CYLINDER HEAD GASKET REMOVAL

PROCEDURE


  1. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

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  2. REMOVE MANIFOLD STAY

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  3. REMOVE NO. 2 MANIFOLD STAY

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  4. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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  5. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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  6. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY

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  7. REMOVE VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)

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  8. DISCONNECT NO. 2 VENTILATION HOSE

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  9. DISCONNECT UNION TO VACUUM TUBE HOSE (for LHD)

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  10. DISCONNECT UNION TO CHECK VALVE HOSE (for RHD)

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  11. REMOVE FUEL DELIVERY PIPE

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  12. REMOVE INTAKE MANIFOLD

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  13. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

      A01VZGFE02
      Text in Illustration
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark *d Crankshaft Pulley Key

      Tech Tips

      "A" is not a timing mark.

    2. Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing sprocket, camshaft timing gear assembly and camshaft timing exhaust gear assembly are as shown in the illustration.

      Tech Tips

      If the timing marks do not align, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration.

    3. Remove the crankshaft pulley bolt.

  14. REMOVE TIMING CHAIN GUIDE


    1. A01W42E

      Remove the bolt and timing chain guide.

  15. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01W5MUE09
      Text in Illustration
      *1 Stopper Plate
      *2 Plunger

      Allow the plunger to extend slightly, and then rotate the stopper plate counterclockwise to release the lock. Once the lock is released, push the plunger into the No. 1 chain tensioner assembly.

    2. A01W4AZE11
      Text in Illustration
      *1 Pin

      Move the stopper plate clockwise to set the lock, and insert a pin into the stopper plate hole.

    3. A01VZ9O

      Remove the 2 bolts, No. 1 chain tensioner assembly and gasket.

  16. REMOVE CHAIN TENSIONER SLIPPER


    1. A01W2GT

      Remove the bolt and chain tensioner slipper.

  17. REMOVE CHAIN SUB-ASSEMBLY

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  18. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01W56I

      Remove the 2 bolts and No. 1 chain vibration damper.

  19. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01W3J6E01
      Text in Illustration
      *a Hold
      *b Turn

      Hold the hexagonal portion of the camshaft with a wrench and remove the bolt and camshaft timing gear assembly.

      Note


      • Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.

      • Do not disassemble the camshaft timing gear assembly.

  20. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A01W34DE01
      Text in Illustration
      *a Hold
      *b Turn

      Hold the hexagonal portion of the No. 2 camshaft with a wrench and remove the bolt and camshaft timing exhaust gear assembly.

      Note


      • Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.

      • Do not disassemble the camshaft timing exhaust gear assembly.

  21. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A01W4NNE02

      Uniformly loosen and remove the 20 bolts in the sequence shown in the illustration.

    2. A01W3LG

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

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

  22. REMOVE CAMSHAFT BEARING CAP


    1. A01W0P5E01

      Remove the 11 bolts in the sequence shown in the illustration.

    2. Remove the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap and 3 No. 3 camshaft bearing caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  23. REMOVE OIL CONTROL VALVE FILTER

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  24. REMOVE NO. 1 CAMSHAFT BEARING

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  25. REMOVE CAMSHAFT


    1. Remove the camshaft and No. 2 camshaft.

  26. REMOVE NO. 2 CAMSHAFT BEARING

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  27. REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY


    1. Remove the 16 No. 1 valve rocker arm sub-assemblies from the cylinder head sub-assembly.

      Tech Tips

      Arrange the removed parts in the correct order.

  28. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. Remove the 16 valve lash adjuster assemblies from the cylinder head sub-assembly.

      Tech Tips

      Arrange the removed parts in the correct order.

  29. REMOVE VALVE STEM CAP


    1. Remove the 16 valve stem caps from the cylinder head sub-assembly.

      Tech Tips

      Arrange the removed parts in the correct order.

  30. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01W1JFE02

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

      Tech Tips

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

      Note


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

      • Head warpage or cracking could result from removing bolts in the incorrect order.

    2. Remove the cylinder head sub-assembly.

  31. REMOVE CYLINDER HEAD GASKET


    1. Remove the cylinder head gasket from the cylinder block sub-assembly.