Cylinder Head Gasket Removal

Remove the 5 bolts and No. 1 exhaust manifold heat insulator.

HINT:

1. It is only necessary to move the No. 1 exhaust manifold heat insulator so that the intake pipe can be removed in a later step.
   
2. It is not possible to fully remove the No. 1 exhaust manifold heat insulator in this step.
   

Remove the 4 nuts, No. 4 intake pipe and 2 gaskets.

NOTICE:

Be careful not to damage the installation surface of the gaskets.

Disconnect the vacuum hose.

Disconnect the connector.

Remove the 2 nuts and air switching valve.

Remove the No. 1 exhaust manifold heat insulator.

Slide the 2 clips and remove the 2 heater hoses from the No. 1 water by-pass pipe and No. 2 water by-pass pipe.

Slide the clip and disconnect the No. 1 water by-pass hose from throttle body with motor assembly.

Slide the clip and disconnect the No. 1 ventilation hose from the PCV valve sub-assembly.

Slide the clip and disconnect the No. 3 ventilation hose from the ventilation pipe.

Slide the clip and disconnect the No. 3 water by-pass hose from the cylinder head sub-assembly.

Remove the bolt and ventilation pipe.

Remove the 2 bolts and cylinder head cover connector sub-assembly.

Remove the No. 2 camshaft bearing cap oil hole gasket and 3 No. 3 camshaft bearing cap oil hole gaskets from the No. 1 camshaft bearing cap.

Remove the 2 bolts, timing chain guide and O-ring.

Temporarily install the crankshaft pulley bolt.

Rotate the crankshaft clockwise so that the timing marks on the crankshaft timing gear and camshaft timing gears are as shown in the illustration.

HINT:

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

Remove the crankshaft pulley bolt.

Move the stopper plate upward to release the lock and push the plunger deep into the tensioner.

Move the stopper plate downward to set the lock and insert a hexagon wrench into the stopper plate hole.

Remove the bolt, nut, No. 1 chain tensioner assembly and gasket.

Remove the bolt and chain tensioner slipper.

Remove the bolt, nut and No. 1 chain vibration damper.

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

NOTICE:

Uniformly loosen the bolts while keeping the camshaft level.

Remove the 9 bearing caps.

HINT:

Arrange the removed parts in the correct order.

Remove the camshaft.

Remove the No. 2 camshaft.

Remove the 16 No. 1 valve rocker arm sub-assemblies from the cylinder head sub-assembly.

HINT:

Arrange the removed parts in the correct order.

Remove the 16 valve lash adjuster assemblies from the cylinder head sub-assembly.

HINT:

Arrange the removed parts in the correct order.

Remove the 16 valve stem caps from the cylinder head sub-assembly.

HINT:

Arrange the removed parts in the correct order.

Remove the 3 bolts and disconnect the engine wire from the cylinder head sub-assembly.

w/ Oil Cooler:
Remove the bolt and disconnect the No. 4 water by-pass pipe.

Uniformly loosen the 10 cylinder head set bolts in the sequence shown in the illustration. Remove the 10 cylinder head set bolts and plate washers.

NOTICE:

1. Be careful not to drop plate washers into the cylinder head sub-assembly.
   
2. Head warpage or cracking could result from removing cylinder head set bolts in the incorrect order.
   

Remove the cylinder head sub-assembly.

Remove the cylinder head gasket from the cylinder block.

Using a vernier caliper, measure the diameter of the most elongated threads in the measuring area.

Standard outside diameter:

10.76 to 10.97 mm (0.424 to 0.432 in.)

Minimum outside diameter:

10.40 mm (0.409 in.)

Distance:

30 mm (1.18 in.)

Using a precision straightedge and feeler gauge, measure the warpage of the surfaces that contact the cylinder block and manifolds.

Maximum warpage:

0.05 mm (0.00197 in.)

Using a dye penetrant, check the intake ports, exhaust ports and cylinder head surface for cracks.
If cracked, replace the cylinder head sub-assembly.