Part 2

CYLINDER HEAD

COMPONENTS:

REMOVAL (STEPS 31-67)
31. REMOVE WATER OUTLET
a. Disconnect the ground cable connector (A).

b. Disconnect the engine coolant temperature sensor connector (B).
c. Remove the clamp (C).
d. Remove the 2 bolts, 2 nuts and 2 washers.
e. Lock the hose clamp as shown in the illustration (D) and remove the water outlet together with water bypass hose No. 1 (E).
f. Remove the 2 gaskets from the 2 cylinder heads.
32. SEPARATE BRAKE MASTER CYLINDER RESERVOIR SUB-ASSEMBLY
33. REMOVE RESERVOIR BRACKET
34. REMOVE AIR CLEANER BRACKET
35. REMOVE ENGINE MOVING CONTROL ROD
36. REMOVE ENGINE MOUNTING STAY NO. 2 RH
37. REMOVE CRANKSHAFT PULLEY
38. REMOVE TIMING BELT NO. 1 COVER
39. REMOVE TIMING BELT NO. 2 COVER
40. REMOVE ENGINE MOUNTING BRACKET RH
41. REMOVE TIMING BELT GUIDE NO. 2
42. REMOVE TIMING BELT
43. REMOVE TIMING BELT IDLER SUB-ASSEMBLY NO. 2
44. REMOVE CAMSHAFT TIMING PULLEY
45. REMOVE TIMING BELT NO. 3 COVER
46. REMOVE EXHAUST PIPE ASSEMBLY FRONT
47. REMOVE EXHAUST PIPE SUB-ASSEMBLY FRONT NO. 3

48. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1
a. Remove the 3 bolts and exhaust manifold heat insulator No. 1.
49. REMOVE MANIFOLD STAY
a. Remove the 2 bolts and manifold stay.
50. REMOVE EXHAUST MANIFOLD SUB-ASSEMBLY RH
a. Disconnect the heated oxygen sensor connector.

b. Using several steps, loosen and remove the 6 nuts in the sequence shown in the illustration.
c. Remove the exhaust manifold RH and the gasket from the cylinder head RH.
51. REMOVE IGNITION COIL ASSEMBLY
52. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
53. REMOVE CAMSHAFT
54. REMOVE NO. 2 CAMSHAFT

55. REMOVE CYLINDER HEAD SUB-ASSEMBLY
a. Disconnect the VVT sensor connector.
b. Disconnect the camshaft timing oil control valve connector.
c. Remove the nut and disconnect the engine wire harness clamp.

d. Using a socket hexagon wrench 8 mm, remove the hexagon bolt.

e. Using several steps, loosen the 8 cylinder head bolts uniformly in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.
SST 09011-38121

NOTICE:
^ Do not drop the washers into the cylinder head.
^ Head warpage or cracking could result from removing bolts in an incorrect order.

56. REMOVE CYLINDER HEAD GASKET

57. REMOVE MANIFOLD CONVERTER INSULATOR NO. 3
a. Remove the bolt, nut and manifold converter insulator No. 3.

58. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 2
a. Remove the 2 bolts and manifold heat insulator No. 2.
59. SEPARATE COOLING FAN ECU
a. Remove the 2 bolts and separate the cooling fan ECU.

HINT:
^ The cooling fan ECU should be separated to prevent it from being interfered with by the exhaust manifold.
^ Be sure to hang the disconnected ECU with the string to ensure safety.

60. REMOVE EXHAUST MANIFOLD CONVERTER SUB ASSEMBLY NO. 2
a. Disconnect the heated oxygen sensor connector.

b. Using several steps, loosen and remove the 6 nuts and bolt in the sequence shown in the illustration.
c. Remove the exhaust manifold converter No. 2 and the gasket from the cylinder head LH.

61. REMOVE OIL LEVEL GAUGE GUIDE
a. Remove the bolt which is used to secure the oil level gauge guide from the cylinder head LH.
b. Pull out the oil level gauge guide and the oil level gauge together from the cylinder block.
c. Remove the O-ring from the oil level gauge guide.
62. REMOVE WATER INLET PIPE
63. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
64. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY
65. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY

66. REMOVE CYLINDER HEAD LH
a. Disconnect the VVT sensor connector (A).
b. Disconnect the camshaft timing oil control valve connector (B).
c. Remove the 2 nuts and disconnect the ground cable P.
d. Remove the 2 bolts, wire harness clamp and intake air connector bracket No. 2.

e. Using a socket hexagon wrench 8 mm, remove the hexagon bolt.

f. Using several steps, loosen the 8 cylinder head bolts uniformly in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.
SST 09011-38121

NOTICE:
^ Do not drop the washers into the cylinder head.
^ Head warpage or cracking could result from removing bolts in an incorrect order.

67. REMOVE CYLINDER HEAD GASKET NO. 2