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CYLINDER HEAD GASKET REPLACEMENT [ZJ, ZY]

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  Warning

  • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedure". (See BEFORE REPAIR PROCEDURE.)

1. Remove the timing chain. (See TIMING CHAIN REMOVAL/INSTALLATION [ZJ, ZY].)

2. Remove the EGR pipe and EGR valve bracket. (With EGR) (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [WITH WU-TWC].) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [WITH WU-TWC].) (See EGR VALVE REMOVAL/INSTALLATION [WITH WU-TWC].)

3. Remove the exhaust manifold. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [WITHOUT WU-TWC].) (See EXHAUST SYSTEM REMOVAL/INSTALLATION [WITH WU-TWC].)

4. Remove the intake manifold. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [WITHOUT WU-TWC].) (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [WITH WU-TWC].)

5. Disconnect the heater hose, bypass hose, and radiator hose.

6. Remove in the order indicated in the table.

7. Install in the reverse order of removal.

8. Inspect the compression. (See COMPRESSION INSPECTION [ZJ, ZY].)

1 | Camshaft cap (See Camshaft Cap Removal Note.) (See Camshaft Cap Installation Note.)
2 | Camshaft
3 | Cylinder head (See Cylinder Head Removal Note.) (See Cylinder Head Installation Note.)
4 | Cylinder head gasket

## Camshaft Cap Removal Note

1. Loosen the camshaft cap installation bolts in two or three steps in the order shown in the figure, and remove them.

## Cylinder Head Removal Note

1. Loosen the cylinder head installation bolts in two or three steps in the order shown in the figure, and remove them.

## Cylinder Head Installation Note

1. Measure the length of each cylinder head installation bolt.

  • If it exceeds the maximum specification, replace the cylinder head installation bolt.

Cylinder head bolt length

  Standard: 128.9-129.5 mm {5.075-5.098 in}
  Maximum: 130.2 mm {5.125 in}

2. Tighten the cylinder head installation bolts in three steps in the order shown in the figure.

(1) Tightening torque: 17.5-22.5 N·m {1.79-2.29 kgf·m, 13.0-16.5 ft·lbf}

(2) Tightening angle: 85°-95°

(3) Tightening angle: 85°-95°

## Camshaft Cap Installation Note

1. Align the No.1 cylinder camshaft position to the TDC position, and install the camshaft.

2. Install the camshaft caps in the positions numbered as shown in the figure, and then temporarily tighten the No.2 and No.7 camshaft cap installation bolts.

3. Tighten the camshaft cap installation bolts in two or three steps uniformly in the order shown in the figure.

Tightening torque

  11.3-14.2 N·m {116-144 kgf·cm, 100.1-125.6 in·lbf}