CYLINDER HEAD GASKET REMOVAL

PROCEDURE

1. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

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2. REMOVE MANIFOLD STAY

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3. REMOVE NO. 2 MANIFOLD STAY

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4. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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

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6. REMOVE THROTTLE BODY WITH MOTOR ASSEMBLY

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7. REMOVE VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)

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8. DISCONNECT NO. 2 VENTILATION HOSE

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9. DISCONNECT UNION TO VACUUM TUBE HOSE

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10. REMOVE FUEL DELIVERY PIPE

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11. REMOVE INTAKE MANIFOLD

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12. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    
    

    1. Temporarily install the crankshaft pulley bolt.

       

       *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 bolt.

13. REMOVE TIMING CHAIN GUIDE

    
    

    1. 

       Remove the bolt and timing chain guide.

14. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    
    

    1. 

       *a	Stopper Plate
       *b	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 No. 1 chain tensioner assembly.

    2. 

       *a

       Pin

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

    3. 

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

15. REMOVE CHAIN TENSIONER SLIPPER

    
    

    1. 

       Remove the bolt and chain tensioner slipper.

16. REMOVE CHAIN SUB-ASSEMBLY

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17. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    
    

    1. 

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

18. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

    
    
    1. 

       *a	Hold
       *b	Turn

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

19. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    
    
    1. 

       *a	Hold
       *b	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.

20. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    
    

    1. 

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

    2. 

       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.

21. REMOVE CAMSHAFT BEARING CAP

    
    

    1. 

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

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

       Tech Tips

       Arrange the removed parts in the correct order.

22. REMOVE OIL CONTROL VALVE FILTER

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23. REMOVE NO. 1 CAMSHAFT BEARING

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24. REMOVE CAMSHAFT

    
    

    1. Remove the camshaft and No. 2 camshaft.

25. REMOVE NO. 2 CAMSHAFT BEARING

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

    
    

    1. Remove the 16 No. 1 valve rocker arm sub-assemblies from the cylinder head sub-assembly.

       Tech Tips

       Arrange the removed parts in the correct order.

27. 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.

28. 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.

29. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    
    

    1. 

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

30. REMOVE CYLINDER HEAD GASKET

    
    

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