CYLINDER HEAD GASKET REMOVAL

PROCEDURE


  1. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  2. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

    Click here

  3. DISCONNECT NO. 1 WATER BY-PASS HOSE

    Click here

  4. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY

    Click here

  5. REMOVE MANIFOLD STAY

    Click here

  6. REMOVE NO. 2 MANIFOLD STAY

    Click here

  7. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    Click here

  8. REMOVE NO. 3 WATER BY-PASS PIPE

    Click here

  9. REMOVE NO. 1 WATER BY-PASS PIPE

    Click here

  10. REMOVE INTAKE MANIFOLD

    Click here

  11. REMOVE FUEL DELIVERY PIPE

    Click here

  12. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

      A0007YDE05
      Text in Illustration
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark *d Crankshaft Pulley Key

      Tech Tips

      "A" is not a timing mark.

    2. Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing sprocket, camshaft timing gear assembly and camshaft timing sprocket are as shown in the illustration.

      Tech Tips

      If the timing marks do not align, turn the crankshaft 1 revolution (360°) to align the timing marks as shown in the illustration.

    3. Remove the crankshaft pulley bolt.

  13. REMOVE TIMING CHAIN GUIDE


    1. A000974

      Remove the bolt and timing chain guide.

  14. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A000851E09
      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 No. 1 chain tensioner assembly.

    2. A0003MME11
      Text in Illustration
      *1 Pin

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

    3. A0006M0

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

  15. REMOVE CHAIN TENSIONER SLIPPER


    1. A00085Y

      Remove the bolt and chain tensioner slipper.

  16. REMOVE CHAIN SUB-ASSEMBLY

    Click here

  17. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A0005VY

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

  18. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. A0006CXE02
      Text in Illustration
      *a Hold
      *b Turn

      Hold the hexagonal portion of the camshaft with a wrench and 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 SPROCKET


    1. A000765E02
      Text in Illustration
      *a Hold
      *b Turn

      Hold the hexagonal portion of the No. 2 camshaft with a wrench and remove the bolt and camshaft timing sprocket.

      Note

      Be careful not to damage the cylinder head sub-assembly or spark plug tube with the wrench.

  20. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A00086IE09

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

    2. A0006PI

      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. A00095BE09

      Remove the 11 bolts in the sequence 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

    Click here

  23. REMOVE NO. 1 CAMSHAFT BEARING

    Click here

  24. REMOVE CAMSHAFT


    1. Remove the camshaft and No. 2 camshaft.

  25. REMOVE NO. 2 CAMSHAFT BEARING

    Click here

  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. A0009K3E01

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

      • Head warpage or cracking could result from removing cylinder head 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.