CYLINDER HEAD GASKET REMOVAL

  1. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY

    Click here

  2. REMOVE MANIFOLD STAY

    1. Remove the bolt, nut and manifold stay.

      A011U54

  3. REMOVE NO. 2 MANIFOLD STAY

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

      A011UR1

  4. REMOVE EGR INLET EXHAUST MANIFOLD PLATE (for PZEV)

    1. Remove the bolt and EGR inlet exhaust manifold plate.

      A011TZO

  5. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR (except PZEV)

    1. Remove the 4 bolts and No. 1 exhaust manifold heat insulator.

      A011R7L

  6. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    1. Remove the 5 nuts and exhaust manifold converter sub-assembly (except PZEV).

      A011TIM

    2. Remove the 5 nuts and exhaust manifold converter sub-assembly (for PZEV).

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    3. Remove the exhaust manifold to head gasket (except PZEV).

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    4. Remove the exhaust manifold to head gasket (for PZEV).

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  7. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY

    Click here

  8. REMOVE VACUUM SWITCHING VALVE ASSEMBLY (for ACIS)

    1. Disconnect the union to connector tube hose and wire harness clamp.

      A011QSH

    2. Disconnect the 2 vacuum hoses and connector.

    3. Remove the bolt and vacuum switching valve assembly.

  9. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY

    1. Remove the 2 bolts, and then remove the fuel delivery pipe together with the 4 fuel injectors.

      A011TK5

      Note

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

    2. Remove the 2 fuel delivery spacers from the cylinder head.

      A011TA2

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

  10. DISCONNECT NO. 2 VENTILATION HOSE

    1. Disconnect the No. 2 ventilation hose from the intake manifold.

      A011SGQ

  11. REMOVE INTAKE MANIFOLD

    1. Remove the 2 bolts and 2 wire harness clamp brackets.

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    2. Disconnect the fuel vapor feed hose.

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    3. Disconnect the 3 wire harness clamps and connector.

    4. Remove the bolt and wire harness clamp bracket.

    5. Apply battery voltage to the terminals of the connector to close the tumble control valves.

      A011TCJ
      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 actuator may be damaged.

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

    6. Remove the bolt and separate the wire harness.

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    7. Disconnect the 2 wire harness clamps and intake air control valve actuator connector.

    8. Remove the 6 bolts and intake manifold.

      A011T1N

      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 actuator to operate the motor and close the valves Click here.

    9. Remove the intake manifold gasket from the intake manifold.

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

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    11. Remove the bolt and wire harness clamp bracket.

      A011UPG

  12. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    1. Temporarily install the crankshaft pulley bolt.

      A011S1XE03
      Text in Illustration
      *a Approximately 7° *b Approximately 32°
      *c Timing Mark *d Key

      Tech Tips

      "A" is not a timing mark.

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

      Tech Tips

      If the timing marks do not align, rotate the crankshaft clockwise again and align the timing marks.

    3. Remove the crankshaft pulley bolt.

  13. REMOVE TIMING CHAIN GUIDE

    1. Remove the bolt and timing chain guide.

      A011U2T

  14. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    1. 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 tensioner.

      A011R06E02
      Text in Illustration
      *1 Stopper Plate
      *2 Plunger

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

      A011TKYE02
      Text in Illustration
      *1 Pin

    3. Remove the 2 bolts, chain tensioner and gasket.

      A011S8X

  15. REMOVE CHAIN TENSIONER SLIPPER

    1. Remove the bolt and chain tensioner slipper.

      A011QSZ

  16. REMOVE CHAIN SUB-ASSEMBLY

    1. Remove the chain sub-assembly.

  17. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    1. Remove the 2 bolts and chain vibration damper.

      A011R86

  18. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

    1. Hold the hexagonal portion of the camshaft with a wrench and remove the bolt and camshaft timing gear assembly.

      A011U9KE01
      Text in Illustration
      *a Hold
      *b Turn

      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. Hold the hexagonal portion of the camshaft with a wrench and remove the bolt and camshaft timing exhaust gear assembly.

      A011QMHE01
      Text in Illustration
      *a Hold
      *b Turn

      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 bearing cap bolts in the sequence shown in the illustration.

      A011TH3E01

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

      A011U5H

      Tech Tips

      Tape the screwdriver tip before use.

      Note

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

  21. REMOVE CAMSHAFT BEARING CAP

    1. Remove the 11 bearing cap bolts in the sequence shown in the illustration.

      A011SZ9E01

    2. Remove the 5 bearing caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  22. REMOVE OIL CONTROL VALVE FILTER

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

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  23. REMOVE NO. 1 CAMSHAFT BEARING

    1. Remove the 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

    1. Remove the No. 2 camshaft bearing.

      A011T64

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

    1. Remove the 16 valve rocker arms 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 adjusters 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 sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

      A011QM2E01

      Tech Tips

      Be sure to keep the removed parts separate for each installation position.

      Note

      • Be careful not to drop 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.

  30. REMOVE CYLINDER HEAD GASKET

    1. Remove the cylinder head gasket from the cylinder block.