4.1 Cylinder Head Cover and Gasket

Because the cylinder head cover gasket is deformed as it is compressed, it is not reusable. It should be replaced any time the cylinder head cover is removed and any time there is evidence of leaks. A thorough visual inspection will usually detect a faulty cylinder head cover gasket. The gasket used on most engines is a three-piece set. A two-piece gasket set is used on 16-valve engines.

To remove and install cylinder head cover and gaskets (except 16-valve engines):

1.	Remove the eight 10 mm nuts and the reinforcing strips.

2.	Remove the socket-head flanged nut from the camshaft drive belt upper cover.

3.

Lift off the cylinder head cover and its gasket. Raise the camshaft drive belt upper cover slightly for clearance. If the gasket is stuck to the cylinder head, use a gasket removing tool to separate the gasket from the head. Remove the sealing plug from the rear of the cylinder head and remove the semi-circular gasket piece from inside the front of the cover.

4.	Installation is the reverse of removal. Make sure the tabs on the semi-circular piece correctly mate the slots on the gasket to ensure a good seal. Torque the eight nuts and the socket head flanged nut to 10 Nm (7.5 ft.lb. or 87 in. lb.).

To remove and install cylinder head cover and gasket (16-valve engines only):

1.	Remove spark plug wire connectors. Remove the intake air boot from the throttle housing and remove the small rubber hose between the intake air boot and the idle air valve.

2.	Disconnect the electrical connector for the charcoal canister control valve, and the large vacuum hose from the back of the upper intake manifold.

3.	Remove the support bolt from the back of the upper intake manifold, then remove the five nuts and washers that join the upper intake manifold to the lower intake manifold.

4.	Rotate the upper manifold up and away from the engine. Remove and label electrical connections or vacuum hoses as required. Then secure the manifold out of the way.

5.	Remove the two inner bolts and the six outer bolts from the cover, and lift the cover from the cylinder head. If necessary, use a soft hammer to loosen the cover. Remove the center gasket from the cylinder head or the cover.