Removal and Replacement
CYLINDER HEAD GASKETREPLACEMENT
1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
2. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER)
3. DRAIN COOLANT
4. DISCONNECT RADIATOR HOSE OUTLET
5. DISCONNECT UNION TO CONNECTOR TUBE HOSE
6. DISCONNECT HEATER INLET WATER HOSE
7. DISCONNECT FUEL TUBE SUB-ASSY
8. REMOVE INTAKE MANIFOLD
a) Disconnect the 2 water by-pass hoses of the throttle body.
b) Remove the 5 bolts, 2 nuts, intake manifold and gasket.
9. REMOVE INTAKE MANIFOLD RUNNER VALVE ASSY (PZEV ONLY)
10. DISCONNECT ENGINE WIRE
11. REMOVE INTAKE MANIFOLD INSULATOR NO.1
12. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1
13. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSY
a) Remove the 3 bolts, 2 nuts, and No. 1 and No. 2 exhaust manifold stays.
b) Remove the 5 nuts, exhaust manifold and gasket.
14. REMOVE CHAIN SUB-ASSY
15. REMOVE NO.2 CAMSHAFT
a) Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Then remove the 5 bearings.
b) Remove the camshaft.
16. REMOVE CAMSHAFT
a) Uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration. Then remove the 5 bearings.
b) Remove the camshaft.
17. REMOVE CAMSHAFT BEARING NO.2
18. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY
19. REMOVE CYLINDER HEAD SUB-ASSY
a) Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 bolts in the sequence shown in the illustration. Remove the 10 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.
20. REMOVE CYLINDER HEAD GASKET
21. INSPECT CYLINDER HEAD SET BOLT
a) Using a vernier caliper, measure the length of the head bolts from the seat to the end.
Specified bolt length: 161.3 to 164.2 mm (6.350 to 6.465 inch)
If the length is greater than the maximum, replace the bolt.
22. INSTALL CYLINDER HEAD GASKET
a) Place a new gasket on the cylinder block surface with the "Lot No." stamp facing upward.
NOTICE:
^ Remove any oil from contact surface.
^ Be careful of the installation direction.
^ To avoid damage to the gasket, place the cylinder head on the gasket carefully.
23. INSTALL CYLINDER HEAD SUB-ASSY
HINT: The cylinder head bolts are tightened in 2 progressive steps.
a) Apply a light coat of engine oil on the threads and under the heads of the cylinder head bolts.
b) Install the bolts and plate washers to the cylinder head.
NOTICE: Do not drop the washers into the cylinder head.
c) Using a 10 mm bi-hexagon wrench, uniformly tighten the 10 bolts in the sequence shown in the illustration.
Torque: 79 Nm (806 kgf-cm, 58 ft. lbs.)
d) Mark the front side of the cylinder head bolt with paint.
e) Retighten the cylinder head bolts by 90° in the sequence shown in the illustration. Check that the painted mark is now at a 90° angle to the front.
24. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
25. INSTALL CAMSHAFT BEARING NO.2
26. INSTALL CAMSHAFT
a) Examine the front marks and numbers of the 5 bearing caps and install them. Then install the 10 bearing cap bolts. Uniformly tighten the bolts in the sequence shown in the illustration.
Torque: 30 Nm (301 kgf-cm, 22 ft. lbs.) for bearing cap No. 1
9.0 Nm (92 kgf-cm, 80 inch lbs.) for bearing cap No. 3
27. INSTALL NO.2 CAMSHAFT
a) Examine the front marks and numbers of the 5 bearing caps and install them. Then install the 10 bearing cap bolts. Uniformly tighten the bolts in the sequence shown in the illustration.
Torque: 30 Nm (301 kgf-cm, 22 ft. lbs.) for bearing cap No. 2
9.0 Nm (92 kgf-cm, 80 inch lbs.) for bearing cap No. 3
28. INSTALL CHAIN SUB-ASSY
29. INSTALL EXHAUST MANIFOLD CONVERTER SUB-ASSY
a) Install a new gasket and the exhaust manifold with the 5 nuts.
Torque: 37 Nm (378 kgf-cm, 27 ft. lbs.)
b) Install the No. 1 and No. 2 exhaust manifold stays with the 3 bolts and 2 nuts.
Torque: 44 Nm (449 kgf-cm, 32 ft. lbs.)
30. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
Torque: 12 Nm (122 kgf-cm, 9 ft. lbs.)
31. INSTALL INTAKE MANIFOLD RUNNER VALVE ASSY (PZEV ONLY)
32. INSTALL INTAKE MANIFOLD
a) Install a new gasket and the intake manifold with the 5 bolts and 2 nuts.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
b) Connect the 2 water by-pass hose to the throttle body.
33. CONNECT FUEL TUBE SUB-ASSY
34. ADD ENGINE OIL
35. ADD ENGINE COOLANT
36. CHECK FOR ENGINE OIL LEAKS
37. CHECK FOR ENGINE COOLANT LEAKS
38. INSPECT FOR FUEL LEAKS
39. INSPECT CHECK IDLE SPEED AND IGNITION TIMING
40. INSPECT CO/HC