Cylinder Head Gasket (For Sedan) Removal

Using a screwdriver with its tip wrapped in protective tape, disengage the claw and remove the 2 front wiper arm head caps.

Operate the wiper, then stop the windshield wiper motor in the automatic stop position.

Remove the nut and front wiper arm.

Using a screwdriver with its tip wrapped in protective tape, disengage the 3 claws and remove the cowl side ventilator sub-assembly LH.

Disengage the 3 clips, the 4 claws and the 8 hooks.

Remove the cowl top ventilator louver sub-assembly.

Disconnect the washer hoses.

Disengage the 5 hooks.

Remove the 2 bolts.

Slide the wiper link. Disengage the meshing of the rubber pin, then disconnect the connector and remove the front wiper motor and link.

Disengage the 3 claws and remove the front air shutter seal RH.

Disengage the wire harness clamp.

Remove the 2 bolts and remove the cowl top to cowl inner brace.

Remove the 8 bolts and remove the cowl top panel outer.

Remove the oil filler cap.

Remove the oil pan drain plug and drain the engine oil.

Clean the drain plug.

Install the drain plug with a new gasket.

Torque:

38 N*m{382 kgf*cm, 28 ft.*lbf}

Loosen the radiator drain cock plug.

Remove the radiator cap sub-assembly.

Loosen the cylinder block drain cock plug, then drain the coolant.

Remove the 4 nuts and cylinder head cover No. 2.

Disconnect fuel vapor feed hose No. 1 and fuel vapor feed hose No. 2 from the vacuum switching valve assembly.

Disconnect the vacuum switching valve assembly connector and wire harness clamp.

Disconnect ventilation hose No. 2.

Disconnect the wire harness clamp and mass air flow meter connector.

Loosen the hose clamp, unlock the air cleaner assembly clamp and remove air cleaner cap sub-assembly with air cleaner hose No. 1.

Disconnect No. 3 radiator hose.

Disconnect the reserve tank hose.

Separate No. 1 radiator hose from the cylinder head.

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

Disconnect No. 2 water by-pass hose.

Disconnect the water by-pass hose.

Separate the wire harness clamp.

Remove the nut and separate the throttle with motor body connector.

Disconnect the ventilation hose.

Disconnect the union to connector tube hose.

Separate the 3 wire harness clamps shown in the illustration.

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

Remove the wire harness clamp and the bolt and remove the oil level dipstick guide.

Remove the fuel pipe clamp.

Pinch the retainer of the fuel tube connector, then pull the fuel tube connector to disconnect the fuel tube out of the fuel delivery pipe sub-assembly.

NOTICE:

1. Remove any dirt and foreign matter from the fuel tube connector before performing this work.
   
2. Do not allow any scratches or foreign matter on the parts when disconnecting, as the fuel tube connector has the O-ring that seals the pipe.
   
3. Perform this work by hand. Do not use any tools.
   
4. Do not forcibly bend, twist or turn the nylon tube.
   
5. Protect the disconnected parts by covering them with a vinyl bag after disconnecting the fuel tube.
   
6. If the fuel tube connector and pipe are stuck, push and pull to release them.
   

Disconnect the booster vacuum tube.

Disconnect the camshaft position sensor connector.

Disconnect the engine coolant temperature sensor connector.

Remove the bolts and separate the sensor bracket.

Disconnect the heated oxygen sensor connector.

Disconnect heater water inlet hose A.

Remove the bolt and separate No. 1 water by-pass pipe.

Remove the 2 bolts and disconnect the wire harness.

Remove the 2 bolts and 2 compression springs and separate the front exhaust pipe assembly.

Remove the 3 bolts and remove the manifold support bracket.

Loosen bolts A and B.

Release the fan and generator V belt tension and remove the fan and generator V belt.

Remove the terminal cap.

Separate the connector and the harness clamp.

Remove the nut and remove terminal B.

Remove fan belt adjusting slider fixing bolts A and B and remove the fan belt adjusting slider.

Remove fixing bolt B and remove the generator.

Disconnect the 4 ignition coil connectors.

Remove the 4 bolts and 4 ignition coils.

Disconnect the ventilation hose.

Disconnect fuel vapor feed hose assembly.

Disconnect the fuel injector connectors.

Disconnect the connector and 3 wire harness clamps shown in the illustration and disconnect the engine wire harness.

Remove the bolt and remove the wire harness bracket.

Remove the 9 bolts, 2 nuts and 2 seal washers and then remove the cylinder head cover sub-assembly.

Remove the gasket from the cylinder head cover sub-assembly.

Place a wooden block on a jack underneath the engine.

Remove the 5 bolts and nut and remove the engine mounting insulator sub-assembly RH.

Set the No. 1 cylinder to TDC/compression.

1. Turn the crankshaft damper sub-assembly, and align its timing notch with timing mark "0" of the oil pump.
   





2. Check that the timing marks on the camshaft timing sprocket and the camshaft timing gear are all facing upward as shown in the illustration.
   If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.
   

Using 2 SSTs, loosen the bolt while holding the crankshaft damper sub-assembly.

SST

09213-14010(91651-60865)
09330-00021

NOTICE:

Check the SST installation positions when installing them, to avoid the SST fixing bolts from coming into contact with the oil pump assembly.

Remove the SST and the bolt.

Remove the crankshaft damper sub-assembly.

Disconnect the crankshaft position sensor connector.

Remove the bolt and remove the crankshaft position sensor.

Disconnect the camshaft timing oil control valve assembly connector.

Remove the bolt and nut and remove the camshaft timing oil control valve assembly.

Remove the O-ring from the camshaft timing oil control valve assembly.

Using SST, hold the water pump pulley.

SST

09960-10010(09962-01000,09963-00700)

Remove the 3 bolts and remove the water pump pulley.

Remove the 3 bolts and 2 nuts and remove the engine water pump assembly and gasket.

Remove the 4 bolts and remove the transverse engine engine mounting bracket.

Remove the 15 bolts and the nut.

Using a screwdriver with its tip wrapped in protective tape, prize the oil pump assembly to remove it.

NOTICE:

Do not damage the contact surfaces of the oil pump assembly and oil pan sub-assembly.

Remove the 2 O-rings from the cylinder block and oil pan sub-assembly.

Using a screwdriver with its tip wrapped in protective tape, remove the oil pump seal.

Pull up the stopper plate and hold it with its lock released.

Unlock the plunger of the tensioner and push it in to the end.

Pull down the stopper plate with the plunger pushed to the end and lock the plunger.

Insert a 3 mm (0.12 in.) diameter bar into the hole in the stopper plate and lock the plunger.

Remove the 2 bolts and remove the No. 1 chain tensioner assembly.

Remove the chain tensioner slipper.

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

Using several steps, uniformly loosen and remove the 19 bearing cap bolts in the sequence shown in the illustration, and then remove No. 1 camshaft bearing cap and No. 2 camshaft bearing cap.

NOTICE:

Loosen each bolt uniformly while keeping the camshaft level.

Remove the camshaft and No. 2 camshaft.

Using several steps, uniformly loosen and remove the 10 cylinder head bolts with an 8 mm bi-hexagon wrench in the sequence shown in the illustration. Remove the 10 plate washers.

NOTICE:

1. Do not drop the washers into the cylinder head.
   
2. Head warpage or cracking could result from removing the bolts in the wrong order.
   

Remove the cylinder head gasket.