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 tighten the pulley set bolt.

    2. A01FGWVE02
      Text in Illustration
      *1 Timing Mark
      *a Center Line

      Set the timing mark on the crank angle sensor plate to the RH block bore center line (TDC/compression).

    3. A01FIO7E01
      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 cap as shown in the illustration.

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

  3. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY


    1. A01FDIGE04
      Text in Illustration
      *1 Stopper Plate
      *2 Plunger

      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 of 1.27 mm (0.0500 in.) diameter into the hole of the stopper plate.

    3. Install the chain tensioner with the 2 bolts.

      Torque:
      10 N*m  { 102 kgf*cm, 7 ft.*lbf }

    4. Remove the lock pin of the chain tensioner.

  4. REMOVE CHAIN TENSIONER SLIPPER


    1. Remove the chain tensioner slipper.

  5. REMOVE CHAIN SUB-ASSEMBLY


    1. A01FFWSE04
      Text in Illustration
      *1 Timing Mark
      *a Center Line

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

    2. Remove the pulley set bolt.

    3. A01FEOP

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

    4. A01FEXEE17
      Text in Illustration
      *A for Bank 1

      Turn the camshaft timing gear assembly on bank 1 clockwise (approximately 60°) and set it as shown in the illustration. Be sure to loosen the chain between the banks.

    5. Remove the chain.

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


    1. A01FI6WE11
      Text in Illustration
      *1 Pin
      *2 Plunger
      *a Push

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

    2. A01FI2CE08
      Text in Illustration
      *a Turn
      *b Hold

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

      SST
      09922-10010

      Note


      • Be careful not to damage the cylinder head with SST.

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

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

  7. REMOVE NO. 2 CHAIN TENSIONER ASSEMBLY


    1. A01FDUO

      Remove the bolt and No. 2 chain tensioner assembly.

  8. REMOVE CAMSHAFT BEARING CAP (for Bank 1)


    1. A01FDDNE01
      Text in Illustration
      *1 Knock Pin
      *a IN
      *b EX

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

    2. A01FFE5E01

      Uniformly loosen and remove the 9 bearing cap bolts in several steps and in the sequence shown in the illustration.

    3. A01FD91E01

      Uniformly loosen and remove the 14 bearing cap bolts in several steps and in the sequence shown in the illustration.

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

  9. REMOVE CAMSHAFT

  10. REMOVE NO. 2 CAMSHAFT

  11. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY RH


    1. A01FGD9E02
      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.

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


    1. A01FEIKE09
      Text in Illustration
      *1 Pin
      *2 Plunger
      *a Push

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

    2. A01FGE8E06
      Text in Illustration
      *a Turn
      *b Hold

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

      SST
      09922-10010

      Note


      • Be careful not to damage the cylinder head with SST.

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

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

  13. REMOVE NO. 3 CHAIN TENSIONER ASSEMBLY


    1. A01FI5T

      Remove the bolt and No. 3 chain tensioner assembly.

  14. REMOVE CAMSHAFT BEARING CAP (for Bank 2)


    1. A01FFWRE01
      Text in Illustration
      *1 Knock Pin
      *a IN
      *b EX

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

    2. A01FDCME01

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

    3. A01FJ2UE01

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

      Note

      Uniformly loosen the bolts while keeping the camshaft level.

    4. Remove the 5 camshaft bearing caps.

  15. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY

  16. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY

  17. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY LH


    1. A01FHMWE02
      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 CHAIN VIBRATION DAMPER


    1. A01FDTC

      Remove the 2 bolts and vibration damper.

  19. REMOVE NO. 2 CHAIN VIBRATION DAMPER


    1. A01FGKP

      Remove the 2 vibration dampers.

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


    1. Remove the 24 No. 1 valve rocker arms.

      Tech Tips

      Arrange the removed parts in the correct order.

  21. 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.

  22. REMOVE VALVE STEM CAP


    1. Remove the 24 valve stem caps.

      Tech Tips

      Arrange the removed parts in the correct order.

  23. REMOVE REAR WATER BY-PASS JOINT


    1. A01FERC

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

    2. A01FE8A

      Remove the 2 gaskets and O-ring.

  24. REMOVE NO. 3 FUEL PIPE SUB-ASSEMBLY


    1. A01FHF6

      Remove the 4 bolts and fuel pipe from the fuel delivery pipe sub-assembly.

      Text in Illustration
      A01FJ4N Front

      Note

      Pull and remove the fuel pipe in a straight line to avoid damage to the seal surface of the delivery pipe O-rings.

    2. Remove the O-rings, backup rings and E-rings from the No. 3 fuel pipe sub-assembly.

  25. REMOVE NO. 2 FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. A01FHO7E04
      Text in Illustration
      *1 Nut
      *2 Bolt
      *a Front

      Disconnect the 3 wire harness clamps.

    2. Remove the 2 bolts and 2 nuts.

    3. A01FERZ

      With the connectors still connected, disconnect the No. 2 fuel delivery pipe.

      Text in Illustration
      A01FJ4N Front

      Note


      • Make sure that the fuel delivery pipe is disconnected from the delivery pipe (LH side).

      • Be extremely careful not to touch or strike the tips of the injectors.

      • Pull and remove the fuel pipe in a straight line without tilting it.

    4. Disconnect the 3 injector connectors.

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

  26. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY


    1. A01FI62

      Disconnect the fuel pressure sensor connector.

    2. Detach the wire harness clamp.

    3. A01FFQGE02
      Text in Illustration
      *1 Nut
      *2 Bolt
      *a Front

      Disconnect the 2 wire harness clamps.

    4. Remove the 2 bolts and 2 nuts.

    5. A01FG46

      With the connectors still connected, disconnect the No. 1 fuel delivery pipe.

      Text in Illustration
      A01FJ4N Front

      Note


      • Be extremely careful not to touch or strike the tips of the injectors.

      • Pull and remove the fuel pipe in a straight line without tilting it.

    6. Disconnect the 3 injector connectors.

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

  27. REMOVE FUEL INJECTOR ASSEMBLY


    1. A01FG7SE01

      Secure the delivery pipe in a vise between aluminum plates and pull out the injector in a straight line.

      Note


      • Pull and remove the injector in a straight line to avoid damage to the seal surface of the delivery pipe O-ring.

      • For reinstallation, attach a tag or label to the injector shaft.

    2. Remove the nozzle holder clamps from the injectors.

    3. Remove the O-ring, backup rings and E-ring from the fuel injector.

  28. REMOVE FUEL INJECTOR SEAL


    1. A01FIJD

      Using the tips of a pair of needle nose pliers, pinch and pull one of the 2 injector seals at several points to stretch it. Repeat this for the other injector seal.

      Note


      • Excessively pinching the injector seal may damage the groove of the injector.

      • If an injector is dropped or the tips of the injectors are struck, replace it with a new one.

    2. Remove the 2 injector seals from the injector.

  29. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. A01FIH6E01

      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.

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

      Tech Tips

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

    2. Remove the cylinder head sub-assembly.

  30. REMOVE CYLINDER HEAD GASKET

  31. REMOVE CYLINDER HEAD LH


    1. A01FH3ZE02

      Uniformly loosen and remove the bolts in the sequence shown in the illustration.

    2. A01FESFE02

      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.

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

      Tech Tips

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

    3. Remove the cylinder head sub-assembly.

  32. REMOVE NO. 2 CYLINDER HEAD GASKET

  33. INSPECT CYLINDER HEAD SET BOLT

    A01FIDZE03

    1. Using a vernier caliper, measure the length of the cylinder head set bolt from the seat to the end.

      Standard length
      141.3 to 142.7 mm (5.56 to 5.62 in.)
      Maximum length
      143.7 mm (5.66 in.)
      Text in Illustration
      *1 Measurement Length

      If the length is more than the maximum, replace the cylinder head set bolt.

    2. A01FI73

      Using a vernier caliper, measure the diameter of the elongated thread at the narrowest visible area.

      Standard diameter
      10.80 to 11.00 mm (0.425 to 0.433 in.)
      Minimum diameter
      10.70 mm (0.421 in.)

      If the diameter is less than the minimum, replace the cylinder head set bolt.

      Tech Tips

      If a visual check reveals no excessively thin areas, check the center of the bolt (refer to illustration) and find the area that has the smallest diameter.