CYLINDER HEAD GASKET REPLACEMENT [L3]

id0110a4800700

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 SERVICE PRECAUTION [L3].)

1.  Remove the splash shield (LH).

2.  Drain the engine coolant.

3.  Remove the timing chain. (See TIMING CHAIN REMOVAL/INSTALLATION [L3].)

4.  Disconnect the generator, but do not remove it from the vehicle.

5.  Fix the generator using a rope to prevent it from falling. (See GENERATOR REMOVAL/INSTALLATION [L3 L.H.D.].)(See GENERATOR REMOVAL/INSTALLATION [L3 R.H.D.].)

6.  Remove the cooling fan assembly.

7.  Remove the exhaust manifold. (See EXHAUST SYSTEM REMOVAL/INSTALLATION [L3].)

8.  Remove the intake manifold. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION [L3].)

9.  Remove the ignition coil (R.H.D.model). (See IGNITION COIL REMOVAL/INSTALLATION [L3 R.H.D.].)

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

11.  To firmly support the engine, first set the engine jack and attachment to the oil pan.

atraaw00003535

12.  Remove in the order indicated in the table.

13.  Install in the reverse order of removal.

14.  Inspect the compression. (See COMPRESSION INSPECTION [L3].)

atraaw00003546

1	Camshaft (See Camshaft Removal Note.) (See Camshaft Installation Note.)
2	Cylinder head (See Cylinder Head Removal Note.) (See Cylinder Head Installation Note.)
3	Cylinder head gasket (See Cylinder Head Gasket Installation Note.)

Camshaft Removal Note

Note

•  The cylinder head and the camshaft caps are numbered to be reassembled in their original position correctly. When removed, keep the caps with the cylinder head they were removed from. Do not mix the caps.

1.  Loosen the camshaft cap bolts in two or three steps in the order shown.

am5ezw00006860

Cylinder Head Removal Note

1.  Loosen the cylinder head bolts in two or three steps in the order shown.

am5ezw00006861

Cylinder Head Gasket Installation Note

1.  Apply silicone sealant to the areas shown in the figure.

Caution

•  Install the cylinder head gasket and cylinder head before the applied silicone sealant starts to harden.

acxaaw00001646

2.  Install the cylinder block with a new cylinder head gasket.

3.  Apply silicone sealant to the areas shown in the figure.

acxaaw00001647

4.  Install the cylinder head referring to the Cylinder Head Installation Note.

Cylinder Head Installation Note

1.  Measure the length of each cylinder head bolt.

•  Replace any that exceeds maximum length.

am5ezw00006862

2.  Tighten the cylinder head bolts in the order shown using the following 5 steps.

am5ezw00006863

(1)  Tighten 3—11 N·m {0.4—1.1 kgf·m, 2.3—8.1 ft·lbf}

(2)  Tighten 13—17 N·m {1.4—1.7 kgf·m, 10.0—12.5 ft·lbf}

(3)  Tighten 43—47N·m {4.4—4.7 kgf·m, 31.8—34.6 ft·lbf}

(4)  Tighten 88°—92°

(5)  Tighten 88°—92°

Camshaft Installation Note

1.  Apply the gear oil (SAE No. 90 or equivalent) to each journal of the cylinder head as shown in the figure.

atraaw00003537

2.  Set the cam position of No.1 cylinder at the top dead center (TDC) and install the camshaft.

3.  Apply the gear oil (SAE No. 90 or equivalent) to each journal of the camshaft as shown in the figure.

atraaw00003538

4.  Temporarily tighten the camshaft bearing caps evenly in two or three steps.

5.  Tighten the camshaft cap bolts in the order shown with the following two steps.

am5ezw00006866

(1)  Tighten to 5.0—9.0 N·m {51.0—91.7 kgf·cm, 44.6—79.5 in·lbf}

(2)  Tighten to 14.0—17.0 N·m {1.5—1.7 kgf·m, 10.4—12.5 ft·lbf}