CYLINDER HEAD GASKET REMOVAL


  1. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  2. REMOVE MANIFOLD STAY


    1. B000MFE

      Remove the bolt, nut and manifold stay.

  3. REMOVE NO. 2 MANIFOLD STAY


    1. B000KX3

      Remove the bolt, nut and No. 2 manifold stay.

  4. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. B000GXT

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

  5. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. B000KES

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

    2. B000J7FE01

      Remove the exhaust manifold to head gasket.

  6. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY


    1. B000GYB

      Disconnect the fuel tube from the clamp.

    2. Disconnect the throttle body connector.

    3. B000JKF

      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. B000KIQ

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

    6. B000I82

      Remove the bolt and fuel tube bracket.

    7. B000LGR

      Remove the gasket from the intake manifold.

  7. REMOVE VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)


    1. B000JNA

      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.

    4. B000M40

      Remove the bolt and vacuum hose clamp.

  8. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. B000JXH

      Remove the 2 bolts and fuel delivery pipe sub-assembly with the 4 fuel injector assemblies.

      Note

      Do not drop the fuel injector assemblies when removing the fuel delivery pipe sub-assembly.

    2. B000N6RE01
      Text in Illustration
      *1 Fuel Delivery Spacer
      *2 Injector Vibration Insulator

      Remove the 2 fuel delivery spacers from the cylinder head.

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

  9. DISCONNECT NO. 2 VENTILATION HOSE


    1. B000MDG

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

  10. REMOVE INTAKE MANIFOLD


    1. B000M0E

      Remove the 2 bolts and 2 wire harness clamp brackets.

    2. B000MD8

      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. B000H4G

      Apply battery voltage to the terminals of the connector to close the tumble control valves (w/ TCV).

      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. B000MXZE01

      Remove the bolt and separate the wire harness.

    7. Disconnect the 2 wire harness clamps and intake air control valve actuator connector (w/ TCV).

    8. Disconnect the 2 wire harness clamps (w/o TCV).

      Text in Illustration
      *A w/ TCV
      *B w/o TCV
    9. B000K5V

      Remove the 6 bolts and intake manifold (w/ TCV).

      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.

    10. B000M9A

      Remove the 6 bolts and intake manifold (w/o TCV).

    11. B000LUC

      Remove the intake manifold gasket from the intake manifold (w/ TCV).

    12. B000K60

      Remove the intake manifold gasket from the intake manifold (w/o TCV).

    13. B000J2C

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

    14. B000IDI

      Remove the bolt and wire harness clamp bracket.

  11. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

      B000LRAE03
      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.

  12. REMOVE TIMING CHAIN GUIDE


    1. B000N8X

      Remove the bolt and timing chain guide.

  13. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B000IEHE02
      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. B000MBTE02
      Text in Illustration
      *1 Pin

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

    3. B000IVV

      Remove the 2 bolts, chain tensioner and gasket.

  14. REMOVE CHAIN TENSIONER SLIPPER


    1. B000L2Q

      Remove the bolt and chain tensioner slipper.

  15. REMOVE CHAIN SUB-ASSEMBLY


    1. Remove the chain sub-assembly.

  16. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. B000IU7

      Remove the 2 bolts and chain vibration damper.

  17. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. B000LSS

      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.

  18. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. B000K88

      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.

  19. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. B000IM0E01

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

    2. B000JFV

      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.

  20. REMOVE CAMSHAFT BEARING CAP


    1. B000JHVE01

      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.

  21. REMOVE OIL CONTROL VALVE FILTER


    1. B000KN8

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

  22. REMOVE NO. 1 CAMSHAFT BEARING


    1. B000M5Z

      Remove the No. 1 camshaft bearing.

  23. REMOVE CAMSHAFT


    1. Remove the camshaft and No. 2 camshaft.

  24. REMOVE NO. 2 CAMSHAFT BEARING


    1. B000K8Z

      Remove the No. 2 camshaft bearing.

  25. 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.

  26. 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.

  27. 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.

  28. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. B000MYME01

      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 the incorrect order.

    2. Remove the cylinder head.

  29. REMOVE CYLINDER HEAD GASKET


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