Removal and Replacement
CYLINDER HEAD GASKET (1ZZ-FE)
COMPONENTS
REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. REMOVE FRONT WHEEL RH
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE CYLINDER HEAD COVER NO.2
6. DRAIN ENGINE COOLANT
7. SEPARATE EXHAUST PIPE ASSEMBLY FRONT
8. REMOVE MANIFOLD STAY
9. REMOVE FAN AND GENERATOR V BELT
10. SEPARATE VANE PUMP ASSEMBLY
11. REMOVE GENERATOR ASSEMBLY
12. REMOVE ENGINE MOUNTING INSULATOR RH
13. REMOVE IGNITION COIL ASSEMBLY
14. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
15. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
16. REMOVE ENGINE MOUNTING BRACKET RH
17. REMOVE WATER PUMP ASSEMBLY
18. SEPARATE CRANKSHAFT POSITION SENSOR
19. SET NO.1 CYLINDER TO TDC/COMPRESSION
20. REMOVE CRANKSHAFT PULLEY
SST 09960-10010 (09962-01000, 09963-01000)
21. REMOVE CHAIN TENSIONER ASSEMBLY NO.1
22. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
23. REMOVE TIMING CHAIN OR BELT COVER OIL SEAL
24. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO.1
25. REMOVE CHAIN TENSIONER SLIPPER
26. REMOVE CHAIN SUB-ASSEMBLY
27. REMOVE CHAIN VIBRATION DAMPER NO.1
28. REMOVE AIR CLEANER HOSE NO.1
a. Disconnect the VSV connector.
b. Remove the clamp of the engine wire.
c. Disconnect the fuel vapor feed hose No.1 from the VSV.
d. Disconnect the fuel vapor feed hose No.3 from the VSV.
e. Loosen the 2 hose clamp bolts, then remove the air cleaner hose No.1.
29. REMOVE OIL LEVEL GAGE SUB-ASSEMBLY
30. REMOVE INTAKE MANIFOLD
a. Remove the 2 clamps of the engine wire from the clamp bracket.
b. Disconnect the throttle control motor connector.
c. Disconnect the water by-pass hose from the throttle body.
d. Disconnect the water by-pass hose No.2 from the throttle body.
e. Disconnect the union to check valve hose from the intake manifold.
f. Remove the 4 bolts, 2 nuts and 2 clamp brackets.
g. Remove the intake manifold and throttle body.
h. Remove the gasket from the intake manifold.
31. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
a. Remove the bolt, then remove the camshaft timing oil control valve.
32. REMOVE CAMSHAFT
a. Using several steps, uniformly loosen and remove the 19 bearing cap bolts in the sequence shown in the illustration.
b. Remove the 9 bearing caps, then remove the 2 camshafts from the cylinder head.
33. DISCONNECT FUEL TUBE SUB-ASSEMBLY
SST 09268-21010
34. REMOVE CYLINDER HEAD SUB-ASSEMBLY
a. Disconnect the engine wire.
(1) Disconnect the 4 fuel injector connectors.
(2) Disconnect the oil pressure switch connector.
(3) Disconnect the crankshaft position sensor connector.
(4) Disconnect the knock sensor connector.
(5) Disconnect the camshaft position sensor connector.
(6) Disconnect the engine coolant temperature sensor connector.
(7) Disconnect the radio setting condenser connector.
(8) Disconnect the 2 engine earths.
(9) Remove the clamp from the clamp bracket.
(10) Disconnect the heated oxygen sensor connector.
b. Disconnect the radiator hose inlet.
c. Disconnect the heater inlet water hose.
d. Remove the bolt, then separate the water by-pass pipe No.1.
e. Using several steps, uniformly loosen and remove the 10 cylinder head bolts with a bi-hexagon wrench 10 mm in the sequence shown in the illustration. Remove the 10 cylinder head bolts and 10 plate washers.
NOTICE:
- Be careful not to drop the plate washers into the cylinder head.
- Head warpage or cracking could result from removing the bolts in the wrong order.
f. Remove the cylinder head.
35. REMOVE CYLINDER HEAD GASKET
36. INSPECT CYLINDER HEAD SET BOLT
a. Using vernier calipers, measure the length of the cylinder head bolts from the seat to the end.
Standard length: 146.8 to 148.2 mm (5.780 to 5.835 inch)
Maximum length: 148.5 mm (5.846 inch)
If the bolt length is greater than maximum, replace the cylinder head set bolt.
37. INSTALL CYLINDER HEAD GASKET
a. Place a new cylinder head gasket on the cylinder block surface with the Lot No.stamp upward.
NOTICE:
- Make sure that the cylinder head gasket is mounted in the correct direction.
- Place the cylinder head gently in order to avoid damaging the gasket.
38. INSTALL CYLINDER HEAD SUB-ASSEMBLY
HINT: The cylinder head bolts should be tightened in 2 successive steps.
a. Apply a light coat of engine oil to the threads of the cylinder head bolts.
b. Using several steps, uniformly install and tighten the 10 cylinder head bolts and plate washers with a bi-hexagon wrench 10 mm in the sequence shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)
c. Mark the front of the cylinder head bolts with paint.
d. Retighten the cylinder head bolts 90° in the same sequence as step (b).
e. Check that the paint mark of each bolt is at a 90° angle to the front.
f. Install the water by-pass pipe No.1 with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
g. Connect the heater inlet water hose.
h. Connect the radiator hose inlet.
i. Connect the engine wire.
(1) Connect the heated oxygen sensor connector.
(2) Install the clamp onto the clamp bracket.
(3) Connect the 2 engine earths.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
(4) Connect the radio setting condenser connector.
(5) Connect the engine coolant temperature sensor connector.
(6) Connect the camshaft position sensor connector.
(7) Connect the knock sensor connector.
(8) Connect the crankshaft position sensor connector.
(9) Connect the oil pressure switch connector.
(10) Connect the 4 fuel injector connectors.
39. CONNECT FUEL TUBE SUB-ASSEMBLY
40. INSTALL CAMSHAFT
a. Apply a light coat of engine oil to the camshaft journals.
b. Place the 2 camshafts on the cylinder head as shown in the illustration.
c. Examine the front marks and numbers and check that the sequence order is as shown in the illustration, then tighten the bolts.
Torque:
23 Nm (235 kgf-cm, 17 ft. lbs.) for bearing cap No.1
13 Nm (133 kgf-cm, 10 ft. lbs.) for bearing cap No.3
HINT:
- Bearing Cap No.1 = Nos. 9-11 in illustration
- Bearing Cap No.3 = Nos. 1-8 in illustration
41. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
a. Apply a light coat of engine oil to a new O-ring, then install it onto the camshaft timing oil control valve.
b. Install the camshaft timing oil control valve with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
42. INSTALL INTAKE MANIFOLD
a. Install a new gasket onto the intake manifold.
b. Install the intake manifold and throttle body with the 2 rackets, 4 bolts and 2 nuts.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
c. Connect the union to check valve hose to the intake manifold.
d. Connect the water by-pass hose No.2 to the throttle body.
e. Connect the water by-pass hose to the throttle body.
f. Connect the throttle control motor connector.
g. Install the 2 clamps of the engine wire onto the clamp bracket.
43. INSTALL OIL LEVEL GAGE SUB-ASSEMBLY
44. INSTALL AIR CLEANER HOSE NO.1
a. Install the air cleaner hose No.1 with the 2 hose clamp bolts.
b. Connect the fuel vapor feed hose No.3 to the VSV.
c. Connect the fuel vapor feed hose No.1 to the VSV.
d. Install the clamp of the engine wire.
e. Connect the VSV connector.
45. INSTALL CHAIN VIBRATION DAMPER NO.1
46. INSTALL CHAIN SUB-ASSEMBLY
SST 09223-22010
47. INSTALL CHAIN TENSIONER SLIPPER
48. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO.1
49. INSTALL TIMING CHAIN OR BELT COVER OIL SEAL
SST 09223-22010
50. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSEMBLY
51. INSTALL CHAIN TENSIONER ASSEMBLY NO.1
52. INSTALL CRANKSHAFT PULLEY
SST 09960-10010 (09962-01000, 09963-01000)
53. INSTALL CRANKSHAFT POSITION SENSOR
54. INSTALL WATER PUMP ASSEMBLY
55. INSTALL ENGINE MOUNTING BRACKET RH
56. INSTALL V-RIBBED BELT TENSIONER ASSEMBLY
57. INSTALL CYLINDER HEAD COVER SUB-ASSEMBLY
58. INSTALL IGNITION COIL ASSEMBLY
59. INSTALL ENGINE MOUNTING INSULATOR RH
60. INSTALL GENERATOR ASSEMBLY
61. INSTALL VANE PUMP ASSEMBLY
62. INSTALL FAN AND GENERATOR V BELT
63. INSTALL MANIFOLD STAY
64. INSTALL EXHAUST PIPE ASSEMBLY FRONT
65. ADD ENGINE COOLANT
66. INSTALL BATTERY NEGATIVE TERMINAL
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
67. CHECK FOR ENGINE COOLANT LEAKAGE
68. CHECK FOR ENGINE OIL LEAKAGE
69. CHECK FOR FUEL LEAKAGE
70. CHECK FOR EXHAUST GAS LEAKAGE
71. INSPECT IGNITION TIMING
SST 09843-18040
72. INSPECT ENGINE IDLING SPEED
73. INSPECT COMPRESSION
SST 09992-00500
74. INSPECT CO/HC
75. INSTALL CYLINDER HEAD COVER NO.2
76. INSTALL ENGINE UNDER COVER RH
77. INSTALL FRONT WHEEL RH
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)