CYLINDER HEAD GASKET REMOVAL

PROCEDURE


  1. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

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  2. SET NO. 1 CYLINDER TO TDC/COMPRESSION

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  3. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

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  4. REMOVE CHAIN TENSIONER SLIPPER

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  5. REMOVE CHAIN SUB-ASSEMBLY

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  6. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)


    1. A000QQFE02
      Text in Illustration
      *1 Pin
      *2 Plunger
      *a Push

      While raising the No. 2 chain tensioner, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold the No. 2 chain tensioner.

    2. A000SWAE01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST to hold the hexagonal portion of each camshaft, loosen the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly RH.

      SST
      09922-10010

      Note


      • Be careful not to damage the cylinder head with SST.

      • Do not loosen the other bolts. If any of the bolts is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly with a new one.

    3. Remove the 2 bolts and the camshaft timing gear assembly together with the No. 2 chain.

  7. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A000QTT

      Remove the bolt and No. 2 chain tensioner.

  8. REMOVE CAMSHAFT BEARING CAP (for Bank 1)


    1. A000RLEE02
      Text in Illustration
      *1 Knock Pin
      *a IN
      *b EX

      Check that the camshafts are positioned as shown in the illustration.

    2. A000SC3E02

      Uniformly loosen and remove the 9 bearing cap bolts in several steps and in the sequence shown in the illustration.

    3. A000OQQE03

      Uniformly loosen and remove the 15 bearing cap bolts in several steps and in the sequence shown in the illustration.

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

  9. REMOVE FUEL PUMP LIFTER HOUSING


    1. A000MXI

      Remove the fuel pump lifter housing.

  10. REMOVE CAMSHAFT

  11. REMOVE NO. 2 CAMSHAFT

  12. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A000NWWE02
      Text in Illustration
      *1 Protective Tape

      Remove the camshaft housing RH by prying between the cylinder head and camshaft housing RH with a screwdriver.

      Note

      Be careful not to damage the contact surfaces of the cylinder head and camshaft housing RH.

      Tech Tips

      Tape the screwdriver tip before use.

  13. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 2)


    1. A000SV4E02
      Text in Illustration
      *1 Pin
      *2 Plunger
      *a Push

      While pushing down the No. 3 chain tensioner, insert a pin of 1.0 mm (0.0394 in.) diameter into the hole to hold the No. 3 chain tensioner.

    2. A000P3FE05
      Text in Illustration
      *a Turn
      *b Hold

      Using SST to hold the hexagonal portion of each camshaft, loosen the flange bolts of the camshaft timing gear assembly and the camshaft timing exhaust gear assembly LH.

      SST
      09922-10010

      Note


      • Be careful not to damage the cylinder head with SST.

      • Do not loosen the other bolts. If any of the bolts is loosened, replace the camshaft timing gear assembly and/or the camshaft timing exhaust gear assembly with a new one.

    3. Remove the 2 bolts and the camshaft timing gear together with the No. 2 chain.

  14. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A000OEF

      Remove the bolt and No. 3 chain tensioner.

  15. REMOVE CAMSHAFT BEARING CAP (for Bank 2)


    1. A000PK3E02
      Text in Illustration
      *1 Knock Pin
      *a IN
      *b EX

      Check that the camshafts are positioned as shown in the illustration.

    2. A000PNDE03

      Uniformly loosen and remove the 8 bearing cap bolts in several steps and in the sequence shown in the illustration.

    3. A000T6OE05

      Uniformly loosen and remove the 13 bearing cap bolts in several steps and in the sequence shown in the illustration.

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

    4. Remove the 5 camshaft bearing caps.

  16. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY

  17. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY

  18. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A000Q04E02
      Text in Illustration
      *1 Protective Tape

      Remove the camshaft housing LH by prying between the cylinder head LH and camshaft housing LH with a screwdriver.

      Note

      Be careful not to damage the contact surfaces of the cylinder head and camshaft housing LH.

      Tech Tips

      Tape the screwdriver tip before use.

  19. REMOVE NO. 1 CHAIN VIBRATION DAMPER

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  20. REMOVE NO. 2 CHAIN VIBRATION DAMPER

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


    1. Remove the 24 No. 1 valve rocker arms.

      Tech Tips

      Arrange the removed parts in the correct order.

  22. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. Remove the 24 valve lash adjusters from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  23. REMOVE VALVE STEM CAP


    1. Remove the 24 valve stem caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  24. REMOVE REAR WATER BY-PASS JOINT

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  25. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY

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  26. REMOVE FUEL DELIVERY PIPE LH

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  27. REMOVE FUEL DELIVERY PIPE RH

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  28. REMOVE FUEL INJECTOR ASSEMBLY

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  29. REMOVE FUEL INJECTOR SEAL

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  30. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A000NSQE03

      Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

      Note


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

      • Cylinder head warpage or cracking could result from removing bolts in an incorrect order.

      Tech Tips

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

    2. Remove the cylinder head.

  31. REMOVE CYLINDER HEAD GASKET

  32. REMOVE CYLINDER HEAD LH


    1. A000PC1E03

      Uniformly loosen and remove the bolts in the sequence shown in the illustration.

    2. A000P45E03

      Using a 10 mm bi-hexagon wrench, uniformly loosen the 8 bolts in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

      Note


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

      • Cylinder head warpage or cracking could result from removing bolts in an incorrect order.

      Tech Tips

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

    3. Remove the cylinder head LH.

  33. REMOVE NO. 2 CYLINDER HEAD GASKET

  34. INSPECT CYLINDER HEAD SET BOLT

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