CYLINDER HEAD GASKET REMOVAL

PROCEDURE


  1. REMOVE TIMING CHAIN COVER ASSEMBLY

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  2. REMOVE NO. 2 WATER BY-PASS PIPE

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  3. REMOVE PURGE VSV

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  4. REMOVE INTAKE MANIFOLD WITH INTERCOOLER ASSEMBLY AND THROTTLE WITH MOTOR BODY ASSEMBLY

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  5. REMOVE FUEL DELIVERY PIPE (for Port Injection)

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  6. REMOVE FUEL INJECTOR ASSEMBLY (for Port Injection)

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  7. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY (for Direct Injection)

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  8. REMOVE FUEL INJECTOR SET (for Direct Injection)

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  9. REMOVE FUEL INJECTOR SEAL (for Direct Injection)

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  10. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR

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  11. REMOVE NO. 2 EXHAUST MANIFOLD HEAT INSULATOR

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  12. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

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  13. DISCONNECT TURBO OIL INLET PIPE SUB-ASSEMBLY

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  14. REMOVE TURBOCHARGER SUB-ASSEMBLY

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  15. REMOVE VACUUM PUMP ASSEMBLY

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  16. REMOVE ENGINE OIL LEVEL DIPSTICK GUIDE

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  17. SET NO. 1 CYLINDER TO TDC/COMPRESSION

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  18. REMOVE NO. 1 CHAIN TENSIONER ASSEMBLY

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  19. REMOVE TIMING CHAIN GUIDE

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  20. REMOVE CHAIN TENSIONER SLIPPER

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  21. REMOVE CHAIN SUB-ASSEMBLY

  22. REMOVE NO. 1 CHAIN VIBRATION DAMPER

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  23. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY

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  24. REMOVE CAMSHAFT TIMING EXHAUST GEAR ASSEMBLY

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  25. REMOVE CAMSHAFT HOUSING SUB-ASSEMBLY

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  26. REMOVE NO. 3 WATER BY-PASS PIPE

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  27. DISCONNECT NO. 7 WATER BY-PASS HOSE


    1. B008IV3

      Slide the clamp and disconnect the No. 7 water by-pass hose from the cylinder head sub-assembly.

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

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  29. REMOVE VALVE LASH ADJUSTER ASSEMBLY

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  30. REMOVE VALVE STEM CAP

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  31. REMOVE CYLINDER HEAD SUB-ASSEMBLY


    1. B008HWVN03

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

      Note


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

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

      Tech Tips

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

    2. Remove the cylinder head sub-assembly.

  32. REMOVE CYLINDER HEAD GASKET


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

  33. INSPECT CYLINDER HEAD SET BOLT

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  34. INSPECT CYLINDER HEAD SUB-ASSEMBLY

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