Removal

CYLINDER HEAD

Components:

REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

3. REMOVE TIMING BELT
a. Remove the timing belt.

4. REMOVE IGNITION COIL

5. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY RH
a. Remove the bolt, and disconnect the wire clamp bracket from the camshaft bearing cap.
b. Remove the bolt, and disconnect the engine wire protector from the cylinder head cover.
c. Remove the 9 bolts, 9 seal washers and cylinder head cover.

6. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
a. Remove the bolt, and disconnect the wire clamp bracket from the camshaft bearing cap.
b. Remove the 9 bolts, 9 seal washers and cylinder head cover.

7. WORK FOR PISTON AND VALVE DAMAGE PREVENTION
a. Turn the crankshaft timing pulley counterclockwise by 45° and match the timing mark with the illustrated position.

HINT: When the No.1 cylinder is positioned at 45° BTDC, the valve and piston do not interfere with each other even when the valve is fully open.

NOTICE: Be sure to match the cut part by turning it counterclockwise.

8. REMOVE CAMSHAFT TIMING PULLEY
a. Hold the crankshaft with a wrench, and remove the 4 bolts and timing pulley.

9. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
10. REMOVE CAMSHAFT

NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.

a. Bring the service bolt hole of the sub gear upward by turning the hexagon head portion of the No.2 camshaft with a wrench.
b. Secure the sub gear to the main gear with a service bolt.

Recommended Service Bolt:

HINT: When removing the camshaft, make sure that the torsional spring force of the sub gear has been eliminated by the above operation.

c. Set a wrench to the hexagon head portion of the No.2 camshaft. Rotate the wrench so that the timing mark (1 dot mark) on the camshaft main gear is moved approximately 10°, as shown in the illustration.

d. Uniformly loosen the 22 bearing cap bolts in several passes in the sequence shown in the illustration.
e. Remove the 22 bearing cap bolts, 4 seal washers, oil feed pipe, 9 bearing caps, camshaft housing plug, oil control valve filter and 2 camshafts.

NOTICE:
^ Do not forcibly pry the camshaft with a tool.
^ Do not damage the reception part of the thrust on the cylinder head side.

11. REMOVE NO.3 CAMSHAFT SUB-ASSEMBLY

NOTICE: Since the thrust clearance of the camshaft is small, the camshaft must be kept level while it is being removed. If the camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing the camshaft to seize or break. To avoid this, the following steps should be carried out.

a. Bring the service bolt hole of the sub gear upward by turning the hexagon head portion of the exhaust camshaft with a wrench.
b. Secure the sub gear to the main gear with a service bolt.

Recommended Service Bolt:

HINT: When removing the camshaft, make sure that the torsional spring force of the sub gear has been eliminated by the above operation.

c. Set a wrench to the hexagon head portion of the No.4 camshaft. Rotate the wrench so that the timing marks (2 dot marks each) on the camshaft drive and driven main gears are aligned, as shown in the illustration.

d. Uniformly loosen the 22 bearing cap bolts in several passes in the sequence shown in the illustration.
e. Remove the 22 bearing cap bolts, 4 seal washers, oil feed pipe, 9 bearing caps, camshaft housing plug, oil control valve filter and 2 camshafts.

NOTICE:
^ Do not forcibly pry the camshaft with a tool.
^ Do not damage the reception part of the thrust on the cylinder head side.

12. REMOVE NO.2 FUEL PIPE SUB-ASSEMBLY
13. REMOVE INTAKE MANIFOLD ASSEMBLY
a. Removal procedure.

14. REMOVE REAR WATER BY-PASS JOINT
a. Disconnect the heater inlet hose from the water bypass joint.
b. Remove the 4 nuts, water by-pass joint and 2 gaskets.

15. REMOVE WATER INLET HOUSING
a. Remove the 2 bolts and inlet housing.

16. REMOVE FRONT WATER BY-PASS JOINT
a. Disconnect the ECT sensor connector.
b. Remove the 4 nuts, water by-pass joint and 2 gaskets.

17. REMOVE FRONT TWC

RH Bank:

18. REMOVE CYLINDER HEAD SUB-ASSEMBLY
a. Uniformly loosen 10 cylinder head bolts on cylinder head in several passes, in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

NOTICE: Be careful not to drop washers into the cylinder head.

b. Remove cylinder head together with the exhaust manifold.

19. REMOVE CYLINDER HEAD GASKET
20. REMOVE NO.1 EXHAUST MANIFOLD HEAT INSULATOR
a. Remove the 4 bolts and heat insulator.

21. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Remove the 8 nuts, exhaust manifold and gasket.

22. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.
Maximum warpage: 0.50 mm (0.0197 inch)
If the warpage is greater than the maximum, replace the manifold.

LH Bank:

23. REMOVE CYLINDER HEAD LH
a. Uniformly loosen 10 cylinder head bolts on cylinder head in several passes, in the sequence shown in the illustration. Remove the 10 cylinder head bolts and plate washers.

NOTICE: Be careful not to drop washers into the cylinder head.

b. Remove cylinder head together with the exhaust manifold.

24. REMOVE NO.2 CYLINDER HEAD GASKET
25. REMOVE NO.2 EXHAUST MANIFOLD HEAT INSULATOR
a. Remove the 4 bolts and heat insulator.

26. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY LH
a. Remove the 8 nuts, exhaust manifold and gasket.

27. INSPECT EXHAUST MANIFOLD SUB-ASSEMBLY LH
a. Using a precision straightedge and feeler gauge, measure the surface contacting the cylinder head for warpage.
Maximum warpage: 0.50 mm (0.0197 inch)
If the warpage is greater than the maximum, replace the manifold