CYLINDER HEAD GASKET REMOVAL


  1. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

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  2. REMOVE MANIFOLD STAY


    1. A01HY3K

      Remove the bolt, nut and manifold stay from the exhaust manifold converter sub-assembly and stiffening crankcase assembly.

  3. REMOVE NO. 2 MANIFOLD STAY


    1. A01I10Z

      Remove the bolt, nut and No. 2 manifold stay from the exhaust manifold converter sub-assembly and stiffening crankcase assembly.

  4. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01I0MS

      Remove the 4 bolts and No. 1 exhaust manifold heat insulator from the exhaust manifold converter sub-assembly.

  5. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. A01I1IU

      Remove the 5 nuts and exhaust manifold converter sub-assembly from the cylinder head sub-assembly.

    2. A01HYLLE01

      Remove the exhaust manifold to head gasket from the cylinder head sub-assembly.

  6. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY


    1. A01I23I

      Disconnect the fuel tube from the clamp.

    2. Disconnect the throttle body connector.

    3. A01I01R

      Disconnect the water by-pass hose from the throttle with motor body assembly.

    4. Disconnect the No. 2 water by-pass hose from the throttle with motor body assembly.

    5. A01I0NW

      Remove the 4 bolts and throttle with motor body assembly with fuel tube bracket.

    6. A01HY83

      Remove the bolt and fuel tube bracket.

    7. A01HZI8

      Remove the gasket from the intake manifold.

  7. REMOVE VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)


    1. A01HXV7

      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.

  8. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. A01HXOG

      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. A01I1AV

      Remove the 2 fuel delivery spacers from the cylinder head.

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

  9. REMOVE FUEL INJECTOR ASSEMBLY


    1. A01I0ANE01

      Pull the 4 fuel injectors out of the fuel delivery pipe.

    2. Remove the O-ring from each fuel injector.

    3. For reinstallation, attach a tag or label to each injector shaft.

      Note

      Prevent entry of foreign matter by covering the fuel injectors with plastic bags.

  10. DISCONNECT NO. 2 VENTILATION HOSE


    1. A01HZWS

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

  11. REMOVE INTAKE MANIFOLD


    1. A01HYLI

      Remove the 2 bolts and 2 wire harness clamp brackets.

    2. A01HXIE

      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. A01I25U

      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. A01HZMV

      Remove the bolt and separate the wire harness.

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

    8. A01HZOZ

      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. A01HYFJ

      Remove the intake manifold gasket from the intake manifold.

    10. A01HXI4

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

    11. A01I0Q1

      Remove the bolt and wire harness clamp bracket.

  12. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

      A01HZKXE03
      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. A01HZVM

      Remove the bolt and timing chain guide.

  14. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01I0N4E02
      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. A01HYXBE02
      Text in Illustration
      *1 Pin

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

    3. A01I1SI

      Remove the 2 bolts, chain tensioner and gasket.

  15. REMOVE CHAIN TENSIONER SLIPPER


    1. A01I157

      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. A01HYUW

      Remove the 2 bolts and chain vibration damper.

  18. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01I1BME01
      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. A01I15BE01
      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. A01I1RZE01

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

    2. A01HYDJ

      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. A01HYMBE01

      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. A01I17V

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

  23. REMOVE NO. 1 CAMSHAFT BEARING


    1. A01I04B

      Remove the No. 1 camshaft bearing.

  24. REMOVE CAMSHAFT


    1. Remove the camshaft and No. 2 camshaft.

  25. REMOVE NO. 2 CAMSHAFT BEARING


    1. A01HZFV

      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. A01HY0YE01

      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.