Cylinder Head Assembly: Service and Repair
CYLINDER HEAD GASKET REPLACEMENTWarning
- 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".
1. Remove the timing chain.
2. Remove the ignition coil.
3. Remove the high-tension lead.
4. Disconnect the generator, but do not remove it from the vehicle. Fix the generator using a rope to prevent it from falling.
5. Remove the front pipe.
6. Remove the intake manifold.
7. Disconnect the heater hose, bypass hose, and radiator hose.
8. To firmly support the engine, first set the engine jack and attachment to the oil pan.
9. Remove in the order indicated in the table.
10. Install in the reverse order of removal.
11. Inspect the compression.
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.
Cylinder Head Removal Note
1. Loosen the cylinder head bolts in two or three steps in the order shown.
Cylinder Head Installation Note
1. Measure the length of each cylinder head bolt.
- Replace any that exceeds maximum length.
Length L 149.0 - 150.0 mm (5.86 - 5.90 inches)
Maximum 150.5 mm (5.92 inches)
2. Tighten the cylinder head bolts in the order shown following 5 steps using the SST (49 D032 316).
1) Tighten to 5.0 Nm (51.0 kgf-cm, 44.3 inch lbs.)
2) Tighten 13 - 17 Nm (1.4 - 1.7 kgf-cm, 10.0 - 12.5 ft. lbs.)
3) Tighten 44 - 46 Nm (4.5 - 4.6 kgf-cm, 32.5 - 33.9 ft. lbs.)
4) Tighten 88° - 92°
5) Tighten 88° - 92°
Camshaft Installation Note
1. Set the cam position of No.1 cylinder at the Top Dead Center (TDC) and install the camshaft.
2. Temporarily tighten the camshaft bearing caps evenly in two or three steps.
3. Tighten the camshaft cap bolts in the order shown - with the following two steps.
1) Tighten to 5.0 - 9.0 Nm (51.0 - 91.7 kgf-cm, 44.3 - 79.6 inch lbs.)
2) Tighten to 14.0 - 17.0 Nm (1.5 - 1.7 kgf-cm, 10.4 - 12.5 ft. lbs.)