CYLINDER HEAD GASKET REMOVAL

PROCEDURE

1. REMOVE ENGINE AND TRANSAXLE

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2. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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3. REMOVE THROTTLE WITH MOTOR BODY ASSEMBLY

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4. DISCONNECT FUEL TUBE SUB-ASSEMBLY

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5. DISCONNECT WIRE HARNESS

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6. REMOVE FUEL DELIVERY PIPE

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7. REMOVE WIRE HARNESS

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8. DISCONNECT NO. 2 PCV HOSE

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9. REMOVE INTAKE MANIFOLD

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10. REMOVE TIMING CHAIN COVER ASSEMBLY

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11. SET NO. 1 CYLINDER TO TDC/COMPRESSION

    1. Temporarily install the crankshaft pulley bolt.

       

       *1	Timing Mark	*2	Key
       *a	Approximately 7°	*b	Approximately 32°

       Tip:

       "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.

       Tip:

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

    3. Remove the crankshaft pulley bolt.

12. REMOVE TIMING CHAIN GUIDE

    1. 

       Remove the bolt and timing chain guide.

13. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

    1. 

       *1	Stopper Plate
       *2	Plunger

       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.

    2. 

       *1

       Pin

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

    3. 

       Remove the 2 bolts, No. 1 chain tensioner and gasket.

14. REMOVE CHAIN TENSIONER SLIPPER

    1. 

       Remove the bolt and chain tensioner slipper.

15. REMOVE CHAIN SUB-ASSEMBLY

16. REMOVE NO. 1 CHAIN VIBRATION DAMPER

    1. 

       Remove the 2 bolts and No. 1 chain vibration damper.

17. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

    1. 

       *a	Hold
       *b	Turn

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

       Note:

       • Be careful not to damage the cylinder head or spark plug tube with the wrench.

       • Do not disassemble the camshaft timing gear.

18. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

    1. 

       *a	Hold
       *b	Turn

       Hold the hexagonal portion of the No. 2 camshaft with a wrench and remove the bolt and camshaft timing exhaust gear.

       Note:

       • Be careful not to damage the cylinder head or spark plug tube with the wrench.

       • Do not disassemble the camshaft timing exhaust gear.

19. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

    1. 

       Uniformly loosen and remove the 20 bearing cap bolts in the sequence shown in the illustration.

    2. 

       Remove the camshaft housing by prying between the cylinder head and camshaft housing with a screwdriver.

       Note:

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

       Tip:

       Tape the screwdriver tip before use.

20. REMOVE CAMSHAFT BEARING CAP

    1. 

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

    2. Remove the 5 camshaft bearing caps.

       Tip:

       Arrange the removed parts in the correct order.

21. REMOVE OIL CONTROL VALVE FILTER

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22. REMOVE NO. 1 CAMSHAFT BEARING

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23. REMOVE CAMSHAFT

    1. Remove the camshaft and No. 2 camshaft.

24. REMOVE NO. 2 CAMSHAFT BEARING

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

    1. Remove the 16 valve rocker arms from the cylinder head.

       Tip:

       Arrange the removed parts in the correct order.

26. REMOVE VALVE LASH ADJUSTER ASSEMBLY

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

       Tip:

       Arrange the removed parts in the correct order.

27. REMOVE VALVE STEM CAP

    1. Remove the 16 valve stem caps from the cylinder head.

       Tip:

       Arrange the removed parts in the correct order.

28. 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.

       Note:

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

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

       Tip:

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

    2. Remove the cylinder head.

29. REMOVE CYLINDER HEAD GASKET

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

30. INSPECT CYLINDER HEAD BOLT

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31. INSPECT CYLINDER HEAD SUB-ASSEMBLY

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