CYLINDER HEAD GASKET > REMOVAL

for Preparation Click here

1. Remove the engine assembly with the transaxle (Click here).
   

1. Open the terminal cap.
   

2. Remove the nut and disconnect the terminal 30.
   

3. Disconnect the connector.
   

4. Remove the 2 bolts and the starter assembly.
   

1. Use SST to hold the crankshaft pulley in place.
   

   SST

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

2. Remove the 6 drive plate and torque converter setting bolts.
   

1. Remove the 2 bolts, the nut and the manifold stay.
   

1. Disconnect the wire harness clamp and air fuel ratio sensor connector.
   

2. Using SST, remove the air fuel ratio sensor from the exhaust manifold.
   

   SST

   09224-00010  
   

1. Remove the 3 bolts and the No. 1 exhaust manifold heat insulator.
   

1. Remove the 2 bolts, the 4 nuts and the exhaust manifold.
   

2. Remove the 2 gaskets from the cylinder head.
   

1. Remove the 9 bolts and the CVT.
   

   NOTICE:

   Do not twist the CVT when removing it from the engine, because the knock pins could be damaged.

1. Using SST, hold the crankshaft.
   

   SST

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

2. Remove the 6 bolts and the rear spacer, drive plate and the front spacer.
   

1. Remove the 8 bolts and the manual transaxle.
   

1. Using a union nut wrench 10 mm, separate the clutch release tube from the clutch release with bearing cylinder assembly.
   

1. Using a union nut wrench 10 mm, separate the clutch release bleeder from the bleeder clutch release tube.
   

2. Remove the 2 bolts and clutch release bleeder.
   

1. Remove the 3 bolts and the clutch release with bearing cylinder assembly together with the bleeder clutch release tube.
   

1. Using a union nut wrench 10 mm, separate the clutch release tube from the clutch release with bearing cylinder assembly.
   

1. Put the matchmarks on the clutch cover and the flywheel.
   

2. Loosen each set bolt one turn at a time until the spring tension is released.
   

3. Remove the set bolts and pull off the clutch cover.
   

   NOTICE:

   Do not drop the clutch disc.

1. Using SST, hold the crankshaft.
   

   SST

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

2. Remove the 6 bolts and the flywheel sub-assembly.
   

1. Remove the terminal cap.
   

2. Disconnect the connector and 2 harness clamps.
   

3. Remove the nut and terminal B.
   

4. Remove the 2 bolts and 2 brackets.
   

5. Remove the 2 bolts and fan belt adjusting bar.
   

6. Remove the bolt and generator assembly.
   

1. Separate the 2 water by-pass hoses from the hose clamp.
   

2. Disconnect the 2 water by-pass hoses.
   

3. Disconnect the throttle with motor body assembly connector.
   

4. Remove the 3 bolts, the nut and the throttle with motor body assembly.
   

5. Remove the gasket from the intake manifold.
   

1. Disconnect the 2 connectors and 4 harness clamps from the intake manifold.
   

2. Disconnect the vacuum hose and ventilation hose and remove the 2 bolts from the intake manifold.
   

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

4. Remove the gasket from the intake manifold.
   

1. Remove the nut, the 2 bolts and the intake manifold insulator.
   

2. Remove the gasket from the cylinder head.
   

1. Disconnect the EGR valve connector.
   

2. Separate the water by-pass hose.
   

3. Rotate the EGR valve to avoid contact with the delivery pipe, and remove the EGR valve.
   

4. Remove the gasket.
   

1. Loosen the 2 clips and remove the water by-pass hose assembly.
   

1. Loosen the 2 clips and remove the No. 1 radiator hose.
   

1. Disconnect the 3 No. 1 ignition coil connectors.
   

2. Remove the 3 bolts and the 3 No. 1 ignition coils.
   

1. Loosen the clip and remove the No. 2 radiator hose.
   

1. Remove the 3 bolts and the idler pulley.
   

1. Remove the bolt and the oil level dipstick guide sub-assembly.
   

2. Remove the O-ring from the oil level dipstick guide sub-assembly.
   

1. Remove the bolt and the water filler assembly.
   

1. Remove the bolt and the wiring harness clamp bracket.
   

1. Remove the 2 bolts and the drive shaft bearing bracket.
   

1. Remove the oil filler cap sub-assembly.
   

1. Disconnect the vacuum hose from the vacuum switching valve.
   

2. Disconnect the vacuum switching valve connector.
   

3. Separate the wire harness from the cylinder head cover sub-assembly
   

4. Remove the 16 bolts and the cylinder head cover sub-assembly.
   

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

1. Remove the bolt, the 2 nuts and the No. 1 water by-pass pipe.
   

2. Remove the gasket from the No. 1 water by-pass pipe.
   

3. Remove the gasket from the cylinder head.
   

1. Remove the 5 bolts and the water pump assembly.
   

2. Remove the gasket.
   

1. Remove the 2 bolts and the oil filter bracket.
   

2. Remove the gasket.
   

1. Remove the 2 bolts and the oil filter bracket.
   

2. Remove the gasket.
   

1. Remove the 12 bolts and 3 nuts.
   

2. Using an oil pan seal cutter, remove the oil pan.
   

   Text in Illustration 

   *1	Oil Pan Seal Cutter

   NOTICE:

   Be careful not to damage the contact surfaces of the oil pan.

1. Remove the 2 bolts and oil strainer.
   

2. Remove the gasket.
   

1. Disconnect the camshaft timing oil control valve assembly connector.
   

2. Remove the bolt and the camshaft timing oil control valve assembly.
   

1. Disconnect the crank position sensor connector.
   

2. Remove the bolt and the crank position sensor.
   

1. Turn the crankshaft pulley clockwise to align the timing mark on the pulley with the timing pointer of the timing chain cover.
   

   Text in Illustration 

   *1	Timing Mark
   *2	Timing Pointer

2. Make sure that the timing mark of the camshaft sprocket is at the top.
   

1. Operate the jack and slowly lower the engine.
   

   NOTICE:

   Do not lower the engine more than necessary.

2. Using SST, hold the pulley in place and loosen the pulley bolt.
   

   SST

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

3. Using SST, remove the crankshaft pulley and pulley bolt.
   

   SST

   09950-40011   (09951-04010, 09953-04030, 09958-04011, 09955-04011, 09954-04010, 09952-04010)
   

1. Using an 8 mm socket hexagon wrench, remove the timing gear cover tight plug.
   

   Text in Illustration 

   *1	8 mm Socket Hexagon Wrench

1. Remove the 12 bolts.
   

2. Using a screwdriver with its tip wrapped in protective tape, remove the timing chain cover by prying between the timing cover and cylinder head or cylinder block.
   

   Text in Illustration 

   *1	Protective Tape

   NOTICE:

   Do not damage the contact surfaces of the cylinder head, cylinder block and timing chain cover.

3. Remove the gasket.
   

1. Remove the 2 stud bolts.
   

1. Remove the 3 bolts and the ventilation case sub-assembly.
   

1. Using a screwdriver with its tip wrapped in protective tape, pry out the oil seal.
   

   Text in Illustration 

   *1	Protective Tape

1. Turn the stopper plate of the chain tensioner clockwise and push in the plunger with the lock released.
   

   Text in Illustration 

   *1	Stopper Plate

2. Insert a hexagon wrench into the hole in the stopper plate to lock with the plunger pushed in.
   

   Text in Illustration 

   *1	Hexagon Wrench
   *2	Stopper Plate

3. Remove the 2 bolts and the timing chain tensioner.
   

1. Remove the bolt and the chain tensioner arm.
   

1. Remove the crankshaft timing chain gear or sprocket from the crankshaft.
   

1. Remove the 2 bolts and the timing chain guide.
   

1. Slightly turn the crankshaft clockwise.
   

   NOTICE:

   Do not allow the lifted valve and piston to come into the contact with each other when removing the camshaft.

2. Remove the bolt from the sprocket while holding the hexagonal portion of the camshaft.
   

3. Remove the camshaft timing sprocket from the camshaft.
   

4. Remove the 15 bolts in the order shown in the illustration.
   

5. Remove the camshaft.
   

1. Remove the No. 2 camshaft.
   

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

   NOTICE:

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

2. Remove the cylinder head from the cylinder block.
   

1. Remove the cylinder head gasket.