CYLINDER HEAD GASKET REMOVAL


  1. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

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  2. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. B000GXT

      Remove the 4 bolts and No. 1 exhaust manifold heat insulator from the exhaust manifold converter sub-assembly (TWC: Front Catalyst).

  3. REMOVE EGR PIPE CONNECTOR


    1. B000JFS

      Remove the 4 bolts, nut and EGR pipe connector from the exhaust manifold converter sub-assembly (TWC: Front Catalyst), EGR cooler assembly and cylinder block sub-assembly.

      Text in Illustration
      B000K70 Bolt
      B000IB9 Nut
    2. B000L15

      Remove the 2 EGR cooler gaskets from the EGR pipe connector.

  4. REMOVE MANIFOLD STAY


    1. B000HXZ

      Remove the bolt, nut and manifold stay from the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and stiffening crankcase assembly.

  5. REMOVE NO. 2 MANIFOLD STAY


    1. B000HYA

      Remove the bolt, nut and No. 2 manifold stay from the exhaust manifold converter sub-assembly (TWC: Front Catalyst) and stiffening crankcase assembly.

  6. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY (TWC: Front Catalyst)


    1. B000KES

      Remove the 5 nuts and exhaust manifold converter sub-assembly (TWC: Front Catalyst) from the cylinder head sub-assembly.

    2. B000J7F

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

  7. DISCONNECT FUEL TUBE SUB-ASSEMBLY

    Note

    Remove any foreign matter on the fuel tube connector and fuel pipe before performing this work.


    1. Disconnect the fuel tube sub-assembly from the fuel delivery pipe.


      1. B000MGZE03
        Text in Illustration
        *a Fuel Tube Connector Cover
        B000K70 Pull off

        Pull off the fuel tube connector cover.

      2. B000LMBE01
        Text in Illustration
        *a Retainer
        *b Fuel Tube Connector
        *c Nylon Tube
        *d O-ring
        *e Fuel Pipe
        B000K70 Pinch
        B000IB9 Pull

        Pinch the retainer of the fuel tube connector, and then pull the fuel tube connector off of the fuel pipe.

        Note

        Be sure to disconnect the fuel tube connector by hand.

      3. If the fuel tube connector and fuel pipe are stuck, push and pull the fuel tube connector to release it. Pull the fuel tube connector off of the fuel pipe carefully.

        Note


        • Be sure to disconnect the fuel tube connector by hand.


        • Do not scratch or allow any foreign matter to get on the parts when disconnecting them as the fuel tube connector has O-rings that seal the pipe (fuel pipe).


        • Do not bend, twist, pinch or kink the nylon tube.

      4. Check that there is no foreign matter on the sealing surfaces of the disconnected fuel lines. Clean them if necessary.

      5. Cover the disconnected fuel pipe and fuel tube connector with plastic bags to prevent damage and contamination.

  8. REMOVE FUEL DELIVERY PIPE


    1. B000JXY

      Remove the 2 bolts and fuel delivery pipe with the port fuel injector assemblies.

      Note

      Be careful not to drop the port fuel injector assemblies when removing the fuel delivery pipe.

  9. REMOVE FUEL DELIVERY SPACER


    1. B000LWR

      Remove the 2 fuel delivery spacers from the cylinder head sub-assembly.

  10. REMOVE INJECTOR VIBRATION INSULATOR


    1. B000MRT

      Remove the 4 injector vibration insulators from the cylinder head sub-assembly.

  11. REMOVE PORT FUEL INJECTOR ASSEMBLY


    1. B000KYP

      Pull the 4 port fuel injector assemblies out of the fuel delivery pipe.

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

    3. Attach a tag or label with the corresponding cylinder number to each port fuel injector assembly so that they can be installed to their original locations.

      Note

      Cover the port fuel injector assemblies with plastic bags to prevent damage and contamination.

  12. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY


    1. B000NN4

      Disconnect the throttle body with motor assembly connector.

    2. Remove the 4 bolts and throttle body with motor assembly from the intake manifold.

      Note

      If the throttle body with motor assembly has been struck or dropped, replace it.

    3. B000L5AE01
      Text in Illustration
      *1 No. 2 Water By-pass Hose
      *2 No. 3 Water By-pass Hose

      Slide the 2 clips and disconnect the No. 2 water by-pass hose and No. 3 water by-pass hose from the throttle body with motor assembly.

  13. REMOVE THROTTLE BODY GASKET


    1. B000MAL

      Remove the throttle body gasket from the intake manifold.

  14. REMOVE NO. 2 EGR PIPE


    1. B000M5N

      Disengage the 2 wire harness clamps from the No. 2 EGR pipe.

    2. B000MGH

      Remove the 4 bolts and No. 2 EGR pipe from the EGR valve assembly and intake manifold.

    3. B000HBI

      Remove the No. 2 EGR pipe gasket from the EGR valve assembly.

    4. B000KK2

      Remove the EGR inlet gasket from the intake manifold.

  15. REMOVE INTAKE MANIFOLD


    1. B000JU3

      Remove the 6 bolts and intake manifold from the cylinder head sub-assembly.

    2. B000ME8

      Remove the manifold gasket from the intake manifold.

  16. REMOVE NO. 5 ENGINE WIRE


    1. B000KLZ

      Remove the 2 bolts and disconnect the No. 5 engine wire from the fuel delivery pipe sub-assembly.

    2. Disconnect the fuel pressure sensor connector, knock control sensor connector and 4 fuel injector set connectors.

    3. Disengage the 2 clamps and remove the No. 5 engine wire.

  17. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. B000JBS

      Remove the 3 bolts, 2 nuts and fuel delivery pipe sub-assembly with the direct fuel injector assemblies.

      Text in Illustration
      B000K70 Bolt
      B000IB9 Nut

      Note


      • Make sure not to touch or strike the tips of the direct fuel injector assemblies.


      • Pull and remove the fuel delivery pipe sub-assembly in a straight line without tilting it.

  18. REMOVE DIRECT FUEL INJECTOR ASSEMBLY


    1. B000LF3E01

      Secure the fuel delivery pipe sub-assembly in a vise between aluminum plates and pull out the 4 direct fuel injector assemblies.

      Note


      • Pull and remove each direct fuel injector assembly in a straight line to avoid damaging the seal surface of the fuel delivery pipe sub-assembly O-ring.


      • Attach a tag or label with the corresponding cylinder number to each direct fuel injector assembly so that they can be installed to their original locations.

    2. Remove the nozzle holder clamp from each direct fuel injector assembly.

    3. Using needle nose pliers, remove the No. 3 fuel injector back-up ring from each direct fuel injector assembly.

    4. Remove the O-ring and No. 1 fuel injector back-up ring from each direct fuel injector assembly.

    5. Remove the C-ring and injector vibration insulator from each direct fuel injector assembly.

  19. REMOVE FUEL INJECTOR SEAL


    1. B000L5W

      Using the tip of needle nose pliers, pinch and pull the fuel injector seal at several points to stretch it.

      Note


      • Excessively pinching the fuel injector seal may damage the groove of the direct fuel injector assembly.


      • If a direct fuel injector assembly is dropped or the tip of a direct fuel injector assembly is struck, replace it with a new one.

    2. Remove the fuel injector seal from each direct fuel injector assembly.

  20. REMOVE EGR VALVE WITH COOLER ASSEMBLY


    1. B000HLO

      Disconnect the EGR valve assembly connector.

    2. B000IE5

      Remove the engine cover joint and separate the fuel hose bracket from the EGR valve bracket.

    3. B000JNF

      Remove the 4 bolts and 2 EGR valve brackets.

    4. B000I48

      Disengage the water hose from the hose clamp.

    5. B000HQE

      Slide the clip and disconnect the water hose sub-assembly from the EGR cooler assembly.

    6. B000I5ME01
      Text in Illustration
      *1 No. 2 Water By-pass Hose
      *2 No. 3 Water By-pass Hose
      *3 No. 4 Water By-pass Hose

      Slide the clip and disconnect the No. 2 water by-pass hose from the EGR valve assembly.

    7. Slide the clip and disconnect the No. 3 water by-pass hose from the EGR cooler assembly.

    8. Slide the clip and disconnect the No. 4 water by-pass hose from the EGR cooler assembly.

    9. B000NPA

      Remove the 2 nuts and EGR valve with cooler assembly from cylinder head sub-assembly.

    10. B000H11

      Remove the No. 2 EGR pipe gasket from the EGR valve assembly.

  21. REMOVE VACUUM PUMP ASSEMBLY


    1. B000HXI

      Remove the 4 bolts and vacuum pump assembly.

    2. B000GY1E01
      Text in Illustration
      *1 No. 2 O-ring
      *2 No. 3 O-ring

      Remove the No. 2 O-ring and No. 3 O-ring from the vacuum pump assembly.

  22. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley set bolt.

      B000MMVE01
      Text in Illustration
      *1 Crankshaft Pulley Key - -
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark - -

    2. Rotate the crankshaft clockwise and align the crankshaft pulley key as shown in the illustration.

    3. Check that the timing marks on the camshaft timing exhaust gear assembly and camshaft timing gear assembly are as shown in the illustration.

      Tech Tips

      "A" is not a timing mark.

    4. Remove the crankshaft pulley set bolt.

  23. REMOVE TIMING CHAIN GUIDE


    1. B000N2D

      Remove the bolt and timing chain guide.

  24. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. B000KGNE01
      Text in Illustration
      *a Stopper Plate
      *b Plunger

      Allow the plunger to extend slightly, and then turn the stopper plate counterclockwise to release the lock. Once the lock is released, push the plunger into the No. 1 chain tensioner assembly.

    2. B000LFJE01
      Text in Illustration
      *a Pin

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

    3. B000KE3

      Remove the 2 bolts, No. 1 chain tensioner assembly and gasket.

  25. REMOVE CHAIN TENSIONER SLIPPER


    1. B000NI4

      Remove the bolt and chain tensioner slipper.

  26. REMOVE CHAIN SUB-ASSEMBLY


    1. Remove the chain sub-assembly.

  27. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. B000MCS

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

  28. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. B000JUOE01
      Text in Illustration
      *a Hold
      B000K70 Turn

      Using a wrench to hold the hexagonal portion of the camshaft, remove the camshaft timing gear 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.

  29. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. B000LY2E01
      Text in Illustration
      *a Hold
      B000K70 Turn

      Using a wrench to hold the hexagonal portion of the No. 2 camshaft, 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.

  30. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. B000JSPE01

      Uniformly loosen and remove the 20 bolts in the order shown in the illustration.

    2. B000M1H

      Remove the camshaft housing sub-assembly by prying between the cylinder head sub-assembly and camshaft housing sub-assembly with a screwdriver.

      Note

      Be careful not to damage the contact surfaces of the cylinder head sub-assembly and camshaft housing sub-assembly.

      Tech Tips

      Tape the screwdriver tip before use.

  31. REMOVE CAMSHAFT BEARING CAP


    1. B000JYWE01

      Remove the 11 bolts in the order shown in the illustration.

    2. Remove the No. 1 camshaft bearing cap, No. 2 camshaft bearing cap, No. 3 camshaft bearing cap and No. 4 camshaft bearing cap.

      Tech Tips

      Arrange the removed parts in the correct order.

  32. REMOVE CAMSHAFT


    1. Remove the camshaft from the camshaft housing sub-assembly.

  33. REMOVE NO. 2 CAMSHAFT


    1. Remove the No. 2 camshaft from the camshaft housing sub-assembly.

  34. REMOVE OIL CONTROL VALVE FILTER


    1. B000JAM

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

  35. REMOVE NO. 1 CAMSHAFT BEARING


    1. B000K64

      Remove the No. 1 camshaft bearing from the No. 1 camshaft bearing cap.

  36. REMOVE NO. 2 CAMSHAFT BEARING


    1. B000NCB

      Remove the No. 2 camshaft bearing from the camshaft housing sub-assembly.

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


    1. Remove the 16 No. 1 valve rocker arm sub-assemblies.

      Tech Tips

      Arrange the removed parts in the correct order.

  38. 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.

  39. 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.

  40. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. B000I2IE01

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

      Tech Tips

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

      Note


      • Be careful not to drop plate washers into the cylinder head sub-assembly.

      • Cylinder head warpage or cracking may result from removing bolts in the incorrect order.

    2. Remove the cylinder head sub-assembly.

  41. REMOVE CYLINDER HEAD GASKET


    1. Remove the cylinder head gasket from the cylinder block sub-assembly.