CYLINDER HEAD GASKET REMOVAL


  1. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  2. REMOVE MANIFOLD STAY


    1. A01G4J1

      Remove the bolt, nut and manifold stay.

  3. REMOVE NO. 2 MANIFOLD STAY


    1. A01G59Z

      Remove the bolt, nut and No. 2 manifold stay.

  4. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR


    1. A01G4OI

      Remove the 4 bolts and No. 1 exhaust manifold heat insulator from the exhaust manifold converter sub-assembly.

  5. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY


    1. A01G7NZ

      Remove the 5 nuts and exhaust manifold converter sub-assembly from the cylinder head sub-assembly.

    2. A01G80EE01

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

  6. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY


    1. A01G71O

      Disconnect the fuel tube from the fuel tube bracket.

    2. Disconnect the throttle with motor body assembly connector.

    3. A01G9OC

      Disconnect the No. 1 water by-pass hose from the throttle with motor body assembly.

    4. Disconnect the No. 2 water by-pass hose from the throttle with motor body assembly.

    5. A01G825

      Remove the 4 bolts, throttle with motor body assembly and fuel tube bracket.

    6. A01G722

      Remove the bolt and fuel tube bracket.

    7. A01G6CY

      Remove the gasket from the intake manifold.

  7. REMOVE VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)


    1. for LHD:


      1. A01G9RQ

        Disconnect the union to vacuum tube hose.

      2. Disengage the wire harness clamp.

    2. for RHD:


      1. Disconnect the union to check valve hose.

      2. Disengage the wire harness clamp.

    3. Disconnect the 2 vacuum hoses and vacuum switching valve assembly connector.

    4. Remove the bolt and vacuum switching valve assembly from the intake manifold.

  8. DISCONNECT NO. 2 VENTILATION HOSE


    1. A01G6SM

      Slide the clip and disconnect the No. 2 ventilation hose from the intake manifold.

  9. DISCONNECT UNION TO VACUUM TUBE HOSE (for LHD)


    1. A01G97A

      Slide the clip and disconnect the union to vacuum tube hose from the intake manifold.

  10. DISCONNECT UNION TO CHECK VALVE HOSE (for RHD)


    1. A01G97A

      Slide the clip and disconnect the union to check valve hose from the intake manifold.

  11. REMOVE FUEL DELIVERY PIPE


    1. A01G4GI

      Remove the 2 bolts, and then remove the fuel delivery pipe together with the 4 fuel injector assemblies.

      Note

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

    2. A01G960

      Remove the 2 fuel delivery spacers from the cylinder head.

    3. Remove the 4 injector vibration insulators from the cylinder head.

  12. REMOVE INTAKE MANIFOLD


    1. A01G73S

      Remove the 2 bolts and 2 wire harness clamp brackets from the intake manifold.

    2. A01G4TD

      Slide the clip and disconnect the fuel vapor feed hose from the intake manifold.

    3. Disengage the 3 wire harness clamps.

    4. Disconnect the wire harness connector.

    5. Remove the bolt and wire harness clamp bracket.

    6. A01G5MYE01

      Apply battery voltage to the terminals of the connector to close the tumble control valves (w/ TCV).

      Standard
      Tester Connection Specified Condition
      Positive (+) battery voltage applied to terminal 8 (M-), and negative (-) battery voltage applied to terminal 4 (M+) Open → Closed

      Note


      • If this procedure is not performed, the tumble control valves may be damaged when the intake manifold is removed.

      • Apply battery voltage for 1 to 3 seconds.

      • If battery voltage is applied for more than 3 seconds, the intake air control valve actuator may be damaged.

      • Do not allow the lead wires to contact the other terminals.

    7. A01G8Z3E01
      Text in Illustration
      *A w/ TCV
      *B w/o TCV

      Remove the bolt and separate the wire harness.

    8. Disengage the 2 wire harness clamps and disconnect the intake air control valve actuator connector (w/ TCV).

    9. Disengage the 2 wire harness clamps (w/o TCV).

    10. A01G8IH

      Remove the 6 bolts and intake manifold (w/ TCV).

      Note

      The tumble control valves may be damaged if they are not closed before removing the intake manifold.

      Tech Tips

      Connect the battery to the terminals of the intake air control valve actuator to operate the motor and close the tumble control valves Click here.

    11. A01G81V

      Remove the 6 bolts and intake manifold (w/o TCV).

    12. A01G63C

      Remove the intake manifold gasket from the intake manifold (w/ TCV).

    13. A01G4DR

      Remove the intake manifold gasket from the intake manifold (w/o TCV).

    14. A01G7TV

      Disconnect the 2 vacuum hoses from the intake manifold to remove the No. 1 check valve.

    15. A01G5J4E01

      Remove the bolt and wire harness clamp bracket from the intake manifold.

  13. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley bolt.

      A01G4FEE03
      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 exhaust gear assembly 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.

  14. REMOVE TIMING CHAIN GUIDE


    1. A01G6XS

      Remove the bolt and timing chain guide.

  15. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01G553E02
      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. A01G7HWE02
      Text in Illustration
      *1 Pin

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

    3. A01G5UC

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

  16. REMOVE CHAIN TENSIONER SLIPPER


    1. A01G5YD

      Remove the bolt and chain tensioner slipper.

  17. REMOVE CHAIN SUB-ASSEMBLY


    1. Remove the chain sub-assembly.

  18. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A01G9DH

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

  19. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY


    1. A01G59VE01
      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.

  20. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY


    1. A01G8RQE01
      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 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.

  21. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY


    1. A01G84FE01

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

    2. A01G7KK

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

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

  22. REMOVE CAMSHAFT BEARING CAP


    1. A01G59JE01

      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.

  23. REMOVE OIL CONTROL VALVE FILTER


    1. A01G5I2

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

  24. REMOVE NO. 1 CAMSHAFT BEARING


    1. A01G9CC

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

  25. REMOVE CAMSHAFT


    1. Remove the camshaft and No. 2 camshaft.

  26. REMOVE NO. 2 CAMSHAFT BEARING


    1. A01G5ZL

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

  27. 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.

  28. 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.

  29. 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.

  30. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01G9SEE01

      Using a 10 mm bi-hexagon wrench, uniformly loosen the 10 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 bolts in the incorrect order.

    2. Remove the cylinder head sub-assembly.

  31. REMOVE CYLINDER HEAD GASKET


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