CYLINDER HEAD GASKET REMOVAL


  1. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

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  2. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the pulley set bolt.

    2. A0156S9E01
      Text in Illustration
      *1 Center Line
      *2 Timing Mark
      *3 Sensor Plate

      Turn the crankshaft clockwise to align the timing mark on the crank angle sensor plate with the RH block bore center line (TDC/compression).

    3. A015AWRE01
      Text in Illustration
      *1 Timing Mark

      Check that the timing marks of the camshaft timing gears are aligned with the timing marks of the bearing caps as shown in the illustration.

      If not, turn the crankshaft clockwise 1 revolution (360°) and align the timing marks as above.

  3. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A0159K8E05
      Text in Illustration
      *1 Plunger
      *2 Stopper Plate
      *3 Pin

      Move the stopper plate upward to release the lock, and push the plunger deep into the tensioner.

    2. Move the stopper plate downward to set the lock, and insert a pin with a diameter of 1.27 mm (0.0500 in.) into the stopper plate hole.

    3. A015CLUE02

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

  4. REMOVE CHAIN TENSIONER SLIPPER


    1. A0158IU

      Remove the chain tensioner slipper.

  5. REMOVE CHAIN SUB-ASSEMBLY


    1. A0157PTE01
      Text in Illustration
      *1 Center Line
      *2 Timing Mark
      *3 Sensor Plate

      Turn the crankshaft counterclockwise 10° to loosen the chain of the crankshaft timing sprocket.

    2. Remove the pulley set bolt.

    3. A015CVE

      Remove the chain sub-assembly from the crankshaft timing sprocket and place it on the crankshaft.

    4. A015B7EE12

      Turn the camshaft timing gear assembly on bank 1 clockwise approximately 60° so that it is as shown in the illustration. Be sure to loosen the chain sub-assembly between the banks.

    5. Remove the chain sub-assembly.

      Text in Illustration
      *A for Bank 1

  6. REMOVE NO. 1 IDLE GEAR SHAFT


    1. A015DEH

      Using a 10 mm hexagon wrench, remove the No. 2 idle gear shaft, No. 1 idle gear and No. 1 idle gear shaft.

  7. REMOVE NO. 1 CHAIN VIBRATION DAMPER


    1. A015CD6

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

  8. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. A0157Q7

      Remove the 2 No. 2 chain vibration dampers.

  9. REMOVE CRANKSHAFT TIMING SPROCKET


    1. A015AS5E01

      Remove the crankshaft timing sprocket.

  10. REMOVE CAMSHAFT TIMING GEARS AND NO. 2 CHAIN (for Bank 1)


    1. A015AKHE01
      Text in Illustration
      *1 Pin
      *2 Plunger
      *a Push

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

    2. A01563WE01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST to hold the hexagonal portion of each camshaft, loosen the bolts of the camshaft timing gear assembly and camshaft timing exhaust gear assembly.

      SST
      09922-10010

      Note

      Do not loosen the other 4 bolts. If any of the 4 bolts is loosened, replace the camshaft timing gear assembly and/or camshaft timing exhaust gear assembly with a new one.

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

  11. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A0156WT

      Remove the bolt and No. 2 chain tensioner assembly.

  12. REMOVE CAMSHAFT BEARING CAP (for Bank 1)


    1. A0159QDE06
      Text in Illustration
      *1 Knock Pin
      *a Front View

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

    2. A01591JE01

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

    3. A0155AJE01

      Uniformly loosen and remove the 12 bearing cap bolts in several steps in the sequence shown in the illustration.

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

    4. Remove the 5 camshaft bearing caps.

    5. Remove the camshaft and No. 2 camshaft.

  13. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A0158SRE01
      Text in Illustration
      *1 Protective Tape

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

      Note

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

      Tech Tips

      Tape the screwdriver tip before use.

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


    1. A015AVUE01
      Text in Illustration
      *1 Pin
      *2 Plunger
      *a Push

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

    2. A0159USE01
      Text in Illustration
      *a Turn
      *b Hold

      Using SST to hold the hexagonal portion of each camshaft, loosen the bolts of the camshaft timing gear assembly and camshaft timing exhaust gear assembly.

      SST
      09922-10010

      Note

      Do not loosen the other 4 bolts. If any of the 4 bolts is loosened, replace the camshaft timing gear assembly and/or camshaft timing exhaust gear assembly with a new one.

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

  15. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A0157C6

      Remove the bolt and No. 3 chain tensioner assembly.

  16. REMOVE CAMSHAFT BEARING CAP (for Bank 2)


    1. A015C4YE01
      Text in Illustration
      *1 Knock Pin
      *a Front View

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

    2. A0158ZWE01

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

    3. A0159J3E01

      Uniformly loosen and remove the 13 bearing cap bolts in several steps in the sequence shown in the illustration.

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

    4. Remove the 5 camshaft bearing caps.

    5. Remove the No. 3 camshaft and No. 4 camshaft.

  17. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A01555TE01
      Text in Illustration
      *1 Protective Tape

      Remove the camshaft housing sub-assembly LH by prying between the cylinder head 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

      Tape the screwdriver tip before use.

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


    1. Remove the 24 valve rocker arms from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  19. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. Remove the 24 valve lash adjusters from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  20. REMOVE VALVE STEM CAP


    1. Remove the 24 valve stem caps from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  21. REMOVE REAR WATER BY-PASS JOINT


    1. A0156XZE01

      Remove the 2 bolts, 4 nuts, rear water by-pass joint and 2 gaskets.

    2. Remove the O-ring from the No. 1 water outlet pipe.

  22. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01586WE01

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

      Note


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

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

      Tech Tips

      Arrange the removed parts in the correct order.

    2. Remove the cylinder head sub-assembly.

  23. REMOVE CYLINDER HEAD LH


    1. A015D8XE01

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

    2. A015B31E01

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

      Note


      • Be careful not to drop 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 the removed parts for each installation position separate.

    3. Remove the cylinder head LH.

  24. REMOVE CYLINDER HEAD GASKET

  25. REMOVE NO. 2 CYLINDER HEAD GASKET