CYLINDER HEAD GASKET REMOVAL

PROCEDURE


  1. DISCHARGE FUEL SYSTEM PRESSURE

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  2. REMOVE BATTERY

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  3. REMOVE BATTERY TRAY

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  4. REMOVE FRONT WHEEL RH

  5. REMOVE ENGINE UNDER COVER RH

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  6. DRAIN ENGINE OIL

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  7. DRAIN COOLANT

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  8. REMOVE AIR CLEANER ASSEMBLY

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  9. DISCONNECT NO. 3 RADIATOR HOSE

    A005JV6

    1. Disconnect the No. 3 radiator hose.

  10. DISCONNECT RESERVE TANK HOSE

    A005IAO

    1. Disconnect the reserve tank hose.

  11. REMOVE NO. 2 FUEL PIPE CLAMP

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  12. DISCONNECT FUEL TUBE SUB-ASSEMBLY

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  13. DISCONNECT UNION TO CHECK VALVE HOSE

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  14. DISCONNECT OUTLET HEATER WATER HOSE A

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  15. REMOVE WATER FILLER SUB-ASSEMBLY

    A005GR9

    1. Separate the No. 1 radiator hose from the cylinder head.

    2. Remove the 2 nuts and the water filler sub-assembly.

  16. REMOVE EGR VALVE ASSEMBLY

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  17. REMOVE INTAKE MANIFOLD

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  18. REMOVE OIL LEVEL DIPSTICK SUB-ASSEMBLY

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  19. REMOVE OIL LEVEL GAGE GUIDE

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  20. REMOVE EGR DELIVERY CHAMBER

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  21. SEPARATE NO. 4 WATER BY-PASS HOSE

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  22. SEPARATE NO. 3 WATER BY-PASS HOSE

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  23. REMOVE BOOSTER VACUUM TUBE

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  24. DISCONNECT CAMSHAFT POSITION SENSOR CONNECTOR

    A005JSK

    1. Disconnect the camshaft position sensor connector.

  25. DISCONNECT ENGINE COOLANT TEMPERATURE SENSOR CONNECTOR

    A005HKU

    1. Disconnect the engine coolant temperature sensor connector.

  26. REMOVE WIRING HARNESS CLAMP BRACKET

    A005J96

    1. Remove the bolt and separate the wiring harness clamp bracket.

    2. Disconnect the heated oxygen sensor connector.

  27. SEPARATE NO. 1 WATER BY-PASS PIPE

    A005MIX

    1. Remove the bolt and separate the No. 1 water by-pass pipe.

  28. REMOVE NO. 1 OIL PIPE


    1. A005KTQ

      Remove the 2 oil pipe unions, gaskets and No. 1 oil pipe.

  29. DISCONNECT WIRE HARNESS

    A005JM9

    1. Remove the 2 bolts and disconnect the wire harness.

  30. SEPARATE FRONT EXHAUST PIPE ASSEMBLY

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  31. REMOVE MANIFOLD SUPPORT BRACKET

    A005KD1

    1. Remove the 3 bolts and the manifold support bracket.

  32. REMOVE FAN AND GENERATOR V BELT

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  33. REMOVE GENERATOR ASSEMBLY

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  34. REMOVE NO. 1 IGNITION COIL

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  35. REMOVE VENTILATION HOSE

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  36. REMOVE FUEL VAPOR FEED HOSE ASSEMBLY

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  37. REMOVE INLET HEATER WATER HOSE A

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  38. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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  39. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

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  40. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY

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  41. REMOVE CRANKSHAFT POSITION SENSOR

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  42. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

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  43. REMOVE WATER PUMP PULLEY

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  44. REMOVE WATER PUMP ASSEMBLY

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  45. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET

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  46. REMOVE OIL PUMP ASSEMBLY

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  47. REMOVE OIL PUMP SEAL

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  48. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

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  49. REMOVE CHAIN TENSIONER SLIPPER

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  50. REMOVE NO. 1 CHAIN VIBRATION DAMPER

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  51. REMOVE CHAIN SUB-ASSEMBLY

  52. REMOVE CAMSHAFT

    A005JN4E03
    Text in Illustration
    *1 Oil jet
    *a Timing Mark

    Note

    When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first, and align the oil jet hole with the paint mark. This prevents the pistons from coming into contact with the valves.


    1. A005HIN

      Using several steps, loosen and remove the 19 bearing cap bolts uniformly in the sequence shown in the illustration, and then remove the No. 1 and No. 2 camshaft bearing caps.

      Note

      Loosen each bolt uniformly while keeping the camshaft level.

    2. Remove the No. 2 camshaft and camshaft.

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


    1. Remove the 16 valve rocker arms.

      Tech Tips

      Arrange the removed parts in the correct order.

  54. REMOVE VALVE LASH ADJUSTER ASSEMBLY


    1. Remove the 16 valve lash adjusters from the cylinder head.

      Tech Tips

      Arrange the removed parts in the correct order.

  55. REMOVE VALVE STEM CAP


    1. Remove the 16 valve stem caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  56. REMOVE CYLINDER HEAD SUB-ASSEMBLY

    A005GQA

    1. Using several steps, loosen and remove the 10 cylinder head bolts uniformly with an 8 mm bi-hexagon wrench in the sequence shown in the illustration. Remove the 10 plate washers.

      Note


      • Do not drop the washers into the cylinder head.

      • Head warpage or cracking could result from removing the bolts in the wrong order.

  57. REMOVE CYLINDER HEAD GASKET

    A005I2P

    1. Remove the cylinder head gasket.