RM35X0E _51 Engine / Hybrid System _078603 7GR-FKS ENGINE MECHANICAL _0381340 CYLINDER HEAD GASKET A

7GR-FKS ENGINE MECHANICAL CYLINDER HEAD GASKET REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization, or registration) that must be performed after parts are removed, installed, or replaced during the cylinder head gasket removal/installation are shown below.

Necessary Procedure After Parts Removed/Installed/Replaced
Replaced Part or Performed Procedure	Necessary Procedure	Effect/Inoperative Function when Necessary Procedure not Performed	Link
Battery terminal is disconnected/reconnected	Memorize steering angle neutral point	Parking assist monitor system	(201902,999999,_56,_079315,_0385736,RM100000001GNRA,)
Battery terminal is disconnected/reconnected	Memorize steering angle neutral point	Panoramic view monitor system	(201906,999999,_56,_079315,_0396274,RM100000001IGR3,)
Replacement of ECM	Perform Vehicle Identification Number (VIN) or frame number registration	DTC P063051 is stored	(201902,999999,_51,_078720,_0381907,RM100000001G2WM,)
	ECU communication ID registration	Engine start function	See Service Bulletin for the registration method.
	for RC60J: Performing iMT installation information reset	· iMT system · DTCs are output	(201902,999999,_52,_078740,_0383349,RM100000001GAF2,)
· Throttle body with motor assembly · Cleaning the deposits from the throttle body with motor assembly · Engine assembly · Cylinder head sub-assembly · Camshaft (for intake or exhaust camshaft) · Camshaft timing gear assembly · Camshaft timing exhaust gear assembly · Fuel injector assembly (for port injection) · Fuel injector assembly (for direct injection) · Fuel pump assembly (for high pressure side) · Engine coolant temperature sensor · Spark plug · Ignition coil assembly · Air leaks from intake system · Gas leaks from exhaust system	Inspection after repair	· Poor idle, etc. · Engine start function, etc.	(201902,999999,_51,_078720,_0381907,RM100000001G2VV,)
for AC60E: Replacement of automatic transmission assembly	Reset memory	· Large shift shock · Engine overruns	(201902,999999,_52,_078741,_0385245,RM100000001GL7C,)
for AC60E: Replacement of automatic transmission fluid	ATF thermal degradation estimate reset	The value of the Data List item "ATF Thermal Degradation Estimate" is not estimated correctly	(201902,999999,_52,_078741,_0385245,RM100000001GL7C,)
Front wheel alignment adjustment	· Perform reset memory · Perform acceleration sensor zero point calibration and store system information memorization.	· VSC is disabled or malfunctions · DTCs are output · Slip indicator light illuminates · ABS warning light illuminates	(201902,999999,_54,_078667,_0385049,RM100000001GK1P,)
Suspension, tires, etc.	Television camera assembly optical axis (Back camera position setting)	Parking assist monitor system	(201902,999999,_56,_079315,_0385736,RM100000001GNRB,)

HINT:

When the cable is disconnected / reconnected to the battery terminal, systems temporarily stop operating. However, each system has a function that completes learning the first time the system is used.

Learning completes when vehicle is driven

Effect/Inoperative when not Performed	Necessary Procedures	Link
Lane control system	Drive the vehicle straight ahead at 15 km/h (10 mph) or more for 1 second or more.	(201902,999999,_58,_078886,_0382740,RM100000001G6XB,)
Pre-collision system		(201902,999999,_58,_078886,_0382740,RM100000001G6XB,)

Learning completes when vehicle is operated normally

Effect/Inoperative when not Performed	Necessary Procedures	Link
Power slide door system	Fully close the slide door by hand. HINT: Initialization is not necessary if the above procedures are performed while the slide door is closed.	(201902,999999,_59,_078503,_0381017,RM100000001FWXM,)
Air conditioning system	After the ignition switch is turned to ON, the servo motor standard position is recognized.	-

CAUTION:

2.219,0.813 2.646,0.813 false 2.698,0.729 3.01,0.927 0.313,0.198 10 false *a

*a	An Object Exceeding Weight Limit of Engine Lifter

The engine assembly with transmission is very heavy. Be sure to follow the procedure described in the repair manual, or the engine lifter may suddenly drop or the engine assembly may fall off the engine lifter.

To prevent burns, do not touch the engine, exhaust manifold or other high temperature components while the engine is hot.

PROCEDURE

Hide Display 11310 1.REMOVE TIMING CHAIN COVER ASSEMBLY

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Hide Display 2.SET NO. 1 CYLINDER TO TDC/COMPRESSION

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Hide Display 13540 3.REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

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Hide Display 13559 4.REMOVE CHAIN TENSIONER SLIPPER

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Hide Display 13506 5.REMOVE CHAIN SUB-ASSEMBLY

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Hide Display 6.REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1)

3.26,1.917 3.26,2.552 3.26,2.552 2.99,2.552 false 1.667,2.542 1.667,2.906 1.667,2.906 1.521,2.906 false 1.021,2.927 1.021,2.635 false 2.813,2.448 3.01,2.656 0.198,0.208 10 false *a 0.938,2.948 1.167,3.156 0.229,0.208 10 false *b 2.802,0.99 3.031,1.229 0.229,0.24 10 true *c 1.333,2.802 1.552,3.01 0.219,0.208 10 false *a

*a	Pin
*b	Plunger
*c	Push

While raising the No. 2 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold the No. 2 chain tensioner assembly.

2.927,0.344 3.219,0.563 0.292,0.219 10 false *a 1.01,0.271 1.219,0.5 0.208,0.229 10 false *b

*a	Turn
*b	Hold

Using a wrench to hold the hexagonal portion of each camshaft, loosen the camshaft timing gear bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly.

NOTICE:: ·

Be careful not to damage the cylinder head with the wrench.

·

Do not loosen the other bolts. If any of the bolts is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly with a new one.

Remove the 2 bolts and the camshaft timing gear assembly together with the No. 2 chain sub-assembly.

Hide Display 13550 7.REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY

Remove the bolt and No. 2 chain tensioner assembly.

Hide Display 8.REMOVE CAMSHAFT BEARING CAP (for Bank 1)

1.042,3.469 1.406,3.979 1.406,3.979 2.417,3.51 false 2.198,2.823 2.469,3.063 0.271,0.24 10 false *a 0.938,2.823 1.25,3.115 0.313,0.292 10 false *b 2.917,3.292 3.219,3.542 0.302,0.25 10 false 45° 1.344,4.031 1.625,4.26 0.281,0.229 10 false *1

*1	Knock Pin
*a	IN
*b	EX

Check that the camshafts are positioned as shown in the illustration.

0.135,0.74 0.344,0.958 0.208,0.219 10 false 1 1.135,1.552 1.375,1.771 0.24,0.219 10 true 2 1,0.781 1.24,1 0.24,0.219 10 true 3 1.688,0.781 1.906,0.958 0.219,0.177 10 true 4 2.177,0.771 2.333,0.927 0.156,0.156 10 true 5 0.406,0.104 0.646,0.323 0.24,0.219 10 true 6 1.042,0.115 1.281,0.333 0.24,0.219 10 true 7 1.688,0.115 1.927,0.333 0.24,0.219 10 true 8 2.177,0.125 2.313,0.313 0.135,0.188 10 true 9

Uniformly loosen and remove the 9 camshaft bearing cap bolts in several steps and in the sequence shown in the illustration.

0.052,0.677 0.25,0.865 0.198,0.188 10 false 1 0.76,1.854 0.958,2.042 0.198,0.188 10 true 2 0.354,0.396 0.552,0.583 0.198,0.188 10 true 3 3.146,0.667 3.344,0.854 0.198,0.188 10 true 4 3.115,1.771 3.313,1.958 0.198,0.188 10 true 5 3.073,1.229 3.271,1.417 0.198,0.188 10 true 6 1.073,0.719 1.271,0.906 0.198,0.188 10 true 7 1.198,1.854 1.396,2.042 0.198,0.188 10 true 8 1.177,1.281 1.375,1.469 0.198,0.188 10 true 9 1.802,0.74 2,0.927 0.198,0.188 10 true 10 1.802,1.844 2,2.031 0.198,0.188 10 true 11 1.813,1.271 2.01,1.458 0.198,0.188 10 true 12 2.448,0.74 2.646,0.927 0.198,0.188 10 true 13 2.448,1.823 2.646,2.01 0.198,0.188 10 true 14 2.438,1.292 2.635,1.479 0.198,0.188 10 true 15

Uniformly loosen and remove the 15 camshaft bearing cap bolts in several steps and in the sequence shown in the illustration.

NOTICE:: Uniformly loosen the bolts while keeping the camshaft level.

Remove the 5 camshaft bearing caps.

Hide Display 23476 9.REMOVE FUEL PUMP LIFTER HOUSING

Remove the fuel pump lifter housing.

Hide Display 13511 10.REMOVE CAMSHAFT

Hide Display 13512 11.REMOVE NO. 2 CAMSHAFT

Hide Display 11103C 12.REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH

0.875,2.073 0.427,2.948 0.427,2.948 1.656,2.948 true 3.177,2.5 2.646,3.177 2.646,3.177 2.375,2.75 true 0.24,2.854 0.438,3.083 0.198,0.229 10 false *a 2.573,3.198 2.76,3.417 0.188,0.219 10 false *a

*a	Protective Tape

Remove the camshaft housing sub-assembly RH by prying between the cylinder head sub-assembly and camshaft housing sub-assembly RH with a screwdriver.

NOTICE:: Be careful not to damage the contact surfaces of the cylinder head sub-assembly and camshaft housing sub-assembly RH.

HINT:: Tape the screwdriver tip before use.

Hide Display 13.REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2)

0.427,1.74 0.302,2.469 0.302,2.469 1.729,1.813 true 2.031,1.917 1.281,2.917 1.281,2.917 1.083,2.917 true 0.177,2.479 0.448,2.729 0.271,0.25 10 false *a 0.896,2.833 1.094,3.042 0.198,0.208 10 false *b 1.792,0.531 2.052,0.771 0.26,0.24 10 true *c

*a	Pin
*b	Plunger
*c	Push

While pushing down the No. 3 chain tensioner assembly, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold the No. 3 chain tensioner assembly.

0.552,0.281 0.813,0.521 0.26,0.24 10 false *a 1.615,0.104 1.938,0.375 0.323,0.271 10 false *b

*a	Turn
*b	Hold

Using a wrench to hold the hexagonal portion of each camshaft, loosen the camshaft timing gear bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly.

NOTICE:: ·

Be careful not to damage the cylinder head with the wrench.

·

Do not loosen the other bolts. If any of the bolts is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly with a new one.

Remove the 2 bolts and the camshaft timing gear assembly together with the No. 2 chain sub-assembly.

Hide Display 13560A 14.REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY

Remove the bolt and No. 3 chain tensioner assembly.

Hide Display 15.REMOVE CAMSHAFT BEARING CAP (for Bank 2)

1.063,3.385 1.646,3.99 1.646,3.99 2.271,3.375 false 0.917,2.76 1.156,3.052 0.24,0.292 10 false *a 2.229,2.781 2.5,3.031 0.271,0.25 10 false *b 1.594,4.031 1.875,4.344 0.281,0.313 10 false *1

*1	Knock Pin
*a	IN
*b	EX

Check that the camshafts are positioned as shown in the illustration.

3.188,0.938 3.365,1.146 0.177,0.208 10 true 1 2.552,0.948 2.729,1.156 0.177,0.208 10 true 2 1.896,0.948 2.073,1.156 0.177,0.208 10 true 3 1.188,0.896 1.365,1.104 0.177,0.208 10 true 4 3.198,0.25 3.375,0.458 0.177,0.208 10 true 5 2.542,0.292 2.719,0.5 0.177,0.208 10 true 6 1.896,0.292 2.073,0.5 0.177,0.208 10 true 7 1.229,0.229 1.406,0.438 0.177,0.208 10 true 8

Uniformly loosen and remove the 8 camshaft bearing cap bolts in several steps and in the sequence shown in the illustration.

2.563,1.042 2.719,1.271 0.156,0.229 10 true 1 2.583,0.177 2.74,0.385 0.156,0.208 10 true 2 2.385,1.302 2.552,1.49 0.167,0.188 10 true 3 2.396,0.656 2.563,0.833 0.167,0.177 10 true 4 0.333,0.083 0.51,0.281 0.177,0.198 10 true 5 0.333,1.313 0.563,1.552 0.229,0.24 10 false 6 0.313,0.635 0.458,0.813 0.146,0.177 10 true 7 1.75,0.094 1.906,0.271 0.156,0.177 10 true 8 1.75,1.26 1.906,1.448 0.156,0.188 10 true 9 1.708,0.677 1.896,0.885 0.188,0.208 10 true 10 1.031,0.083 1.26,0.292 0.229,0.208 10 true 11 1.042,1.25 1.271,1.49 0.229,0.24 10 true 12 1.042,0.698 1.229,0.906 0.188,0.208 10 true 13

Uniformly loosen and remove the 13 camshaft bearing cap bolts in several steps and in the sequence shown in the illustration.

NOTICE:: Uniformly loosen the bolts while keeping the camshaft level.

Remove the 5 camshaft bearing caps.

Hide Display 13053 16.REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY

Hide Display 13054 17.REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY

Hide Display 11104A 18.REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH

2.51,1.979 2.781,2.969 2.781,2.969 1.552,2.969 true 2.833,2.875 3.042,3.094 0.208,0.219 10 false *a

*a	Protective Tape

Remove the camshaft housing sub-assembly LH by prying between the cylinder head LH and camshaft housing sub-assembly LH with a screwdriver.

NOTICE:: Be careful not to damage the contact surfaces of the cylinder head LH and camshaft housing sub-assembly LH.

HINT:: Tape the screwdriver tip before use.

Hide Display 13561 19.REMOVE NO. 1 CHAIN VIBRATION DAMPER

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Hide Display 13562 20.REMOVE NO. 2 CHAIN VIBRATION DAMPER

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Hide Display 13801 21.REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

Remove the 24 No. 1 valve rocker arm sub-assemblies.

HINT:: Arrange the removed parts in the correct order.

Hide Display 13750 22.REMOVE VALVE LASH ADJUSTER ASSEMBLY

Remove the 24 valve lash adjuster assemblies from the cylinder head sub-assembly and cylinder head LH.

HINT:: Arrange the removed parts in the correct order.

Hide Display 13716 23.REMOVE VALVE STEM CAP

Remove the 24 valve stem caps.

HINT:: Arrange the removed parts in the correct order.

Hide Display 16356 24.REMOVE REAR WATER BY-PASS JOINT

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Hide Display 23802B 25.REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY

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Hide Display 23860 26.REMOVE FUEL DELIVERY WITH SENSOR PIPE ASSEMBLY LH

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Hide Display 23814E 27.REMOVE FUEL DELIVERY PIPE RH

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Hide Display 23250E 28.REMOVE DIRECT FUEL INJECTOR ASSEMBLY

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Hide Display 23255A 29.REMOVE FUEL INJECTOR SEAL

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Hide Display 11101 30.REMOVE CYLINDER HEAD SUB-ASSEMBLY

2.167,0.865 2.354,1.052 0.188,0.188 10 true 1 0.219,0.198 0.385,0.385 0.167,0.188 10 true 2 2.156,0.208 2.323,0.375 0.167,0.167 10 true 3 0.219,0.823 0.417,1.01 0.198,0.188 10 true 4 1.5,0.198 1.667,0.365 0.167,0.167 10 true 5 0.875,0.854 1.042,1.031 0.167,0.177 10 true 6 0.865,0.198 1.052,0.406 0.188,0.208 10 true 7 1.521,0.865 1.698,1.031 0.177,0.167 10 true 8

Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

NOTICE:: ·

Be careful not to drop washers into the cylinder head sub-assembly.

·

Cylinder head warpage or cracking could result from removing bolts in an incorrect order.

HINT:: Be sure to keep separate the removed parts for each installation position.

Remove the cylinder head sub-assembly.

Hide Display 11115 31.REMOVE CYLINDER HEAD GASKET

Hide Display 11102 32.REMOVE CYLINDER HEAD LH

0.302,1.24 0.521,1.469 0.219,0.229 10 false 1 0.302,0.188 0.583,0.448 0.281,0.26 10 false 2

Uniformly loosen and remove the bolts in the sequence shown in the illustration.

0.635,0.135 0.74,0.292 0.104,0.156 10 true 1 1.875,0.146 2,0.344 0.125,0.198 10 true 6 2.531,0.125 2.656,0.302 0.125,0.177 10 true 4 2.49,1.573 2.594,1.729 0.104,0.156 10 true 2 1.865,1.583 1.969,1.74 0.104,0.156 10 true 7 1.219,1.583 1.323,1.74 0.104,0.156 10 true 5 0.635,1.594 0.74,1.75 0.104,0.156 10 true 3 1.24,0.125 1.385,0.313 0.146,0.188 10 true 8

Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

NOTICE:: ·

Be careful not to drop washers into the cylinder head LH.

·

Cylinder head warpage or cracking could result from removing bolts in an incorrect order.

HINT:: Be sure to keep separate the removed parts for each installation position.

Remove the cylinder head LH.

Hide Display 11116 33.REMOVE NO. 2 CYLINDER HEAD GASKET

Hide Display 11101A 34.INSPECT CYLINDER HEAD SET BOLT

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