformed, replace it.





c. Apply a light coat of engine oil to the threads and under the heads of the cylinder head bolts.
d. Install the plate washer to the cylinder head bolt.
e. Install and uniformly tighten the 10 cylinder head bolts, and plate washers, in the order shown in the illustration.
Torque: 40 Nm (408 kgf-cm, 30 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 the 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.





f. Mark the front of the cylinder head bolt head with paint.
g. Retighten the cylinder head bolts by 90° in the order shown.
h. Retighten the cylinder head bolts by an additional 90°.
i. Check that the painted mark is now at a 180° angle to front.
23. INSTALL FRONT EXHAUST PIPE
a. Place a 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.)
24. INSTALL REAR TIMING BELT PLATE LH
a. Install the bolt and rear timing belt plate LH.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
25. INSTALL REAR TIMING BELT PLATE LH NO. 2
a. Install the 2 bolts and rear timing belt plate LH No.2.
Torque: 7.5 Nm (80 kgf-cm, 66 inch lbs.)
26. INSTALL WATER BY-PASS JOINT RR
27. INSTALL AIR SWITCHING VALVE NO.2
28. INSTALL WATER BY-PASS JOINT FR
29. INSTALL WATER INLET HOUSING
30. INSTALL WATER BY-PASS PIPE SUB-ASSEMBLY
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.)
31. INSTALL INTAKE MANIFOLD ASSEMBLY
Nut 18 Nm (185 kgf-cm, 13 ft. lbs.)
32. INSTALL CAMSHAFT (LH BANK)
33. INSTALL TIMING BELT