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Cylinder Head Gasket Replacement: Notes

WARNING:
  • A hot engine can cause severe burns. Turn off the engine and wait until it is cool before servicing.
  • Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
  • Highly pressurized fuel may spray out if the fuel line is cut. Due to the following dangers occurring with a fuel spray, always complete the "Fuel Line Safety Procedure" to prevent the fuel from spraying.
    • Fuel may cause irritation if it comes in contact with skin and eyes.
    • If fuel ignites and causes a fire, it may lead to serious injury or death, and damage to property and facilities.
CAUTION:
  • If the camshaft is rotated with the timing chain removed and the piston at the top dead center position, the valve may contact the piston and the engine could be damaged. When rotating the camshaft with the timing chain removed, rotate it after lowering the piston from the top dead center position.
  1. Disconnect the negative battery cable. (See NEGATIVE BATTERY CABLE DISCONNECTION/CONNECTION .)
  2. Remove the plug hole plate. (See PLUG HOLE PLATE REMOVAL/INSTALLATION .)
  3. Remove the ignition coil/ion sensors. (See IGNITION COIL/ION SENSOR REMOVAL/INSTALLATION .)
  4. Remove the front under cover No. 2. (See FRONT UNDER COVER NO. 2 REMOVAL/INSTALLATION .)
  5. Remove the front splash shield (RH). (See FRONT SPLASH SHIELD REMOVAL/INSTALLATION .)
  6. Remove the drive belt. (See DRIVE BELT REMOVAL/INSTALLATION .)
  7. Drain the engine oil. (See ENGINE OIL REPLACEMENT .)
  8. Drain the engine coolant. (See ENGINE COOLANT REPLACEMENT .)
  9. Remove the intake manifold. (See INTAKE-AIR SYSTEM REMOVAL/INSTALLATION .)
  10. Set aside the exhaust manifold to the vehicle rear. (See EXHAUST SYSTEM REMOVAL/INSTALLATION .)
  11. Remove the vacuum pump. (See VACUUM PUMP REMOVAL/INSTALLATION .)
  12. Remove the high pressure fuel pump and rear housing. (See HIGH PRESSURE FUEL PUMP REMOVAL/INSTALLATION .)
  13. Disconnect 2 heater hoses from the following parts.
    • Vehicles without coolant control valve: Water outlet and water inlet pipe
    • Vehicles with coolant control valve: Coolant control valve and flange
  14. Disconnect the water hose No. 1 from the flange. (With coolant control valve, without oil cooler) (See OIL COOLER REMOVAL/INSTALLATION [EW6A-EL/EW6AX-EL] .)
  15. Disconnect the water hose No. 1 from the water inlet pipe. (With coolant control valve and oil cooler) (See OIL COOLER REMOVAL/INSTALLATION [EW6A-EL/EW6AX-EL] .)
  16. Disconnect the water hose No. 2 from the coolant control valve. (With coolant control valve) (See OIL COOLER REMOVAL/INSTALLATION [EW6A-EL/EW6AX-EL] .)
  17. Removal the coolant control valve. (With coolant control valve) (See COOLANT CONTROL VALVE REMOVAL/INSTALLATION .)
  18. Disconnect the radiator hose (upper and lower). (Without coolant control valve)
  19. Remove the oil pan. (See OIL PAN REMOVAL/INSTALLATION .)
  20. Remove the timing chain and chain guide. (See TIMING CHAIN REMOVAL/INSTALLATION .)
  21. Remove the OCV. (See OIL CONTROL VALVE (OCV) REMOVAL/INSTALLATION .)
  22. Remove in the order indicated in the table.
  23. Install in the reverse order of removal.
  24. Refill with the specified type and amount of the engine oil. (See ENGINE OIL REPLACEMENT .)
  25. Refill the engine coolant. (See ENGINE COOLANT REPLACEMENT .)
  26. Start the engine, and inspect and adjust the following:
    • Leakage of engine oil, engine coolant.
    • Runout and contact of pulley and belt.
    • Ignition timing, idle speed and idle mixture. (See ENGINE TUNE-UP .)
    • Compression pressure (See COMPRESSION INSPECTION .)
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