CYLINDER HEAD GASKET REMOVAL

CAUTION / NOTICE / HINT

Note

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work Click here.

PROCEDURE


  1. DISCHARGE FUEL SYSTEM PRESSURE

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  2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

    Note

    When disconnecting the cable, some systems need to be initialized after the cable is reconnected Click here.

  3. REMOVE FRONT WHEEL RH

  4. REMOVE ENGINE UNDER COVER RH

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  5. DRAIN ENGINE OIL

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  6. DRAIN COOLANT

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  7. REMOVE AIR CLEANER ASSEMBLY

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  8. REMOVE BATTERY

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  9. REMOVE BATTERY TRAY

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  10. DISCONNECT NO. 3 RADIATOR HOSE

    A005JV6

    1. Loosen the hose clamp and disconnect the No. 3 radiator hose.

  11. DISCONNECT RESERVE TANK HOSE

    A005IAO

    1. Disconnect the reserve tank hose.

  12. REMOVE WATER FILLER SUB-ASSEMBLY

    A005GR9

    1. Loosen the hose clamp and separate the No. 1 radiator hose from the cylinder head sub-assembly.

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

  13. REMOVE NO. 2 FUEL PIPE CLAMP

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  14. DISCONNECT FUEL TUBE SUB-ASSEMBLY

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  15. DISCONNECT UNION TO CHECK VALVE HOSE

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  16. DISCONNECT OUTLET HEATER WATER HOSE A

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  17. REMOVE INLET HEATER WATER HOSE A

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  18. REMOVE EGR VALVE ASSEMBLY

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  19. DISCONNECT UNION TO CONNECTOR TUBE HOSE


    1. A005IQT

      Loosen the hose clamp and disconnect the union to connector tube hose.

  20. REMOVE ENGINE OIL LEVEL DIPSTICK SUB-ASSEMBLY

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  21. REMOVE INTAKE MANIFOLD


    1. A005GOC

      Loosen the hose clamp and disconnect the No. 2 water by-pass hose.

    2. A005LXW

      Loosen the hose clamp and disconnect the water by-pass hose.

    3. A005JUE

      Separate the wire harness clamp.

    4. Remove the nut and separate the throttle body connector.

    5. A005JW4

      Separate the 3 wire harness clamps shown in the illustration.

    6. Disconnect the throttle body connector.

    7. A005MF6

      Remove the 3 bolts and 2 nuts, and remove the intake manifold.

    8. Remove the No. 1 intake manifold gasket.

  22. REMOVE NO. 2 INTAKE MANIFOLD INSULATOR

    (See page INTAKE / EXHAUST (1NZ-FE) > INTAKE MANIFOLD > REMOVAL > REMOVE NO.2 INTAKE MANIFOLD INSULATOR)

  23. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

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  24. REMOVE EGR DELIVERY CHAMBER

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  25. REMOVE BOOSTER VACUUM TUBE

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  26. DISCONNECT OUTLET WATER BY-PASS


    1. A005KEM

      Loosen the hose clamp and disconnect the outlet water by-pass.

  27. REMOVE EXHAUST MANIFOLD

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  28. REMOVE NO. 1 WATER BY-PASS PIPE


    1. A005LPO

      Remove the 2 bolts, 2 nuts and the No. 1 water by-pass pipe.

    2. Remove the No. 1 water by-pass pipe gasket from the cylinder block.

  29. REMOVE NO. 1 OIL PIPE


    1. A005KTQ

      Remove the 2 oil pipe union bolts, 2 No. 1 oil pipe gaskets and No. 1 oil pipe.

  30. REMOVE MANIFOLD ABSOLUTE PRESSURE SENSOR


    1. A005IPG

      Remove the nut and manifold absolute pressure sensor.

  31. DISCONNECT WIRE HARNESS

    A005JM9

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

    2. Disconnect all the wire harnesses and connectors. Make sure that no wire harnesses are connected to the cylinder head sub-assembly.

  32. REMOVE FAN AND GENERATOR V BELT

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  33. REMOVE GENERATOR ASSEMBLY

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  34. REMOVE GENERATOR BRACKET

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  35. REMOVE NO. 1 IGNITION COIL

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  36. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY

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  37. REMOVE ENGINE MOUNTING INSULATOR SUB-ASSEMBLY RH

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  38. REMOVE CRANKSHAFT DAMPER SUB-ASSEMBLY

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  39. REMOVE CRANKSHAFT POSITION SENSOR

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  40. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY

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  41. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY

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  42. REMOVE WATER PUMP PULLEY

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  43. REMOVE ENGINE WATER PUMP ASSEMBLY

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  44. REMOVE TRANSVERSE ENGINE ENGINE MOUNTING BRACKET

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  45. REMOVE OIL PUMP ASSEMBLY

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  46. REMOVE OIL PUMP SEAL

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  47. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

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  48. REMOVE NO. 2 CHAIN VIBRATION DAMPER

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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

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  52. REMOVE CAMSHAFT

    A005JN4E03

    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.

    Text in Illustration
    *1 Oil jet
    *a Timing Mark

    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 camshaft bearing cap 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 No.1 valve rocker arm sub-assemblies.

      Tech Tips

      Arrange the removed parts in the correct order.

  54. 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.

  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 set 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.

    2. Remove the cylinder head sub-assembly.

  57. REMOVE CYLINDER HEAD GASKET

    A005I2P

    1. Remove the cylinder head gasket.

  58. INSPECT NO. 1 VALVE ROCKER ARM SUB-ASSEMBLY

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  59. INSPECT VALVE LASH ADJUSTER ASSEMBLY

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  60. INSPECT CYLINDER HEAD SET BOLT

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