Removal

REMOVAL OF CYLINDER HEADS









1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY

CAUTION: Work must be started after approx. 20 seconds or longer from the time the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery.


2. DRAIN ENGINE COOLANT
3. REMOVE CAMSHAFT TIMING PULLEYS



NOTE: Be careful not to drop anything inside the timing belt cover. Do not allow the timing belt to come into contact with oil, water or dust.


4. DISCONNECT CABLES

(a) Accelerator cable
(b) A/T throttle cable
(c) Cruise control actuator cable


5. REMOVE HIGH-TENSION CORD CLAMPS





- Remove the bolt and cord clamp. Remove the four clamps.

6. REMOVE LOWER HIGH-TENSION CORD COVER
- Remove the bolt and cord cover.

7. REMOVE RH IGNITION COIL





- Remove the two bolts and ignition coil.



8. REMOVE WATER INLET AND INLET HOUSING





(a) Remove the two bolts holding the water inlet housing to the water pump.
(b) Disconnect the water by-pass hose from the ISC valve.
(C) Pull out the water inlet and inlet housing assembly.
(d) Remove the 0-ring from the water inlet housing.



9. REMOVE TIMING BELT REAR PLATES





- Remove the two bolts and rear plate. Remove the two rear plates.



10. REMOVE EGR PIPE





- Remove the three bolts, two nuts, EGR pipe and two gaskets.



11. REMOVE FUEL PRESSURE VSV, VCV AND VACUUM PIPE (AS EQUIPPED)





(a) Disconnect the hose from the BVSV.
(b) Disconnect the pipe from the charcoal canister hose.
(c) Disconnect the VSV connector.
(d) Disconnect the two hoses from the vacuum pipe.
(e) Remove the bolt and VCV with vacuum pipe.
(f) Remove the bolt and VSV.

12. REMOVE EGR VSV





(a) Disconnect the VSV connector.
(b) Disconnect the following hoses:

(1) Vacuum hose from EGR valve
(2) Vacuum hose from port "0" of EGR vacuum modulator

(C) Remove the bolt and VSV.



13. REMOVE EGR VALVE AND VACUUM MODULATOR






(a) Disconnect the following hoses:

(1) Water by-pass pipe from water by-pass hose (from ISC valve)
(2) Water by-pass pipe from water by-pass hose (from rear water by-pass joint)
(3) Two vacuum hoses from vacuum pipe

(b) Remove the bolt, two nuts, the EGR valve, vacuum modulator assembly and gasket.


14. REMOVE EGR VALVE ADAPTOR






(a) Disconnect the EGR gas temperature sensor connector.
(b) Remove the two bolts, two nuts, adaptor and gasket.



15. REMOVE VACUUM PIPE





(a) Disconnect the following hoses:

(1) Vacuum hose from fuel pressure regulator
(2) Vacuum hose from air intake chamber
(3) Vacuum hose from EVAP BVSV
(4) Three vacuum hoses from throttle body

(b) Remove the two bolts, the vacuum pipe and five vacuum hoses.


16. REMOVE ISC VALVE






(a) Disconnect the water by-pass hose from the ISC valve.
(b) Remove the two nuts.
(c) Disconnect the ISC valve connector, and remove the ISC valve and gasket.

17. REMOVE THROTTLE BODY






(a) Disconnect the sensor connectors.
(b) Disconnect the water by-pass pipe (from rear water by-pass joint) from the clamp on the engine wire cover.
(c) Disconnect the water by-pass pipe from the water bypass hose (from rear water by-pass joint).
(d) Remove the two bolts and two nuts.
(e) Disconnect the PCV hose from the cylinder head cover, remove the throttle body and gasket.


18. REMOVE ACCELERATOR BRACKET





- Remove the bolt, union bolt and bracket.


19. REMOVE BRAKE BOOSTER UNION

(a) Disconnect the vacuum hose from the union.
(b) Remove the union bolt, union and two gaskets.



20. REMOVE AIR INTAKE CHAMBER

(a) Disconnect the cold start injector connector.





(b) Remove the union bolt and two gaskets, and disconnect the cold start injector tube from the RH delivery pipe.
(c) Remove the four bolts and eight nuts.
(d) Disconnect the check connector from the intake chamber.





(e) Remove the intake chamber and four gaskets.





(f) Remove the three bolts, the cold start injector, tube, wire assembly and gasket.

21. DISCONNECT ENGINE WIRE FROM INTAKE MANIFOLD





- Remove the two bolts, and disconnect the engine wire from the intake manifold.



22. DISCONNECT ENGINE WIRE FROM WIRE BRACKET ON RH CYLINDER HEAD

(a) Remove the wire clip from the wire bracket.





(b) Remove the two bolts, and disconnect the engine wire from the wire bracket.

23. DISCONNECT HEATER HOSES FROM REAR WATER BY- PASS JOINT AND WATER BY-PASS PIPE
24. REMOVE DELIVERY PIPES AND INJECTORS

(a) Disconnect the following connectors:

(1) Water temperature sensor connector
(2) Cold start injector time switch connector
(3) Water temperature sender gauge connector

(b) Disconnect the two connectors from the wire bracket on the front side of the LH delivery pipe.
(c) Remove the six bolts holding the engine wire to the delivery pipes and rear water by-pass joint.
(d) Disconnect the eight injector connectors.
(e) Disconnect the fuel hose (from LH delivery pipe) from the fuel tube.
(f) Disconnect the fuel hose from the fuel return pipe.
(g) Remove the bolt holding the fuel return pipe to the rear side of the cylinder head.
(h) Remove the union bolt, two gaskets and return pipe.
(i) Remove the four nuts, wire bracket, the two delivery pipes, eight injectors assembly, four spacers and eight insulators.

NOTE: Be careful not to drop the injectors.

25. REMOVE INTAKE MANIFOLD





- Remove the six bolts, four nuts, intake manifold and two gaskets.

26. REMOVE FRONT WATER BY-PASS JOINT





- Remove the four nuts, water by-pass joint and two gaskets.



27. REMOVE REAR WATER BY-PASS JOINT





(a) Remove the four nuts, water by-pass joint and two gaskets.
(b) Remove the water by-pass hoses from the water bypass joint.

28. REMOVE FRONT EXHAUST PIPE
29. REMOVE MAIN CATALYTIC CONVERTERS
30. REMOVE RH EXHAUST MANIFOLD

(a) Disconnect the RH main oxygen sensor connector.





(b) Remove the four bolts, four nuts, exhaust manifold and gasket.


31. REMOVE OIL DIPSTICK AND GUIDE






(a) Remove the bolt, and pull out the dipstick guide together with the dipstick.
(b) Remove the 0-ring from the dipstick guide.

32. REMOVE LH EXHAUST MANIFOLD

(a) Disconnect the LH main oxygen sensor connector.





(b) Remove the four bolts, four nuts, exhaust manifold and gasket.



33. REMOVE ENGINE HANGERS





- Remove the two bolts and engine hanger. Remove the two engine hangers.

34. REMOVE ENGINE WIRE BRACKETS FROM RH CYLINDER HEAD





- Remove the two bolts and bracket. Remove the two brackets.


35. REMOVE CYLINDER HEAD COVERS





- Remove the eight bolts, seal washers, cylinder head cover and gasket. Remove the two cylinder head covers.

36. IF NECESSARY, REMOVE SEMI-CIRCULAR PLUGS
37. REMOVE CAMSHAFTS

NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be held 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. Remove exhaust camshaft of RH cylinder head






(a) Bring the service bolt hole of the driven sub-gear upward by turning the exhaust camshaft with a wrench.
(b) Secure the exhaust camshaft sub-gear to the driven gear with a service bolt.

Recommended service bolt:
Thread diameter 6 mm
Thread pitch 1.0 mm
Bolt length 16 - 20 mm (0.63-0.79 in.)

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






(c) Set the timing mark (one pointed mark) of the camshaft driven gear at approx. 10° angle by turning the exhaust camshaft with a wrench.





(d) Alternately loosen and remove the two bearing cap bolts holding the intake camshaft side of the oil feed pipe to the cylinder head.





(e) Uniformly loosen and remove the eight bearing cap bolts in several passes, in the sequence shown.
(f) Remove the oil feed pipe, four bearing caps and exhaust camshaft.



B. Remove intake camshaft of RH cylinder head





(a) Set the timing mark (one pointed mark) of the camshaft drive gear at approx. 45° angle by turning the intake camshaft with a wrench.





(b) Uniformly loosen and remove the eight bearing cap bolts in several passes, in the sequence shown.
(c) Remove the five bearing caps, oil seal and intake camshaft.



C. Remove exhaust camshaft of LH cylinder head

(a) Bring the service bolt hole of the driven sub-gear up-ward by turning the exhaust camshaft with a wrench.

Fig. 19 LH Drive Gear/sub-gear Alignment:

(b) Secure the exhaust camshaft sub-gear to the driven gear with a service bolt.

Recommended service bolt:
Thread diameter 6 mm
Thread pitch 1.0 mm
Bolt length 16 - 20 mm (0.63-0.79 in.)

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






(c) Set the timing mark (two dot marks) of the camshaft driven gear at approx. 15° angle by turning the exhaust camshaft with a wrench.





(d) Alternately loosen and remove the two bearing cap bolts holding the intake camshaft side of the oil feed pipe to the cylinder head.





(e) Uniformly loosen and remove the eight bearing cap bolts in several passes, in the sequence shown.
(f) Remove the oil feed pipe, four bearing caps and exhaust camshaft.


D. Remove intake camshaft of LH cylinder head






(a) Set the timing mark (one pointed mark) of the camshaft drive gear at approx. 60° angle by turning the intake camshaft with a wrench.





(b) Uniformly loosen and remove the eight bearing cap bolts in several passes, in the sequence shown.
(c) Remove the five bearing caps oil seal and intake camshaft.





NOTE: Arrange the bearing caps in correct order.



38. DISASSEMBLE EXHAUST CAMSHAFTS






(a) Mount the hexagonal wrench head portion of the camshaft in a vise.

NOTE: Be careful not to damage the camshaft.





(b) Insert a service bolt (A) into the service hole of the camshaft sub-gear.
(c) Using a screwdriver, turn the sub-gear clockwise, and remove the service bolt (B).

NOTE: Be careful not to damage the camshaft.






(d) Using snap ring pliers, remove the snap ring.





(e) Remove the following parts:

(1) Wave washer
(2) Camshaft subgear
(3) Camshaft gear spring





NOTE: Arrange the camshaft sub-gears and gear springs (RH side and LH side).



39. REMOVE CIRCULAR PLUGS





- Remove the two bolts, seal washers, bearing cap and circular plug. Remove the two circular plugs.





NOTE:Arrange the bearing caps (RH side and LH side).

40. REMOVE CYLINDER HEADS





(a) Disconnect the ground straps and clamps of the engine wire from the rear side of the cylinder heads.





(b) Uniformly loosen the ten cylinder head bolts on one side of each cylinder head in several passes in the sequence shown, then do the other side as shown. Remove the twenty cylinder head bolts and plate washers.

NOTE: Head warpage or cracking could result from removing bolts in an incorrect order.



(c) Lift the cylinder heads from the dowels on the cylinder block, and place the two cylinder heads on wooden blocks on a bench.





NOTE: If the cylinder head is difficult to lift off, pry between the cylinder head and cylinder block with a screwdriver.

NOTE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.