Cylinder Head Gasket No. 1 (RH)

CYLINDER HEAD GASKET
REPLACEMENT
1. WORK FOR PREVENTING GASOLINE FROM SPILLING OUT
2. DRAIN ENGINE COOLANT
3. DRAIN ENGINE OIL
4. REMOVE EXHAUST PIPE NO.1 SUPPORT BRACKET
5. REMOVE EXHAUST PIPE ASSY FRONT
6. REMOVE EXHAUST MANIFOLD SUB-ASSY RH
7. REMOVE V-BANK COVER SUB-ASSY
8. REMOVE FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER)
9. REMOVE AIR CLEANER ASSEMBLY WITH HOSE
10. REMOVE INTAKE AIR SURGE TANK
11. DISCONNECT FUEL PIPE SUB-ASSY NO.1
12. DISCONNECT HEATER INLET WATER HOSE





a) Lock the hose clamp as shown in the illustration.
b) Disconnect the heater inlet water hose.
13. REMOVE INTAKE MANIFOLD





a) Remove the nut and disconnect the ground cable.
b) Disconnect the 6 fuel injector connectors.





c) Uniformly loosen and remove the intake manifold's 9 bolts and 2 nuts in the sequence shown in the illustration. Remove the intake manifold.
14. DISCONNECT RADIATOR HOSE INLET
15. REMOVE WATER OUTLET





a) Disconnect the radiator hose inlet.
b) Disconnect the engine coolant temperature sensor connector.
c) Remove the clamp.
d) Remove the 2 bolts, 2 nuts and 2 washers.
e) Lock the hose clamp as shown in the illustration, and remove the water outlet together with the water by-pass hose No. 1.
f) Remove the 2 gaskets from the 2 cylinder heads.
16. REMOVE FRONT WHEEL RH
17. REMOVE FRONT FENDER APRON SEAL RH
18. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
19. REMOVE VANE PUMP V BELT
20. REMOVE ENGINE MOVING CONTROL ROD
21. REMOVE ENGINE MOUNTING STAY NO.2 RH
22. REMOVE GENERATOR BRACKET NO.2
23. REMOVE CRANKSHAFT PULLEY
24. REMOVE TIMING BELT NO.1 COVER
25. REMOVE TIMING BELT NO.2 COVER
26. REMOVE ENGINE MOUNTING BRACKET RH
27. REMOVE TIMING BELT GUIDE NO.2
28. REMOVE TIMING BELT
29. REMOVE TIMING BELT IDLER SUB-ASSY NO.2
30. REMOVE CAMSHAFT TIMING PULLEY
31. REMOVE TIMING BELT NO.3 COVER
32. REMOVE VANE PUMP ASSY
33. REMOVE IGNITION COIL ASSY
34. REMOVE CYLINDER HEAD COVER SUB-ASSY
35. REMOVE CAMSHAFT
36. REMOVE NO.2 CAMSHAFT
37. REMOVE CYLINDER HEAD SUB-ASSY





a) Disconnect the VVT sensor connector.
b) Disconnect the camshaft timing oil control valve connector.
c) Remove the nut and disconnect the engine wire harness clamp.





d) Using an 8 mm socket hexagon wrench, remove the hexagon bolt.





e) Uniformly loosen the 8 cylinder head bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

NOTICE:
^ Be careful not to drop the washers into the cylinder head.
^ Head warpage or cracking could result from removing bolts in an incorrect order.

38. REMOVE CYLINDER HEAD GASKET
39. INSPECT CYLINDER HEAD SET BOLT





a) Using a vernier caliper, measure the tension portion diameter of the bolt.
Specified outside diameter: 8.75 to 9.05 mm (0.3445 to 0.3563 inch)
If the diameter is less than the minimum, replace the bolt.
40. INSTALL CYLINDER HEAD GASKET





a) Place a new cylinder head gasket on the cylinder block with the R mark upside down, as shown in the illustration.

NOTICE:
^ Remove any oil from the contact surface.
^ Make sure the cylinder head gasket is facing in the correct direction.

41. INSTALL CYLINDER HEAD SUB-ASSY

NOTICE:
^ To prevent damage to the block, place the the gasket carefully.
^ The cylinder head bolts are tightened in 2 successive steps.





a) Apply a light coat of engine oil on the threads of the cylinder head bolts.
b) Install the plate washers to the cylinder head bolts.
c) Uniformly install and tighten the 8 cylinder head bolts in the sequence shown in the illustration.
Torque: 54 Nm (550 kgf-cm, 40 ft. lbs.)





d) Mark the front side of each cylinder head bolt head with paint as shown in the illustration.
e) Retighten the cylinder head bolts by 90° in the same sequence as step (c).
Check that each painted mark is now at a 90° angle to the front.





g) Using an 8 mm socket hexagon wrench, install the hexagon bolt.
Torque: 19 Nm (189 kgf-cm, 14 ft. lbs.)
h) Connect the engine wire harness clamp with the nut.
Torque: 8.4 Nm (85 kgf-cm, 74 inch lbs.)
42. INSTALL NO.2 CAMSHAFT
43. INSTALL CAMSHAFT
44. INSTALL CYLINDER HEAD COVER SUB-ASSY
45. INSTALL IGNITION COIL ASSY
Torque: 8.0 Nm (82 kgf-cm, 71 inch lbs.)
46. INSTALL VANE PUMP ASSY
47. INSTALL TIMING BELT NO.3 COVER
48. INSTALL CAMSHAFT TIMING PULLEY
49. INSTALL TIMING BELT IDLER SUB-ASSY NO.2
Torque: 43 Nm (438 kgf-cm, 32 ft. lbs.)
50. INSPECT TIMING BELT
51. INSTALL TIMING BELT
52. INSTALL TIMING BELT TENSIONER ASSY
53. INSTALL TIMING BELT GUIDE NO.2
54. INSTALL ENGINE MOUNTING BRACKET RH
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
55. INSTALL TIMING BELT NO.2 COVER
56. INSTALL TIMING BELT NO.1 COVER
57. INSTALL CRANKSHAFT PULLEY
58. INSTALL GENERATOR BRACKET NO.2
Torque: 28 Nm (286 kgf-cm, 21 ft. lbs.)
59. INSTALL ENGINE MOUNTING STAY NO.2 RH
60. INSTALL ENGINE MOVING CONTROL ROD
61. INSTALL VANE PUMP V BELT
62. INSTALL V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO.1
63. INSPECT DRIVE BELT TENSION
64. INSTALL WATER OUTLET
a) Install 2 new gaskets to the 2 cylinder heads.
b) Install the water outlet together with the water by-pass hose No. 1 and unlock the hose clamp.
c) Tighten the 2 bolts, 2 nuts and 2 washers.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
d) Install the clamp.
e) Connect the engine coolant temperature sensor connector.
f) Connect the radiator hose inlet.
65. INSTALL INTAKE MANIFOLD





a) Install the intake manifold with the 9 bolts, 2 nuts and 2 washers. Uniformly tighten the bolts and nuts in the sequence shown in the illustration.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
b) Retighten the water outlet mounting bolts and nuts.
Torque: 15 Nm (153 kgf-cm, 11 ft. lbs.)
c) Install the ground cable with the nut.
Torque: 8.4 Nm (86 kgf-cm, 74 inch lbs.)
d) Connect the heater inlet water hose.
66. CONNECT FUEL PIPE SUB-ASSY NO.1
67. INSTALL INTAKE AIR SURGE TANK
68. INSTALL AIR CLEANER ASSEMBLY WITH HOSE
69. CONNECT VACUUM HOSES
70. INSTALL FRONT SUSPENSION UPPER BRACE CENTER (W/ FRONT SUSPENSION BRACE UPPER CENTER)
Torque: 80 Nm (816 kgf-cm, 59 ft. lbs.)
71. INSTALL V-BANK COVER SUB-ASSY
72. INSTALL EXHAUST MANIFOLD SUB-ASSY RH
73. INSTALL EXHAUST PIPE ASSY FRONT
74. INSTALL EXHAUST PIPE NO.1 SUPPORT BRACKET
75. INSTALL FRONT WHEEL RH
76. ADD ENGINE OIL
77. ADD ENGINE COOLANT
78. CHECK FOR ENGINE OIL LEAKS
79. CHECK FOR ENGINE COOLANT LEAKS
80. CHECK FOR FUEL LEAKS
81. CHECK FOR EXHAUST GAS LEAKS
82. INSPECT IGNITION TIMING
83. INSPECT ENGINE IDLE SPEED
84. INSPECT COMPRESSION
85. INSPECT CO/HC