CYLINDER HEAD GASKET REMOVAL

PROCEDURE


  1. REMOVE TIMING CHAIN OR BELT 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. B003ULAC04
      *1 Pin
      *2 Plunger
      *a Push

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

    2. B003WANC01
      *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 sub-assembly 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 RH with a new one.

    3. Remove the 2 bolts, camshaft timing gear assembly and camshaft timing exhaust gear assembly RH together with the No. 2 chain sub-assembly.

    4. Remove the No. 2 chain sub-assembly.

  7. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. B003WHT

      Remove the bolt and No. 2 chain tensioner assembly.

  8. REMOVE CAMSHAFT BEARING CAP (for Bank 1)


    1. B003V4XC01
      *1 Knock Pin
      *a IN
      *b EX
      *c 45°

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

    2. B003TSZN01

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

    3. B003SVWN01

      Uniformly loosen and remove the 14 bolts in several steps and in the sequence shown in the illustration.

      Note

      Uniformly loosen the bolts while keeping the camshafts level.

    4. Remove the 6 camshaft bearing caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  9. REMOVE CAMSHAFT


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

  10. REMOVE NO. 2 CAMSHAFT


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

  11. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. B003VEBC01
      *1 Protective Tape

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

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


    1. B003T3JC05
      *1 Pin
      *2 Plunger
      *a Push

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

    2. B003V7QC02
      *a Turn
      *b Hold

      Using SST to hold the hexagonal portion of each camshaft sub-assembly, 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 LH 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 LH with a new one.

    3. Remove the 2 bolts, camshaft timing gear assembly and camshaft timing exhaust gear assembly LH together with the No. 2 chain sub-assembly.

    4. Remove the No. 2 chain sub-assembly.

  13. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY


    1. B003WP9

      Remove the bolt and No. 3 chain tensioner assembly.

  14. REMOVE CAMSHAFT BEARING CAP (for Bank 2)


    1. B003WLJC01
      *1 Knock Pin
      *a IN
      *b EX

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

    2. B003VDHN01

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

    3. B003UGHN03

      Uniformly loosen and remove the 13 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.

      Tech Tips

      Arrange the removed parts in the correct order.

  15. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY


    1. Remove the No. 3 camshaft sub-assembly from the camshaft housing sub-assembly LH.

  16. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY


    1. Remove the No. 4 camshaft sub-assembly from the camshaft housing sub-assembly LH.

  17. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. B003TAPC01
      *1 Protective Tape

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

  18. REMOVE NO. 1 CHAIN VIBRATION DAMPER

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  19. REMOVE NO. 2 CHAIN VIBRATION DAMPER

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


    1. Remove the 24 No. 1 valve rocker arm sub-assemblies.

      Tech Tips

      Arrange the removed parts in the correct order.

  21. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. Remove the 24 valve lash adjuster assemblies.

      Tech Tips

      Arrange the removed parts in the correct order.

  22. REMOVE VALVE STEM CAP


    1. Remove the 24 valve stem caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  23. REMOVE REAR WATER BY-PASS JOINT

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  24. REMOVE NO. 3 FUEL PIPE SUB-ASSEMBLY

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  25. REMOVE NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY

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  26. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

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  27. REMOVE FUEL INJECTOR ASSEMBLY

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  28. REMOVE FUEL INJECTOR SEAL

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  29. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. B003TBRN01

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

    2. Remove the 8 cylinder head set bolts and plate washers.

      Note


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

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

      Tech Tips

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

    3. Remove the cylinder head sub-assembly.

  30. REMOVE CYLINDER HEAD GASKET


    1. Remove the cylinder head gasket.

      Note


      • Clean the bolt holes of the cylinder block sub-assembly and check for damaged.

      • If the bolt holes are damaged, repair them with a tap.

  31. REMOVE CYLINDER HEAD LH


    1. B003UF0N06

      Uniformly loosen and remove the 2 bolts in the sequence shown in the illustration.

    2. B003TMWN01

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

    3. Remove the 8 cylinder head set bolts and plate washers.

      Note


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

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

      Tech Tips

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

    4. Remove the cylinder head LH.

  32. REMOVE NO. 2 CYLINDER HEAD GASKET


    1. Remove the No. 2 cylinder head gasket.

      Note


      • Clean the bolt holes of the cylinder block sub-assembly and check for damaged.

      • If the bolt holes are damaged, repair them with a tap.

  33. INSPECT CYLINDER HEAD FOR FLATNESS

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  34. INSPECT CYLINDER HEAD FOR CRACKS

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  35. INSPECT CYLINDER HEAD SET BOLT

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