CYLINDER HEAD GASKET REMOVAL

REMOVE ENGINE ASSEMBLY WITH TRANSAXLE
1. Remove the engine and transaxle Click here.
REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
1. Remove the exhaust manifold converter Click here.
REMOVE THROTTLE BODY ASSEMBLY
1. Disconnect the throttle body assembly connector.
2. Disconnect the fuel tube from the clamp.
3. Disconnect the 2 water by-pass hoses from the throttle body assembly.
4. Remove the 4 bolts and the throttle body assembly with the fuel tube bracket.
5. Remove the bolt and fuel tube bracket.
6. Remove the gasket from the intake manifold.
REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY
1. 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. Remove the 2 fuel delivery spacers from the cylinder head.
3. Remove the 4 injector vibration insulators from the cylinder head.
DISCONNECT NO. 2 VENTILATION HOSE
1. Disconnect the No. 2 ventilation hose from the intake manifold.

REMOVE INTAKE MANIFOLD

Remove the 2 bolts and 2 wire harness brackets.
Disconnect the fuel vapor feed hose, clamp and connector.
Remove the bolt and wire harness bracket.

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.

Remove the bolt.
Detach the 2 clamps from the intake manifold and bracket.
Disconnect the intake air control valve actuator connector.
Remove the 6 bolts and intake manifold.

Note

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

Tech Tips

Connect the battery to the terminals of the actuator to operate the motor and close the valves Click here.
Remove the intake manifold gasket from the intake manifold.

REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

Click here
SET NO. 1 CYLINDER TO TDC/COMPRESSION
1. Temporarily install the crankshaft pulley bolt.
  
  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.
REMOVE TIMING CHAIN GUIDE
1. Remove the bolt and timing chain guide.
REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY
1. 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. Text in Illustration
  
  *1 Pin
  
  Move the stopper plate clockwise to set the lock, and insert a pin into the stopper plate hole.
3. Remove the 2 bolts, chain tensioner and gasket.
REMOVE CHAIN TENSIONER SLIPPER
1. Remove the bolt and chain tensioner slipper.
REMOVE CHAIN SUB-ASSEMBLY
1. Remove the chain sub-assembly.
REMOVE NO. 1 CHAIN VIBRATION DAMPER
1. Remove the 2 bolts and chain vibration damper.
REMOVE CAMSHAFT TIMING GEAR ASSEMBLY
1. Hold the hexagonal portion of the camshaft with a wrench and remove the bolt and camshaft timing gear.
  Note
  
  Be careful not to damage the cylinder head or spark plug tube with the wrench.
  
  Do not disassemble the camshaft timing gear.
REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY
1. Hold the hexagonal portion of the camshaft with a wrench and remove the bolt and camshaft timing exhaust gear.
  Note
  
  Be careful not to damage the cylinder head or spark plug tube with the wrench.
  
  Do not disassemble the camshaft timing exhaust gear.
REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY
1. Uniformly loosen and remove the 20 bearing cap bolts in the sequence shown in the illustration.
2. Remove the camshaft housing by prying between the cylinder head and camshaft housing 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.
REMOVE CAMSHAFT BEARING CAP
1. 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.
REMOVE OIL CONTROL VALVE FILTER
1. Remove the oil control valve filter from the No. 1 camshaft bearing cap.
REMOVE NO. 1 CAMSHAFT BEARING
1. Remove the No. 1 camshaft bearing.
REMOVE CAMSHAFT
1. Remove the No. 1 and No. 2 camshafts.
REMOVE NO. 2 CAMSHAFT BEARING
1. Remove the No. 2 camshaft bearing.
REMOVE NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY
1. Remove the 16 valve rocker arms from the cylinder head.
  
  Tech Tips
  
  Arrange the removed parts in the correct order.
REMOVE VALVE LASH ADJUSTER ASSEMBLY
1. Remove the 16 valve lash adjusters from the cylinder head.
  
  Tech Tips
  
  Arrange the removed parts in the correct order.
REMOVE VALVE STEM CAP
1. Remove the 16 valve stem caps from the cylinder head.
  
  Tech Tips
  
  Arrange the removed parts in the correct order.
REMOVE CYLINDER HEAD SUB-ASSEMBLY
1. 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.
  
  Head warpage or cracking could result from removing bolts in an incorrect order.
2. Remove the cylinder head.
REMOVE CYLINDER HEAD GASKET
1. Remove the cylinder head gasket from the cylinder block.