CYLINDER HEAD GASKET REMOVAL

PROCEDURE


  1. REMOVE TIMING CHAIN COVER ASSEMBLY

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  2. SET NO. 1 CYLINDER TO TDC/COMPRESSION


    1. Temporarily install the crankshaft pulley set bolt.

    2. B0074UBC11
      *1 Crankshaft Pulley Set Key
      *a Center Mark

      Set the crankshaft pulley set key to the RH block bore center mark (TDC/compression).

    3. B0074TYC06
      *a Timing Mark

      Set the crankshaft pulley set key to the RH block bore center mark (TDC/compression). If not, turn the crankshaft 1 revolution (360°) and align the timing marks as above.

  3. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

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  4. REMOVE CHAIN TENSIONER SLIPPER

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  5. REMOVE CHAIN SUB-ASSEMBLY

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  6. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY RH AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 1)


    1. B0072YLC01
      *a Pin
      *b Plunger
      *c Push

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

    2. B00771VC02
      *a Hold
      B0073AQ Turn

      Using a wrench to hold the hexagonal portion of the camshaft, loosen the camshaft timing gear bolt of the camshaft timing gear assembly.

      Note


      • Be careful not to damage the camshaft housing sub-assembly RH or spark plug tube with wrench.

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

    3. B007470C02
      *a Hold
      B0073AQ Turn

      Using a wrench to hold the hexagonal portion of the No. 2 camshaft, loosen the camshaft timing gear bolt of the camshaft timing exhaust gear assembly RH.

      Note


      • Be careful not to damage the camshaft housing sub-assembly RH or spark plug tube with wrench.

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

    4. Remove the 2 camshaft timing gear bolts, camshaft timing gear assembly and camshaft timing exhaust gear assembly RH together with the No. 2 chain sub-assembly.

  7. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. B0074CR

      Remove the bolt and No. 2 chain tensioner assembly.

  8. REMOVE CAMSHAFT BEARING CAP (for Bank 1)


    1. B00766SC06
      *a Knock Pin
      *b Front View
      *c 45°

      Check that the camshaft and No. 2 camshaft are positioned as shown in the illustration.

    2. B0076ZKE01

      Uniformly loosen and remove the 9 bolts in several steps and in the order shown in the illustration.

    3. B0076DME01

      Uniformly loosen and remove the 15 bolts in several steps in the order shown in the illustration.

      Note

      Make sure that the camshaft and No. 2 camshaft remains level while uniformly loosening the bolts.

  9. REMOVE FUEL PUMP LIFTER HOUSING


    1. B00740M

      Remove the fuel pump lifter housing.

  10. REMOVE CAMSHAFT


    1. Remove the camshaft from the camshaft housing sub-assembly RH.

  11. REMOVE NO. 2 CAMSHAFT


    1. Remove the No. 2 camshaft from the camshaft housing sub-assembly RH.

  12. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. B0077BDC04
      *a Protective Tape

      Remove the camshaft housing sub-assembly RH by prying between the cylinder head sub-assembly and camshaft housing sub-assembly RH with a screwdriver with its tip wrapped with protective tape.

      Note

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

  13. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY, CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY LH AND NO. 2 CHAIN SUB-ASSEMBLY (for Bank 2)


    1. B0076OMC01
      *a Pin
      *b Plunger
      *c Push

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

    2. B0074UKC02
      *a Hold
      B0073AQ Turn

      Using a wrench to hold the hexagonal portion of the No. 3 camshaft sub-assembly, loosen the camshaft timing gear bolt of the camshaft timing gear assembly.

      Note


      • Be careful not to damage the camshaft housing sub-assembly LH or spark plug tube with wrench.

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

    3. B0073TEC02
      *a Hold
      B0073AQ Turn

      Using a wrench to hold the hexagonal portion of the No. 4 camshaft sub-assembly, loosen the camshaft timing gear bolt of the camshaft timing exhaust gear assembly LH.

      Note


      • Be careful not to damage the camshaft housing sub-assembly LH or spark plug tube with wrench.

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

    4. Remove the 2 camshaft timing gear bolts, camshaft timing gear assembly and camshaft timing exhaust gear assembly LH together with the No. 2 chain sub-assembly.

  14. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY


    1. B0074D9

      Remove the bolt and No. 3 chain tensioner assembly.

  15. REMOVE CAMSHAFT BEARING CAP (for Bank 2)


    1. B00754EC05
      *a Knock Pin
      *b Front View

      Check that the No. 3 camshaft sub-assembly and No. 4 camshaft sub-assembly are positioned as shown in the illustration.

    2. B0073FRE01

      Uniformly loosen and remove the 8 bolts in several steps in the order shown in the illustration.

    3. B0075QUN01

      Uniformly loosen and remove the 15 bolts in several steps and in the order shown in the illustration.

      Note

      Make sure that the No. 3 camshaft sub-assembly and No. 4 camshaft sub-assembly remain level while uniformly loosening the bolts.

    4. Remove the 5 camshaft bearing caps.

  16. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY


    1. Remove the No. 3 camshaft sub-assembly from the camshaft housing sub-assembly LH.

  17. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY


    1. Remove the No. 4 camshaft sub-assembly from the camshaft housing sub-assembly LH.

  18. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. B0076FRC04
      *a Protective Tape

      Remove the camshaft housing sub-assembly LH by prying between the cylinder head LH and camshaft housing sub-assembly LH with a screwdriver with its tip wrapped with protective tape.

      Note

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

  19. REMOVE NO. 1 CHAIN VIBRATION DAMPER

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  20. REMOVE NO. 2 CHAIN VIBRATION DAMPER

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


    1. Remove the 24 No. 1 valve rocker arm sub-assemblies.

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  22. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. Remove the 24 valve lash adjuster assemblies.

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  23. REMOVE VALVE STEM CAP


    1. Remove the 24 valve stem caps.

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

  24. REMOVE REAR WATER BY-PASS JOINT

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  25. REMOVE NO. 2 FUEL PIPE SUB-ASSEMBLY

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  26. REMOVE FUEL DELIVERY PIPE WITH SENSOR ASSEMBLY LH

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  27. REMOVE FUEL DELIVERY PIPE RH

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  28. REMOVE FUEL INJECTOR ASSEMBLY (for Direct Injection)

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  29. REMOVE FUEL INJECTOR SEAL

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  30. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. B00762OE01

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

      Note


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

      • Warpage or cracking of the cylinder head sub-assembly may result from removing the cylinder head set bolts in the incorrect order.

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

    2. Remove the cylinder head sub-assembly.

  31. REMOVE CYLINDER HEAD GASKET


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

  32. REMOVE CYLINDER HEAD LH


    1. B007486E01

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

    2. B0072PAE01

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

      Note


      • Be careful not to drop the cylinder head set plate washers into the cylinder head LH.

      • Warpage or cracking of the cylinder head LH may result from removing the cylinder head set bolts in the incorrect order.

      Tech Tips

      Arrange the removed parts in such a way that they can be reinstalled to their original locations.

    3. Remove the cylinder head LH.

  33. REMOVE NO. 2 CYLINDER HEAD GASKET


    1. Remove the No. 2 cylinder head gasket from the cylinder block sub-assembly.

  34. INSPECT CYLINDER HEAD SET BOLT

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  35. INSPECT CYLINDER HEAD SUB-ASSEMBLY

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