CYLINDER HEAD GASKET REMOVAL


  1. REMOVE ENGINE ASSEMBLY


    1. Remove the engine assembly Click here.

  2. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01DTZOE01

      Remove the 5 bolts and No. 1 exhaust manifold heat insulator.

      Tech Tips


      • It is only necessary to move the No. 1 exhaust manifold heat insulator so that the intake pipe can be removed in a later step.

      • It is not possible to fully remove the No. 1 exhaust manifold heat insulator in this step.

  3. REMOVE NO. 4 INTAKE PIPE


    1. A01DOAH

      Remove the 4 nuts, No. 4 intake pipe and 2 gaskets.

      Note

      Be careful not to damage the installation surface of the gaskets.

  4. REMOVE AIR SWITCHING VALVE ASSEMBLY


    1. A01DUWT

      w/ Manifold Absolute Pressure Sensor:

      Disconnect the vacuum hose.

    2. A01DQWY

      Disconnect the connector.

    3. Remove the 2 nuts and air switching valve.

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

  5. REMOVE EXHAUST MANIFOLD


    1. A01DRRH

      Remove the 8 nuts and exhaust manifold.

    2. Remove the gasket.

  6. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY


    1. Remove the timing chain cover sub-assembly Click here.

  7. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. A01DUVKE01
      Text in Illustration
      *1 Timing Mark
      *2 Key

      Temporarily install the crankshaft pulley bolt.

    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.

  8. REMOVE TIMING CHAIN GUIDE


    1. A01DUWO

      Remove the 2 bolts, chain guide and O-ring.

  9. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Note


    • When the chain tensioner is removed, do not rotate the crankshaft.

    • When the chain is removed and the camshaft needs to be rotated, rotate the crankshaft 90° to the right.

    A01DS7UE07

    1. 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 3.0 mm (0.118 in.) diameter bar into the stopper plate hole.

    3. A01DQEP
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate

      Remove the bolt, nut, chain tensioner and gasket.

  10. REMOVE CHAIN TENSIONER SLIPPER


    1. A01DQ96E01

      Remove the bolt and tensioner slipper.

  11. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01DT7AE01

      Remove the 2 bolts and vibration damper.

  12. REMOVE CHAIN SUB-ASSEMBLY

  13. REMOVE CAMSHAFT BEARING CAP


    1. A01DM7RE01

      Uniformly loosen and remove the 21 bearing cap bolts in the sequence shown in the illustration.

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

    2. A01DUHJ

      Remove the oil delivery pipe and O-ring from the bearing caps.

    3. A01DSMO

      Remove the 9 bearing caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  14. REMOVE CAMSHAFT

    A01DS0Z

  15. REMOVE NO. 2 CAMSHAFT

    A01DT68

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


    1. A01DSZE

      Remove the 16 valve rocker arms from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  17. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. A01DQDC

      Remove the 16 valve lash adjusters from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  18. REMOVE VALVE STEM CAP


    1. A01DQFI

      Remove the valve stem caps from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  19. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01DOINE03

      Uniformly loosen the 10 bolts in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

      Note


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

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

  20. REMOVE CYLINDER HEAD GASKET


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

  21. INSPECT CYLINDER HEAD SET BOLT


    1. A01DM2EE01
      Text in Illustration
      *1 Measuring area
      *2 Distance

      Using a vernier caliper, measure the diameter of the most elongated threads in the measuring area.

      Standard outside diameter
      10.76 to 10.97 mm (0.424 to 0.432 in.)
      Minimum outside diameter
      10.40 mm (0.409 in.)
      Distance
      30 mm (1.18 in.)

      If a visual check reveals no excessively thin areas, check the center of the measuring area (see illustration) and find the area that has the smallest diameter.

      If the diameter is less than the minimum, replace the cylinder head bolt.

  22. INSPECT CYLINDER HEAD SUB-ASSEMBLY


    1. A01DTTXE02
      Text in Illustration
      *a Cylinder Head Lower Side
      *b Intake Manifold Side
      *c Exhaust Manifold Side

      Using a precision straightedge and feeler gauge, measure the warpage of the surfaces that contact the cylinder block and manifolds.

      Maximum warpage
      0.05 mm (0.00197 in.)

      If the warpage is more than the maximum, replace the cylinder head.

    2. Using a dye penetrant, check the intake ports, exhaust ports and cylinder head surface for cracks.

      If cracked, replace the cylinder head.