CYLINDER HEAD GASKET REMOVAL


  1. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  2. REMOVE MANIFOLD STAY


    1. A01HPVC

      Remove the bolt, nut and manifold stay.

  3. REMOVE NO. 2 MANIFOLD STAY


    1. A01HOYS

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

  4. REMOVE EGR INLET EXHAUST MANIFOLD PLATE (for PZEV)


    1. A01HR36

      Remove the bolt and EGR inlet exhaust manifold plate.

  5. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (except PZEV)


    1. A01HOF8

      Remove the 4 bolts and No. 1 exhaust manifold heat insulator.

  6. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. A01HPZB

      Remove the 5 nuts and exhaust manifold converter sub-assembly (except PZEV).

    2. A01HNC1

      Remove the 5 nuts and exhaust manifold converter sub-assembly (for PZEV).

    3. A01HOJ2E01

      Remove the exhaust manifold to head gasket (except PZEV).

    4. A01HO52E01

      Remove the exhaust manifold to head gasket (for PZEV).

  7. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY

    Click here

  8. REMOVE VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)


    1. A01HNWJ

      Disconnect the union to connector tube hose and wire harness clamp.

    2. Disconnect the 2 vacuum hoses and connector.

    3. Remove the bolt and vacuum switching valve assembly.

  9. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. A01HP3F

      Remove the 2 bolts, and then remove the fuel delivery pipe together with the 4 fuel injectors.

      Note

      Be careful not to drop the fuel injectors when removing the fuel delivery pipe.

    2. A01HO6V

      Remove the 2 fuel delivery spacers from the cylinder head.

    3. Remove the 4 injector vibration insulators from the cylinder head.

  10. DISCONNECT NO. 2 VENTILATION HOSE


    1. A01HQUM

      Disconnect the No. 2 ventilation hose from the intake manifold.

  11. REMOVE INTAKE MANIFOLD


    1. A01HONF

      Remove the 2 bolts and 2 wire harness clamp brackets.

    2. A01HOLU

      Disconnect the fuel vapor feed hose.

    3. Disconnect the 3 wire harness clamps and connector.

    4. Remove the bolt and wire harness clamp bracket.

    5. A01HO85

      Apply battery voltage to the terminals of the connector to close the tumble control valves.

      Standard
      Tester Connection Specified Condition
      Positive (+) battery voltage applied to terminal 8 (M-), and negative (-) battery voltage applied to terminal 4 (M+) Open → Closed

      Note


      • If this procedure is not performed, the tumble control valves may be damaged when the intake manifold is removed.

      • Apply battery voltage for 1 to 3 seconds.

      • If battery voltage is applied for more than 3 seconds, the actuator may be damaged.

      • Do not allow the lead wires to contact the other terminals.

    6. A01HNHK

      Remove the bolt and separate the wire harness.

    7. Disconnect the 2 wire harness clamps and intake air control valve actuator connector.

    8. A01HR4E

      Remove the 6 bolts and intake manifold.

      Note

      The tumble control valves may be damaged if they are not closed before removing the intake manifold.

      Tech Tips

      Connect the battery to the terminals of the actuator to operate the motor and close the valves Click here.

    9. A01HQFZ

      Remove the intake manifold gasket from the intake manifold.

    10. A01HQGJ

      Disconnect the 2 vacuum hoses from the intake manifold and remove the No. 1 check valve.

    11. A01HONS

      Remove the bolt and wire harness clamp bracket.

  12. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

      A01HQFGE03
      Text in Illustration
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark *d Key

      Tech Tips

      "A" is not a timing mark.

    2. Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing gear and camshaft timing gears are as shown in the illustration.

      Tech Tips

      If the timing marks do not align, rotate the crankshaft clockwise again and align the timing marks.

    3. Remove the crankshaft pulley bolt.

  13. REMOVE TIMING CHAIN GUIDE


    1. A01HNOS

      Remove the bolt and timing chain guide.

  14. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01HQQOE02
      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 tensioner.

    2. A01HOYIE02
      Text in Illustration
      *1 Pin

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

    3. A01HO3I

      Remove the 2 bolts, chain tensioner and gasket.

  15. REMOVE CHAIN TENSIONER SLIPPER


    1. A01HPNX

      Remove the bolt and chain tensioner slipper.

  16. REMOVE CHAIN SUB-ASSEMBLY


    1. Remove the chain sub-assembly.

  17. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01HNPP

      Remove the 2 bolts and chain vibration damper.

  18. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01HOYRE01
      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.

  19. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A01HPGPE01
      Text in Illustration
      *a Hold
      *b Turn

      Hold the hexagonal portion of the 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.

  20. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A01HNIVE01

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

    2. A01HOPV

      Remove the camshaft housing 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 and camshaft housing sub-assembly.

  21. REMOVE CAMSHAFT BEARING CAP


    1. A01HPJ3E01

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

    2. Remove the 5 bearing caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  22. REMOVE OIL CONTROL VALVE FILTER


    1. A01HQB3

      Remove the oil control valve filter from the No. 1 camshaft bearing cap.

  23. REMOVE NO. 1 CAMSHAFT BEARING


    1. A01HP5Q

      Remove the No. 1 camshaft bearing.

  24. REMOVE CAMSHAFT


    1. Remove the camshaft and No. 2 camshaft.

  25. REMOVE NO. 2 CAMSHAFT BEARING


    1. A01HPR7

      Remove the No. 2 camshaft bearing.

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


    1. Remove the 16 valve rocker arms from the cylinder head sub-assembly.

      Tech Tips

      Arrange the removed parts in the correct order.

  27. REMOVE VALVE LASH ADJUSTER ASSEMBLY


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

      Tech Tips

      Arrange the removed parts in the correct order.

  28. 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.

  29. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01HO63E01

      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 plate washers.

      Tech Tips

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

      Note


      • Be careful not to drop 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.

  30. REMOVE CYLINDER HEAD GASKET


    1. Remove the cylinder head gasket from the cylinder block.