Cylinder Head Gasket: Service and Repair
REPLACEMENT1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
2. DRAIN COOLANT
3. REMOVE FRONT WHEEL RH
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE CYLINDER HEAD COVER NO.2
a. Remove the 3 bolts, the nut and the cylinder head cover No. 2.
6. DISCONNECT ACCELERATOR CONTROL CABLE ASSY
7. REMOVE AIR CLEANER CAP SUB-ASSY
8. DISCONNECT UNION TO CONNECTOR TUBE HOSE
a. Disconnect the union to check valve hose from the brake booster.
9. REMOVE EFI FUEL PIPE CLAMP
10. DISCONNECT FUEL TUBE SUB-ASSY
11. SEPARATE RADIATOR HOSE INLET
12. DISCONNECT HEATER INLET WATER HOSE
13. DISCONNECT HEATER OUTLET WATER HOSE
14. DISCONNECT WATER BY-PASS HOSE NO.2
15. DISCONNECT WATER BY-PASS HOSE NO.3
16. REMOVE WIRE HARNESS PROTECTOR
a. Unfasten the 3 clips, then remove the wire harness protector.
b. Disconnect the pressure sensor connector.
17. REMOVE AIR SWITCHING VALVE ASSY
18. DISCONNECT SUCTION HOSE SUB-ASSY
a. Remove the 2 nuts installing the suction hose sub-assy.
b. Disconnect the suction hose sub-assy.
19. REMOVE FAN AND GENERATOR V-BELT
a. Turn the drive belt tensioner slowly clockwise and loosen it. Then, remove the drive belt and put back the drive belt tensioner little by little and fix it quietly.
20. REMOVE GENERATOR BRACKET NO.1
21. REMOVE GENERATOR ASSY
22. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONER)
HINT: Hang up the hoses instead of detaching.
23. DISCONNECT EXHAUST PIPE ASSY FRONT
b. Remove the gasket.
24. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSY RH
a. Set the jack to the engine.
HINT: Place a wooden block between the jack and engine.
b. Remove the 5 bolts, 2 nuts and engine mounting insulator sub-assy RH
25. REMOVE V-RIBBED BELT TENSIONER ASSY
HINT: Handle a jack up and down to remove the bolt.
26. INSTALL IGNITION COIL ASSY
a. Remove the 4 bolts and the 4 ignition coils.
27. REMOVE CYLINDER HEAD COVER SUBASSY
a. Disconnect the 2 ventilation hoses.
b. Remove the 2 nuts and bolt, then separate the ventilation tube No. 1.
c. Remove the gasket from the cylinder head cover.
d. Remove the 2 nuts, then separate the wire harness protector.
e. Remove the bolt and fuel tube clamp.
f. Remove the bolt and union to connector tube hose clamp.
g. Remove the 9 bolts, bracket, wire harness protector, and cylinder head cover.
h. Remove the Oring from the cylinder head cover.
28. REMOVE MANIFOLD STAY
a. Remove the 2 bolts, nut and exhaust manifold stay.
29. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO.1
30. REMOVE EXHAUST MANIFOLD
a. Remove the 4 bolts and 2 nuts, then remove the exhaust manifold and gasket.
31. REMOVE WATER PUMP PULLEY
a. Using SST, remove the water pump pulley.
SST 09960-10010
32. REMOVE WATER PUMP ASSY
a. Remove the 6 bolts and water pump.
33. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
a. Remove the 4 bolts and the engine mounting bracket.
34. REMOVE CRANK POSITION SENSOR
35. SET NO.1 CYLINDER TO TDC/COMPRESSION
a. Turn the crankshaft pulley, and align its groove with timing mark "0" of the timing chain cover.
b. Check that the point marks of the camshaft timing sprocket and VVT timing sprocket are in straight line on the timing chain cover surface as shown in the illustration.
HINT: If not, turn the crankshaft 1 revolution (360°) and align the marks.
36. REMOVE CRANKSHAFT PULLEY
a. Using SST, remove the pulley bolt.
SST 09213-70011 (09213-70020), 09330-00021
b. Using SST, remove the crankshaft pulley.
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021, 09957-04010)
37. REMOVE CHAIN TENSIONER ASSY NO.1
a. Remove the 2 nuts and the chain tensioner assy No. 1.
NOTICE: Be sure not to revolve the crankshaft without the chain tensioner.
38. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSY
b. Using a torx wrench socket (E8), remove the stud bolt.
a. Remove the 13 bolts.
c. Remove the timing chain cover and 2 gaskets.
NOTICE: Be careful no tot damage the contact surfaces of the timing chain cover, cylinder head and cylinder block.
39. REMOVE TIMING GEAR COVER OIL SEAL
a. Using a screwdriver, remove the oil seal.
40. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
41. REMOVE CHAIN TENSIONER SLIPPER
a. Remove the bolt and the chain tensioner slipper.
42. REMOVE CHAIN VIBRATION DAMPER NO.1
a. Remove the 2 bolts and chain vibration damper No. 1.
43. REMOVE CHAIN SUB-ASSY
a. Remove the timing chain with the crankshaft timing gear prying screwdrivers as shown in the illustration.
NOTICE:
^ Put shop rag to protect the engine.
^ In case of revolving the camshafts with the chain off the sprockets, turn the crankshaft 1/4 revolution for valves not to touch the pistons.
44. REMOVE OIL LEVEL GAGE GUIDE
45. REMOVE OIL LEVEL GAGE SUB-ASSY
46. REMOVE SURGE TANK STAY NO.1
a. Remove the 2 bolts, nut and surge tank stay No. 1.
47. REMOVE INTAKE MANIFOLD
a. Remove the 4 bolts, the 2 nuts, the intake manifold and the gasket.
48. REMOVE CAMSHAFT
a. Uniformly loosen and remove the 20 bearing cap bolts, in several passes, in the sequence shown, and remove the 9 bearing caps, of the intake and exhaust camshafts.
49. REMOVE CYLINDER HEAD SUB-ASSY
a. Detach the water by-pass pipe from the cylinder head.
b. Using a 10 mm bi-hexagon wrench, uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown. 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 and incorrect order.
50. REMOVE CYLINDER HEAD GASKET
51. INSTALL CYLINDER HEAD GASKET
a. Place a new cylinder head gasket on the cylinder block.
NOTICE:
^ Pay attention to the installation direction.
^ Place the cylinder head quietly in order not to damage the gasket with the bottom part of the head.
b. Apply seal packing to the cylinder head gasket as shown in the illustration.
Seal packing:
Part No. 08826-00080 or equivalent
HINT: avoid applying an excessive amount to the surface.
^ Parts must be assembled with in 3 minutes of application. Otherwise the material must be removed and reapplied.
^ Immediately remove nozzle from the tube and reinstall cap.
52. INSPECT CYLINDER HEAD SET BOLT
a. Using vernier calipers, measure the length of head bolts from the seat to the end.
Standard bolt length: 146.0 - 148.2 mm (5.780 - 5.835 inch)
Maximum bolt length: 148.5 mm (5.846 inch)
b. If the length surpasses the maximum, replace the bolt.
53. 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. Using a 10 mm bi-hexagon wrench, install and uniformly tighten the 10 cylinder head bolts and plate washers, in several passes, in the sequence shown.
Torque: 35 Nm (357 kgf-cm, 26 ft. lbs.)
c. Make the front of the cylinder head bolt with paint.
d. Retighten the cylinder head bolts 180° in the numerical order shown.
e. Check that the point marked bolts are moved at 90° angle.
f. Install the water by-pass pipe.
Torque: 21 Nm (214 kgf-cm, 16 ft. lbs.)
54. INSTALL CAMSHAFT
a. Apply light coat of engine oil on the camshaft journals.
b. Place the 2 camshafts on the cylinder head with the No. 1 cam lobes facing as shown the illustration.
c. Examine the front marks and numbers and tighten the bolts in the order shown in the illustration.
Torque: 19 Nm (194 kgf-cm, 14 ft. lbs.)
55. INSTALL INTAKE MANIFOLD
a. Install a new gasket, the intake manifold with the 4 bolts and 2 nuts.
Torque:
A: 34 Nm (347 kgf-cm, 25 ft. lbs.)
B: 46 Nm (469 kgf-cm, 34 ft. lbs.)
56. INSTALL SURGE TANK STAY NO.1
a. Install the surge tank stay with the 2 bolts and nut.
Torque: 24 Nm (245 kgf-cm, 18 ft. lbs.)
57. INSTALL OIL LEVEL GAGE GUIDE:
a. Apply a light coat of engine oil to the new O-ring, install it to the oil level gage guide.
58. INSTALL CHAIN SUB-ASSY
a. Set No. 1 cylinder to TDC/compression.
1 Turn the hexagonal wrench head portion of the camshafts, and align the point marks of the camshaft timing sprockets.
2 Turn the crankshaft and set the set key on the crankshaft upward.
b. Install the timing chain on the crankshaft timing sprocket with the yellow mark link aligned with the timing mark on the crankshaft timing sprocket.
HINT: Three yellow color links are on the chain.
c. Using a SST, install the sprocket.
SST 09223-22010
d. Install the timing chain on the camshaft timing sprockets with the yellow mark links aligned with the timing marks on the camshaft timing sprockets.
59. INSTALL CHAIN VIBRATION DAMPER NO.1
a. Install the chain vibration damper No, 1 with the 2 bolts.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)
60. INSTALL CHAIN TENSIONER SLIPPER
a. Install the chain tensioner slipper with the bolt.
Torque: 21 Nm (214 kgf-cm, 15 ft. lbs.)
b. Check that the chain tensioner slipper moves is caught on the cylinder head stopper.
NOTICE: Do not turn the crankshaft.
61. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1
a. Install the plate with the "F" mark facing forward.
62. INSTALL TIMING GEAR COVER OIL SEAL
a. Apply MP grease to the oil seal lip.
b. Using SST and a hammer, tap in a new oil seal until its surface is flush with the timing chain cover edge.
SST 09223-22010
NOTICE: Keep the lip free of foreign materials.
63. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSY
a. Remove any old packing (FIPG) material and be careful not to drop any oil on the contact surface of the timing chain cover, cylinder head and cylinder block.
^ Using a razor blade and a gasket scraper, remove all the old packing (FIPG) material from the gasket surfaces and sealing grooves.
^ Thoroughly clean all components to remove all the loose material.
^ Using a non-residue solvent, clean both sealing surfaces.
b. Apply seal packing to the timing chain cover an shown in the illustration.
Seal packing:
Part No. 08826-00100 or equivalent
^ Install a nozzle that has been cut to a 1.5 mm opening.
HINT: Avoid applying an excessive amount to the surface.
^ Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
^ Immediately remove nozzle from the tube and reinstall cap.
c. Install the 2 gaskets to the timing chain cover an shown in the illustration.
d. Apply seal packing to 4 locations an shown in the illustration.
Seal packing:
Part No. 08826-00080 or equivalent
^ Install a nozzle that has been cut to a 4 - 5 mm (0.16 - 0.20 inch) opening.
HINT: Avoid applying an excessive amount to the surface.
^ Parts must be assembled within 3 minutes of application. Otherwise the material must be removed and reapplied.
^ Immediately remove nozzle from the tube and rein stall cap.
NOTICE: Do not put into engine oil within 2 hours after installing.
e. Install the timing chain cover, with the 12 bolts and nut.
Torque:
21 Nm (214 kgf-cm, 15 ft. lbs.) (M8)
11 Nm (112 kgf-cm, 8 ft. lbs.) (M6)
f. Install the stud bolt.
Torque: 9.5 Nm (97 kgf-cm, 84 inch lbs.)
64. INSTALL CHAIN TENSIONER ASSY NO.1
a. Check the O-ring is clean, and set the hook as shown in the illustration.
b. Apply engine oil to the chain tensioner and install it.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
NOTICE: When installing the tensioner, set the hook again if the hook release the plunger.
65. INSTALL CRANKSHAFT PULLEY
a. Align the pulley set key with the key groove of the pulley, and slide on the pulley.
b. Using SST, install the pulley bolt.
SST 09213-70011 (09213-70020), 09330-00021
Torque: 120 Nm (1,224 kgf-cm, 89 ft. lbs.)
c. Turn the crankshaft counterclockwise, and disconnect the plunger knock pin form the hook.
d. Turn the crankshaft clockwise, and check that the slipper is pushed by the plunger.
66. INSTALL CRANK POSITION SENSOR
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
67. INSTALL TRANSVERSE ENGINE ENGINE MOUNTING BRACKET
a. Install the engine mounting bracket with the 4 bolts.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
68. INSTALL WATER PUMP ASSY
a. Place a new O-ring on the timing chain cover.
b. Install the water pump with the 6 bolts.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
HINT: Each bolt length is indicated in the illustration.
69. INSTALL WATER PUMP PULLEY
a. Using SST, install the water pump pulley.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
SST 09960-10010
70. INSTALL EXHAUST MANIFOLD
a. Install a new gasket and exhaust manifold with the 4 bolts and 2 nuts.
Torque:
50 Nm (510 kgf-cm, 37 ft-lbf) for bolt A and nut A
21 Nm (214 kgf-cm, 16 ft-lbf) for bolt B
71. INSTALL EXHAUST MANIFOLD HEAT INSULATOR NO.1
Torque: 20 Nm (204 kgf-cm, 15 ft. lbs.)
72. INSTALL MANIFOLD STAY
a. Install the exhaust manifold stay with the 2 bolts and nut
Torque: 50 Nm (510 kgf-cm, 37 ft. lbs.)
73. INSTALL CYLINDER HEAD COVER SUBASSY
a. Install a new Oring to the cylinder head cover.
b. Remove any old packing (FIPG) material.
c. Apply seal packing to 2 locations as shown in the illustration.
Seal packing: Part No. 0882600080 or equivalent
NOTICE:
- Remove any oil from the contact surface.
- Install the cylinder head cover within 3 minutes after applying seal packing.
- Do not put into engine oil within 2 hours of installation.
d. Install the cylinder head cover, wire harness protector and bracket with the 9 bolts. Uniformly tighten the bolts, in the several passes in the sequence shown.
Torque: 10 Nm (102 kgf-cm, 7 ft-lbf)
e. Install the union to connector tube hose clamp with the bolt.
Torque: 7.0 Nm (71 kgf-cm, 62 in.-lbf)
f. Install the fuel tube clamp with the bolt.
Torque: 7.5 Nm (76 kgf-cm, 66 in.-lbf)
g. Install the wire harness protector with the 2 nuts.
Torque: 9.0 Nm (92 kgf-cm, 80 in.-lbf)
h. Install a new gasket and ventilation tube No. 1 with the 2 nuts and bolt.
Torque:
10 Nm (102 kgf-cm, 7 ft-lbf) for nut
24 Nm (245 kgf-cm, 18 ft-lbf) for bolt
74. INSTALL IGNITION COIL ASSY
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
75. INSTALL V-RIBBED BELT TENSIONER ASSY
a. Install the bolt, the nut and v-ribbed belt tensioner assy.
Torque:
Nut 29 Nm (296 kgf-cm, 21 ft. lbs.)
Bolt 100 Nm (1,020 kgf-cm, 74 ft. lbs.)
76. INSTALL ENGINE MOUNTING INSULATOR SUB-ASSY RH
a. Install the engine mounting insulator sub-assy RH with the 5 bolts and the 2 nuts.
Torque: 52 Nm (530 kgf-cm, 38 ft. lbs.)
77. INSTALL EXHAUST PIPE ASSY FRONT
78. INSTALL COMPRESSOR AND MAGNETIC CLUTCH (W/ AIR CONDITIONER)
79. INSTALL GENERATOR ASSY
80. INSTALL GENERATOR BRACKET NO.1
81. INSTALL SUCTION HOSE SUB-ASSY
Torque: 9.8 Nm (100 kgf-cm, 87 inch lbs.)
82. INSTALL AIR SWITCHING VALVE ASSY
83. INSTALL CYLINDER HEAD COVER NO.2
Torque: 7.0 Nm (71 kgf-cm, 62 inch lbs.)
84. INSTALL FRONT WHEEL RH
Torque: 103 Nm (1,050 kgf-cm, 76,ft. lbs.)
85. ADD COOLANT
86. CHECK ENGINE COOLANT LEAK
87. CHECK ENGINE OIL LEAK
88. CHECK IDLE SPEED AND IGNITION TIMING
SST 09843-18040
89. INSPECT COMPRESSION
SST 09992-00500
90. INSPECT CO/HC