CYLINDER HEAD GASKET REMOVAL

PROCEDURE


  1. REMOVE TIMING CHAIN COVER ASSEMBLY

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  2. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the pulley set bolt.

    2. B003TZNC08
      *1 Crankshaft Pulley Set Key
      *a Center Mark

      Set the crankshaft pulley set key to the RH block bore center mark (TDC/compression).

    3. B003VWNC06
      *a Timing Mark

      Set the crankshaft pulley set key to the RH block bore center mark (TDC/compression). If not, turn the crankshaft 1 revolution (360°) and align the timing marks as above.

  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. B003VEXC01
      *a Pin
      *b Plunger
      *c 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. B003X2HC05
      *a Turn
      *b Hold

      Using a wrench to hold the hexagonal portion of each camshaft, loosen the camshaft timing gear bolt of the camshaft timing gear assembly.

      Note


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

      • 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. B003SYPC04
      *a Turn
      *b Hold

      Using a wrench to hold the hexagonal portion of each camshaft, loosen the camshaft timing gear bolt of the camshaft timing exhaust gear assembly RH.

      Note


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

      • 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.

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

  7. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. B003W2U

      Remove the bolt and No. 2 chain tensioner assembly.

  8. REMOVE CAMSHAFT BEARING CAP (for Bank 1)


    1. B003VZUC04
      *1 Knock Pin
      *a 45°
      *b Intake Side
      *c Exhaust Side

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

    2. B003T73E01

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

    3. B003TI0E01

      Uniformly loosen and remove the 15 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. B003VVR

      Remove the fuel pump lifter housing.

  10. REMOVE CAMSHAFT


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

  11. REMOVE NO. 2 CAMSHAFT


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

  12. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. B003WL1C03
      *a 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. B003V91C01
      *a Pin
      *b Plunger
      *c 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. B003TZ3C05
      *a Turn
      *b Hold

      Using a wrench to hold the hexagonal portion of each camshaft sub-assembly No. 3, loosen the camshaft timing gear bolt of the camshaft timing gear assembly.

      Note


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

      • 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. B003UECC05
      *a Turn
      *b Hold

      Using a wrench to hold the hexagonal portion of each camshaft sub-assembly No. 4, loosen the camshaft timing gear bolt of the camshaft timing exhaust gear assembly LH.

      Note


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

      • 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.

    4. Remove the 2 bolts and the camshaft timing gear together with the No. 2 chain sub-assembly.

  14. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY


    1. B003UZK

      Remove the bolt and No. 3 chain tensioner assembly.

  15. REMOVE CAMSHAFT BEARING CAP (for Bank 2)


    1. B003UMUC03
      *1 Knock Pin
      *a Intake Side
      *b Exhaust Side

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

    2. B003UZXE01

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

    3. B003T7SE01

      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.

  16. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY


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

  17. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY


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

  18. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. B003W5GC03
      *a 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 and camshaft housing sub-assembly LH.

      Tech Tips

      Protective 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 arm sub-assemblies.

      Tech Tips

      Arrange the removed parts in the correct order.

  22. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. Remove the 24 valve lash adjuster assemblies.

      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 WITH SENSOR PIPE ASSEMBLY LH

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  27. REMOVE FUEL DELIVERY PIPE RH

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  28. REMOVE FUEL INJECTOR ASSEMBLY (for Direct Injection)

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  29. REMOVE FUEL INJECTOR SEAL

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  30. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. B003WNNE01

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

      Note


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

      • 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 sub-assembly.

  31. REMOVE CYLINDER HEAD GASKET


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

  32. REMOVE CYLINDER HEAD LH


    1. B003X1NE01

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

    2. B003WKCE01

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

      Note


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

      • 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


    1. Remove the No. 2 cylinder head gasket from the cylinder block sub-assembly.

  34. INSPECT CYLINDER HEAD SET BOLT

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  35. INSPECT CYLINDER HEAD SUB-ASSEMBLY

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