Cylinder Head Gasket: Service and Repair
CYLINDER HEAD GASKET REPLACEMENT [ZM]Warning:
- 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". Refer to Powertrain Management; Fuel Delivery and Air Induction.
1. Disconnect the negative battery cable.
2. Drain the engine coolant.
3. Remove the timing belt.
4. Remove the front pipe, exhaust manifold insulator, and EGR pipe.
5. Remove the air cleaner, and fresh-air duct.
6. Disconnect the accelerator cable, and bracket.
7. Disconnect the vacuum hose, and engine harness connector.
8. Disconnect the plastic fuel hoses.
9. Remove the intake manifold bracket.
10. Remove the heater hoses.
11. Remove in the order indicated in the table.
12. Install in the reverse order of removal.
13. Inspect for fuel leakage.
14. Inspect the compression.
15. Start the engine and
1. Inspect the pulleys and drive belt for runout and contact.
2. Inspect the ignition timing. Refer to Powertrain Management; Ignition System.
3. Inspect the idle speed. Refer to Powertrain Management; Fuel Delivery and Air Induction.
Camshaft Pulley Removal Note
1. Temporarily install the No.3 engine mount.
2. Remove the SST (engine support).
3. Hold the camshaft using a wrench on the cast hexagon as shown.
Camshaft Removal Note
1. Loosen the camshaft cap bolts a few turns in the order shown.
2. Remove the camshaft cap.
Cylinder Head Removal Note
1. Loosen the cylinder head bolts a few turns in the order shown.
Cylinder Head Installation Note
1. Measure the length of each bolt.
- Replace any that exceed the maximum length.
Standard length 99.2 - 99.8 mm (3.91 - 3.92 inch)
Maximum length 100.5 mm (3.956 inch)
2. Tighten the cylinder head bolts a few turns in the order shown.
Tightening torque 17.2 - 22.0 Nm (1.75 - 2.25 kgf-m, 12.7 - 16.2 ft. lbs.)
3. Put a paint mark on each bolt head.
4. Using the marks as a reference, tighten the bolts by turning each 85° - 95° in the sequence shown.
5. Further tighten each bolt by turning another 85° - 95° in the sequence shown.
Camshaft Installation Note
Caution: Because there is little camshaft thrust clearance, the camshaft must be held horizontally while it is installed. Otherwise, excessive force will be applied to the thrust area, causing a burr on the thrust receiving area of the cylinder head Journal. To avoid this, the following procedure must be observed.
1. Assemble camshaft onto the cylinder head, facing the cam noses at No.1 and No.3 cylinders as shown.
Note: Keep the camshaft sliding surface free of sealant to prevent engine damage.
2. Apply silicone sealant to the areas shown.
Thickness 1.0 mm (0.04 inch)
3. Apply engine oil to the camshaft and the cylinder head journals.
4. Install the camshaft caps to the positions from which they were removed.
5. Hand tighten the camshaft cap bolts marked 5, 2, and 4, 7,
6. Tighten the camshaft cap bolts a few turns in the order shown.
7. Verify that the camshaft settles horizontally when 2 bearing cap bolts at No.3 journal are tightened.
8. Apply clean engine oil to the camshaft oil seal.
9. Push the oil seal slightly in by hand.
10. Tap the oil seals in evenly using the SST and a hammer.
Camshaft Pulley Installation Note
1. Install the camshaft pulleys with the "I" mark (intake side) or"E" mark (exhaust side) straight up.
2. Hold the camshaft using a wrench on the cast hexagon as shown.
3. Suspend the engine using the SST.
4. Remove the No.3 engine mount.