CYLINDER HEAD REMOVAL


  1. REMOVE AUTOMATIC TRANSMISSION ASSEMBLY

    Click here

  2. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSEMBLY

    Click here

  3. REMOVE INTAKE MANIFOLD

    Click here

  4. REMOVE EXHAUST MANIFOLD

    Click here

  5. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

    2. A003HAQE01
      Text in Illustration
      *1 Key
      *a Timing Mark
      *b Approximately 13°
      *c Approximately 30°

      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.

  6. REMOVE CYLINDER HEAD COVER CONNECTOR SUB-ASSEMBLY


    1. A003BMM

      Remove the 2 bolts and cylinder head cover connector sub-assembly.

    2. Remove the No. 2 camshaft bearing cap oil hole gasket and 3 No. 3 camshaft bearing cap oil hole gaskets from the camshaft bearing cap.

  7. REMOVE TIMING CHAIN GUIDE


    1. A003DWSE01
      Text in Illustration
      *1 O-Ring

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

  8. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    Note


    • When the No. 1 chain tensioner assembly 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.


    1. A003DI2E14
      Text in Illustration
      *a Plunger
      *b Stopper Plate
      *c Hexagon Wrench

      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 hexagon wrench into the stopper plate hole.

    3. A003EKZ

      Remove the bolt, nut, No. 1 chain tensioner assembly and gasket.

  9. REMOVE CHAIN TENSIONER SLIPPER


    1. A003FLJ

      Remove the bolt and chain tensioner slipper.

  10. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A003B1O

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

  11. REMOVE CHAIN SUB-ASSEMBLY

  12. REMOVE CAMSHAFT BEARING CAP


    1. A003HPIE02

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

      Note

      Uniformly loosen the bolts while keeping the camshafts level.

    2. A003C8J

      Remove the 9 bearing caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  13. REMOVE CAMSHAFT


    1. A003D6X

      Remove the camshaft.

  14. REMOVE NO. 2 CAMSHAFT


    1. A003FLI

      Remove the No. 2 camshaft.

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


    1. A003AKHE01
      Text in Illustration
      *1 No. 1 Valve Rocker Arm Sub-assembly
      *2 Valve Lash Adjuster Assembly
      *3 Valve Stem Cap

      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.

  16. 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.

  17. 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.

  18. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A003CIVE04

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

      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.

  19. REMOVE CYLINDER HEAD GASKET

  20. INSPECT CYLINDER HEAD SET BOLT


    1. A003DOBE03
      Text in Illustration
      *a Measuring area
      *b 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 set bolt.

  21. INSPECT CYLINDER HEAD SUB-ASSEMBLY


    1. A003D2DE02
      Text in Illustration
      *a Cylinder Block Side
      *b Intake Manifold Side
      *c Exhaust Manifold Side

      Using a precision straightedge and feeler gauge, measure the warpage of the contact surface of 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 sub-assembly.

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

      If cracked, replace the cylinder head sub-assembly.