CYLINDER HEAD GASKET (for Bank 2) REMOVAL


  1. REMOVE ENGINE ASSEMBLY

    Tech Tips

    Click here.

  2. INSTALL ENGINE STAND

  3. REMOVE IGNITION COIL ASSEMBLY (for LHD)


    1. A017DVRE01

      Remove the 4 bolts [A].

    2. Remove the nut [B].

    3. Disconnect the 2 harness clamps [C].

    4. A017CHVE01

      Disconnect the 6 ignition coil connectors.

    5. Remove the 6 bolts and 6 ignition coils.

  4. REMOVE IGNITION COIL ASSEMBLY (for RHD)


    1. A017BKFE01

      Remove the 2 bolts [D].

    2. Remove the nut [E].

    3. Disconnect the 2 harness clamps [F].

    4. A017CHVE01

      Disconnect the 6 ignition coil connectors.

    5. Remove the 6 bolts and 6 ignition coils.

  5. REMOVE NO. 2 ENGINE MOUNTING STAY RH


    1. A017B2S

      Remove the bolt and No. 2 engine mounting stay RH.

  6. REMOVE INTAKE MANIFOLD


    1. A017C5D

      Uniformly loosen and remove the 6 bolts and 4 nuts.

    2. Remove the intake manifold and 2 gaskets.

  7. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH


    1. A017F6N

      Uniformly loosen and remove the 6 nuts.

    2. Remove the exhaust manifold sub-assembly and gasket.

  8. REMOVE NO. 2 ENGINE OIL LEVEL DIPSTICK GUIDE


    1. A017F23

      Remove the oil level dipstick.

    2. Remove the bolt and No. 2 engine oil level dipstick guide.

    3. A017D2Q

      Remove the O-rings from the No. 2 engine oil level dipstick guide.

  9. REMOVE NO. 2 MANIFOLD STAY


    1. A017EFS

      Remove the bolt, nut and No. 2 manifold stay.

  10. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR


    1. A017F06

      Remove the 3 bolts and No. 2 exhaust manifold heat insulator.

  11. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH


    1. A017F8N

      Uniformly loosen and remove the 6 nuts.

    2. Remove the exhaust manifold assembly and gasket.

  12. REMOVE TRANSVERSE ENGINE MOUNTING BRACKET


    1. A017FPL

      Remove the engine mounting bracket and 3 bolts.

  13. REMOVE GENERATOR ASSEMBLY


    1. A017FW6

      Remove the terminal cap.

    2. Remove the nut and disconnect the wire harness from terminal B.

    3. Disconnect the generator connector from the generator assembly.

    4. Disconnect the connector from the compressor and magnetic clutch.

    5. Disconnect the 3 wire harness clamps.

    6. A017D5C

      Remove the 2 bolts, and then disconnect the bracket.

    7. A017CS4

      Remove the 2 bolts and the generator assembly.

    8. A017FOZ

      Disconnect the wire harness clamp, and then remove the generator bracket.

    9. A017BV6

      Remove the bolt and the wire harness clamp bracket.

  14. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY


    1. A017CLX

      Remove the 5 bolts and V-ribbed belt tensioner assembly.

  15. REMOVE NO. 2 TIMING GEAR COVER


    1. A017FIY

      Remove the 2 bolts and No. 2 timing gear cover.

  16. REMOVE NO. 2 IDLER PULLEY SUB-ASSEMBLY


    1. A017EJRE01

      Remove the bolt, plate and No. 2 idler pulley sub-assembly.

  17. REMOVE NO. 1 ENGINE FRONT MOUNTING BRACKET LH


    1. A017FNW

      Remove the 6 bolts and No. 1 front engine mounting bracket LH.

  18. REMOVE RADIO SETTING CONDENSER


    1. A017G35

      Remove the 2 bolts and 2 radio setting condensers.

  19. REMOVE NO. 1 VACUUM SWITCHING VALVE


    1. A017D52

      Remove the bolt and No. 1 vacuum switching valve.

  20. REMOVE KNOCK CONTROL SENSOR WIRE


    1. A017BWL

      Disconnect the 2 knock control sensor connectors and 3 clamps, and remove the knock control sensor wire from the engine assembly.

  21. REMOVE KNOCK CONTROL SENSOR


    1. A017F0G

      Disconnect the 2 knock control sensor connectors.

    2. Remove the 2 bolts and then remove the 2 knock control sensors.

  22. REMOVE CRANKSHAFT POSITION SENSOR


    1. A017CZI

      Remove the bolt and crankshaft position sensor.

  23. REMOVE NO. 1 OIL PIPE


    1. A017BIAE01

      Remove the 2 oil pipe unions, gaskets and No. 1 oil pipe.

    2. Remove the oil control valve filter LH and gaskets.

  24. REMOVE OIL PIPE


    1. A017ETOE01

      Remove the bolt.

    2. Remove the 2 oil pipe unions and oil pipe.

    3. Remove the oil control valve filter RH and gaskets.

  25. REMOVE CRANKSHAFT PULLEY


    1. A017DNME02

      Using SST, loosen the crankshaft pulley bolt.

      SST
      09213-70011   ( 09213-70020 )
      09330-00021
    2. A017C87E02

      Using SST, remove the crankshaft pulley bolt and crankshaft pulley.

      SST
      09950-50013   ( 09951-05010, 09952-05010, 09953-05020, 09954-05021 )

  26. REMOVE OIL COOLER ASSEMBLY (w/ Oil Cooler)


    1. A017CAH

      Remove the bolt, 2 clamps, and 4 clips and disconnect the 2 water by-pass hoses.

    2. A017E70

      Remove the union bolt, oil cooler assembly, and O-ring.

  27. REMOVE NO. 1 OIL COOLER BRACKET (w/ Oil Cooler)


    1. A017FTV

      Remove the 3 bolts, 3 nuts, and oil cooler pipe with No. 1 oil cooler bracket.

    2. A017BAVE01

      Remove the bolt, 2 nuts, No. 1 oil cooler bracket, and gasket.

    3. Using a "TORX" socket wrench E8, remove the 2 stud bolts.

  28. REMOVE WATER INLET HOUSING


    1. A017ECE

      Remove the 2 nuts, water inlet and thermostat.

    2. Remove the gasket.

    3. Remove the drain cock plug.

    4. Remove the drain cock assembly.

    5. Remove the 2 stud bolts.

    6. Separate the No. 1 water by-pass hose.

    7. A017F72E01

      Remove the 2 bolts, nut, and water inlet housing.

    8. A017E0A

      Remove the 2 O-rings.

  29. REMOVE WATER OUTLET


    1. A017B9GE01

      Remove the 2 bolts, 4 nuts and water outlet.

    2. A017DIQ

      Remove the 2 gaskets and O-ring.

  30. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 1)


    1. A017CFI

      Remove the 12 bolts, seal washer, cylinder head cover sub-assembly and cylinder head cover gasket.

    2. A017F2Q

      Remove the 3 gaskets.

  31. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY (for Bank 2)


    1. A017BDFE02

      Remove the 12 bolts, seal washer, cylinder head cover sub-assembly and cylinder head cover gasket.

      Note

      The baffle plate is located on the back of the portion shown in the illustration. Do not damage the baffle plate when removing the cylinder head cover sub-assembly.

    2. A017FVT

      Remove the 3 gaskets.

  32. REMOVE NO. 2 OIL PAN SUB-ASSEMBLY


    1. A017B87E01

      Remove the 16 bolts and 2 nuts.

    2. A017BN3

      Insert the blade of oil pan seal cutter between the oil pans. Cut through the applied sealer and remove the No. 2 oil pan sub-assembly.

      Note

      Be careful not to damage the contact surfaces of the oil pans.

    3. Using a "TORX" socket wrench E6, remove the 2 stud bolts.

  33. REMOVE OIL STRAINER SUB-ASSEMBLY


    1. A017DJH

      Remove the bolt, 2 nuts, oil strainer sub-assembly and gasket.

    2. Using a "TORX" socket wrench E6, remove the 2 stud bolts.

  34. REMOVE OIL PAN SUB-ASSEMBLY


    1. A017BN6E04

      Remove the 16 bolts and 2 nuts.

      Tech Tips

      Be sure to clean the bolts and stud bolts and check the threads for cracks or other damage.

    2. A017FULE01

      Remove the oil pan sub-assembly by prying between the oil pan sub-assembly and cylinder block sub-assembly with a screwdriver.

      Note

      Be careful not to damage the contact surfaces of the cylinder block and oil pan.

      Tech Tips

      Tape the screwdriver tip before use.

    3. A017D6L

      Remove the 2 O-rings.

    4. Using a "TORX" socket wrench E8, remove the 2 stud bolts.

  35. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. A017G1VE01

      Remove the 15 bolts and 2 nuts as shown in the illustration.

    2. A017EMOE02

      Remove the timing chain cover sub-assembly by prying between the timing chain cover and cylinder head sub-assembly or cylinder block sub-assembly with a screwdriver.

      Note

      Be careful not to damage the contact surfaces of the cylinder head, cylinder block and chain cover.

      Tech Tips

      Tape the screwdriver tip before use.

    3. Remove the 4 bolts, chain cover plate and chain cover plate gasket.

    4. A017CE0E01

      Remove the gasket.

  36. REMOVE TIMING CHAIN CASE OIL SEAL


    1. A017BHBE01

      Using a screwdriver, pry out the timing chain case oil seal.

      Tech Tips

      Tape the screwdriver tip before use.

  37. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily tighten the pulley set bolt.

    2. A017BSAE01

      Set the timing mark on the crank angle sensor plate to the RH block bore center line (TDC / compression).

    3. A017FZJE02

      Check that the timing marks of the camshaft timing gears are aligned with those of the bearing cap as shown in the illustration.

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

  38. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A017G4QE02

      Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.

    2. Move the stopper plate downward to set the lock, and insert a pin of 1.27 mm diameter (0.05 in.) into the stopper plate's hole.

    3. A017FY1

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

  39. REMOVE CHAIN TENSIONER SLIPPER


    1. Remove the chain tensioner slipper.

  40. REMOVE CHAIN SUB-ASSEMBLY


    1. A017CVGE02

      Turn the crankshaft counterclockwise 10° to loosen the chain sub-assembly.

    2. Remove the pulley set bolt.

    3. A017D6Y

      Remove the chain sub-assembly from the crankshaft timing sprocket and place it on the crankshaft.

    4. A017FNHE05

      Turn the camshaft timing gear assembly on the bank 1 clockwise (approximately 60°) and set it as shown in the illustration. Be sure to loosen the chain sub-assembly between the banks.

    5. Remove the chain sub-assembly.

  41. REMOVE IDLE SPROCKET ASSEMBLY


    1. A017BLF

      Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, idle sprocket assembly and No. 1 idle gear shaft.

  42. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. Remove the 2 No. 2 chain vibration dampers.

  43. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)


    1. A017F5RE01

      While pushing down the No. 3 chain tensioner assembly, insert a pin of 1.0 mm diameter (0.039 in.) into the hole to fix the No. 3 chain tensioner assembly.

    2. A017EQQE01

      Hold the hexagonal portion of the camshaft with a wrench, and remove the 2 bolts and 2 camshaft timing gear assemblies.

      Note


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

      • Do not disassemble the camshaft timing gear assemblies.

    3. Remove the No. 2 chain sub-assembly.

  44. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A017CF9

      Remove the bolt and No. 3 chain tensioner assembly.

  45. REMOVE CAMSHAFT BEARING CAP


    1. A017CCRE01

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

    2. A017F42E03

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

    3. A017FNRE01

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

      Note

      Uniformly loosen the bolts while keeping the camshafts level.

    4. Remove the 5 camshaft bearing caps.

  46. REMOVE NO. 3 CAMSHAFT


    1. Remove the No. 3 camshaft.

  47. REMOVE NO. 4 CAMSHAFT


    1. Remove the No. 4 camshaft.

  48. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A017BDME01

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  49. INSPECT CAMSHAFT TIMING GEAR ASSEMBLY


    1. Clamp the camshaft in a vise.

      Note

      Be careful not to damage the camshaft in the vise.

    2. A017DANE02

      Put the camshaft timing gear assembly and camshaft together by aligning the key groove and straight pin.

    3. Lightly press and turn the camshaft timing gear assembly against the camshaft, and press harder after the pin enters the groove.

      Note

      Be sure not to turn the camshaft timing gear assembly in the retard direction.

    4. Check that there is no clearance between the camshaft timing gear assembly's flange and the camshaft.

    5. A017GBO

      Tighten the flange bolt with the camshaft timing gear assembly fixed.

      Torque:
      100 N*m  { 1,020 kgf*cm, 74 ft.*lbf }

    6. Check the lock of the camshaft timing gear assembly.


      1. Clamp the camshaft in a vise, and confirm that the camshaft timing gear assembly locks.

        Note

        Be careful not to damage the camshaft.

    7. A017CPWE06

      Release the lock pin.


      1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

        Tech Tips

        The 2 advance side paths are located in the camshaft grove. Plug one of the paths with a rubber piece.

      2. Break through the tape on the advance side path and the retard side path on the opposite side of the hole of the advance side path, as shown in the illustration.

      3. A017DKKE06

        Apply approximately 200 kPa (2.0 kgf/cm2, 28 psi) of air pressure to the 2 opened paths.

        CAUTION:

        Cover the paths with a piece of cloth when applying pressure to prevent oil from spraying.

      4. A017CFZE05

        Check that the camshaft timing gear assembly revolves in the advance direction when reducing the air pressure applied to the retard side path.

        Tech Tips

        This operation releases the lock pin at the most retarded position.

      5. When the camshaft timing gear assembly reaches the most advanced position, release the air pressure first from the retard side path and then from advance side path.

        Note

        Do not release the air pressure from the advance side path first. The gear may abruptly shift in the retard direction and break the lock pin.

    8. Check for smooth rotation.


      1. Turn the camshaft timing gear assembly within its movable range (21°) 2 or 3 times, but do not turn it to the most retarded position. Make sure that the gear turns smoothly.

        Note

        Do not use air pressure to perform the smooth operation check.

    9. Check the lock in the most retarded position.


      1. Confirm that the camshaft timing gear assembly locks at the most retarded position.

    10. A017F5AE04

      Remove the flange bolt and camshaft timing gear assembly.

      Note


      • Do not remove the other 3 bolts.

      • If planning to reuse the camshaft timing gear, be sure to release the straight pin lock before installing the camshaft timing gear.

  50. INSPECT CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. Clamp the camshaft in a vise.

      Note

      Be careful not to damage the camshaft in the vise.

    2. A017DANE02

      Put the camshaft timing exhaust gear assembly and camshaft together by aligning the key groove and straight pin.

    3. Lightly press and turn the camshaft timing gear against the camshaft, and press harder after the pin enters the groove.

      Note

      Be sure not to turn the camshaft timing exhaust gear in the retard direction.

    4. Check that there is no clearance between the gear's flange and the camshaft.

    5. A017FF7

      Tighten the flange bolt with the camshaft timing exhaust gear assembly fixed.

      Torque:
      100 N*m  { 1020 kgf*cm, 74 ft.*lbf }

    6. Check the camshaft timing exhaust gear lock.


      1. Make sure that the camshaft timing exhaust gear assembly locks.

    7. A017DXBE05

      Release the lock pin.


      1. Cover the 4 oil paths of the cam journal with vinyl tape as shown in the illustration.

        Tech Tips

        The 2 advance side paths are located in the camshaft grove. Plug one of the paths with a rubber piece.

      2. Break through the tape on the advance side path and the retard side path on the opposite side of the hole of the advance side path, as shown in the illustration.

      3. A017EEDE02

        Apply approximately 200 kPa (2.0 kgf/cm2, 28 psi) of air pressure to the 2 opened paths (the advance side path and the retard side path).

        CAUTION:

        Cover the paths with a piece of cloth when applying pressure to prevent oil from spraying.

      4. A017EFGE03

        Make sure that the camshaft timing exhaust gear assembly rotates in the retard direction when reducing the air pressure applied to the advance side path.

        Tech Tips

        The lock pin is released and the camshaft timing exhaust gear assembly turns in the retard direction.

      5. When the camshaft timing exhaust gear assembly moves to the most retarded position, release the air pressure from the advance side path, and then release the air pressure from the retard side path.

        Note

        Be sure to release the air pressure from the advance side path first. If the air pressure of the retard side path is released first, the camshaft timing exhaust gear assembly may abruptly shift in the advance direction and break the lock pin or other parts.

    8. Check for smooth rotation.


      1. Turn the camshaft timing exhaust gear assembly within its movable range (18.5°) 2 or 3 times, but do not turn it to the most advanced position. Make sure that the gear assembly turns smoothly.

        Note

        When the air pressure is released from the advance side path and then from the retard side path, the gear assembly automatically returns to the most advanced position due to the advance assist spring operation and locks. Gradually release the air pressure from the retard side path before performing the smooth rotation check.

    9. Check the lock at the most advanced position.


      1. Make sure that the camshaft timing exhaust gear assembly locks at the most advanced position.

    10. A017FOAE03

      Remove the flange bolt and camshaft timing exhaust gear assembly.

      Note


      • Be sure not to remove the other 4 bolts.

      • If planning to reuse the gear, be sure to release the straight pin lock before installing the gear.

  51. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. Remove the 24 valve lash adjuster assemblies from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  52. REMOVE VALVE STEM CAP


    1. Install the 12 valve stem caps.

  53. REMOVE CYLINDER HEAD SUB-ASSEMBLY LH


    1. A017D6GE01

      Uniformly loosen and remove the 2 cylinder head set bolts in several steps and in the sequence shown in the illustration.

    2. A017DQUE01

      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.

      Note


      • 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.

      Tech Tips

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

    3. Remove the cylinder head sub-assembly LH.

  54. REMOVE NO. 2 CYLINDER HEAD GASKET


    1. Remove the No. 2 cylinder head gasket.