Removal

REMOVE TIMING BELT
1. Disconnect timing belt from Camshaft Timing Pulleys.
2. Remove Camshaft timing pulleys as described under Camshaft, Lifters and Push Rods.

REMOVE AIR INTAKE CHAMBER AND INTAKE MANIFOLD
1. Disconnect the Power Steering (PS) air hose from the air intake chamber.




2. Remove the three bolts and the nut, then disconnect the PS pump from the engine.
3. Disconnect front exhaust pipe from front Three-Way Catalytic Converter (TWC) as follows:



(a) Remove the four bolts and four nuts holding the front exhaust pipe to the TWC.
(b) Disconnect the front exhaust pipe from the two TWC, and remove the two gaskets.
(c) Remove the two bolts and pipe support bracket.




4. Remove the three front TWC nuts, then the TWC and gasket from both sides.
5. Remove high-tension cords (spark plug wires), cord clamps and cord cover assembly as follows:



(a) Disconnect the No.2 high-tension cord from the cord clamp on the RH front high-tension cord clamp.
(b) Remove the two bolts holding the RH high-tension cord clamps to the RH cylinder head cover.



(c) Disconnect the No.1 high-tension cord from the cord clamp on the LH front high-tension cord clamp.
(d) Remove the two bolts holding the LH high-tension cord clamps to the LH cylinder head cover.



(e) Remove the stud bolt holding the lower high-tension cord cover to the No.2 ignition coil.
(f) Disconnect the high-tension cords from the spark plugs, distributor caps and No.2 ignition coil.
NOTE: Pulling on or bending the cords may damage the conductor inside.
(g) Remove the high-tension cords, cord clamps and cord cover assembly.

6. Disconnect the No. two ignition coil connector, then remove the two bolts and ignition coil.
7. Remove the two timing belt rear plate bolts and rear plate, for both plates.

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

8. Remove air intake chamber assembly as follows:
(a) Disconnect the following cables:
- Accelerator cable.
- A/T throttle control cable.
- Cruise control actuator cable.
(b) Remove the two bolts and accelerator bracket.
(c) Disconnect the following connectors:
- Throttle position sensor connector with Traction Control System (TRAC).
- Sub-throttle position sensor connector (with TRAC).
- Sub-throttle actuator connector Idle Air Control (IAC) valve connector.
- EGR valve connector.
- EGR gas temperature sensor connector.
- Vacuum Switching Valve (VSV) for fuel pressure control connector.
- VSV for EVAP connector.




(d) Disconnect the following hoses shown in the illustration:
- Brake booster vacuum hose (1) from union on air intake chamber.
- Positive Crankcase Ventilation (PCV) hose (2) from PCV valve on LH cylinder head.
- EGR valve water bypass hose (3) from rear water bypass joint.
- Throttle body water bypass hose (4) from rear water bypass joint.
- Vacuum hose (5) for VSV for fuel pressure control from fuel pressure regulator.
- Charcoal canister EVAP hose (6) from VSV for EVAP.
(e) Disconnect the heater hose from the water bypass pipe.



(f) Remove the two bolts, two nuts, No.2 EGR pipe and two gaskets.



(g) Remove the four bolts and eight nuts from the air intake chamber.



(h) Disconnect the following hoses shown in the illustration, then remove the air intake chamber assembly and gaskets:
- RH cylinder head PCV hose (1) to throttle body.
- IAC valve water bypass hose (2) to water inlet housing.

9. Disconnect fuel inlet hose from delivery pipe, refer to Powertrain Management.
10. Disconnect fuel return hose from fuel return pipe.
11. Disconnect engine wireing and cables from fuel delivery pipes and rear water bypass joint as follows:
(a) Disconnect the A/T throttle cable from the clamps on the engine hanger and engine wire protector.



(b) Disconnect the following connectors and clamp as shown in the illustration:
- Diagnostic Link Connector 1 (DLC1) (1) from connector bracket on LH delivery pipe.
- The two engine wire connectors (2) from connector bracket on LH delivery pipe.
- Engine wire clamp (3) from wire bracket on LH delivery pipe.



(c) Remove the two bolts, and disconnect the engine wire protector from the RH delivery pipe.
(d) Remove the two bolts, and disconnect the engine wire protector from the water bypass joint.

12. Disconnect the fuel hose from the fuel pressure regulator, then remove the two bolts and fuel return pipe.

13. Remove intake manifold assembly as follows:



(a) Disconnect the eight injector connectors.
(b) Remove the six bolts, four nuts, the intake manifold assembly and two gaskets.

REMOVE WATER MANIFOLDS
1. Remove water inlet and inlet housing assembly as follows:



(a) Remove the two bolts holding the water inlet housing to the water pump.
(b) Disconnect the IAC valve water bypass hose from the water inlet housing, then remove the water inlet and inlet housing assembly housing.
(c) Remove the O-ring from the water inlet housing.

2. Remove front water bypass joint as follows:



(a) Disconnect these connectors as shown in the illustration:
- Engine Coolant Temperature (ECT) sensor connector.
- ECT sender gauge connector.
(b) Remove the bolt, and disconnect the engine wire protector from the water bypass joint.



(c) Remove the four nuts, water bypass joint and two gaskets.

3. Remove rear water bypass joint and No.1 EGR pipe assembly as follows:
(a) Remove the two bolts, nut and RH heat insulator (for the RH front side of the front exhaust pipe).
(b) Remove the two bolts and RH heat insulator (for the RH front TWC).



(c) Remove the two nuts holding the EGR pipe to the RH exhaust manifold.
(d) Disconnect the heater hose from the water bypass joint.



(e) Remove the four nuts, the water bypass assembly and two gaskets.

REMOVE CYLINDER HEAD COVERS
1. Remove oil dipstick and guide for A/T as follows:



(a) Remove the bolt.
(b) Pull out dipstick guide and dipstick from the port of the transmission.
(c) Remove the O-ring from the dipstick guide.

2. Remove oil dipstick and guide for the engine as follows:



(a) Remove the bolt holding the dipstick tube to the LH cylinder head.
(b) Pull dipstick tube and dipstick from oil pan.
(c) Remove the O-ring from the dipstick tube.

3. Remove engine hangers.



4. Remove the eight cylinder head cover bolts, eight seal washers, then the cover and gasket from both sides.
5. If necessary, remove semi-circular plugs.

REMOVE CAMSHAFTS

CAUTION:
- Since the thrust clearance of the camshaft is small, the camshaft must be kept 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 check that the timing mark of the crankshaft pulley is in aligned with the centers of the crankshaft pulley bolt and the idler pulley bolt.
- Having the crankshaft pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when you remove the camshaft, causing damage. So always set the crankshaft pulley at the correct angle.


1. Remove RH exhaust camshaft as follows:



(a) Bring the service bolt hole of the sub-gear upward by turning the hexagon wrench head portion of the exhaust camshaft with a wrench.
(b) Secure the sub-gear to the main gear with a service bolt.
Recommended service bolt:
Thread diameter 6 mm
Thread pitch 1.0 mm
Bolt length 16-20 mm

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




(c) Set the timing mark (1 dot mark) of the camshaft main gear at approx. 10° angle by turning the hexagon wrench head portion of 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.

2. Remove RH intake camshaft as follows:



(a) Remove the rear bearing cap.
(b) Set the timing mark (1 dot mark) of the camshaft drive gear at approx. 45° angle by turning the hexagon wrench head portion of the intake camshaft with a wrench.



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

3. Remove LH exhaust camshaft as follows:



(a) Bring the service bolt hole of the sub-gear upward by turning the hexagon wrench head portion of the exhaust camshaft with a wrench.
(b) Secure the sub-gear to the main gear with a service bolt.
Recommended service bolt:
Thread diameter: 6 mm
Thread pitch: 1.0 mm
Bolt length: 16 - 20 mm

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




(c) Set the timing mark (2 dot marks) of the camshaft drive gear at approx. 15° angle by turning the hexagon wrench head portion of 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.

4. Remove LH intake camshaft as follows:



(a) Remove the bearing cap second from the front.
(b) Set the timing mark (1 dot mark) of the camshaft drive gear at approx. 60° angle by turning the hexagon wrench head portion of the intake camshaft with a wrench.



(c) Uniformly loosen and remove the eight bearing cap bolts in several passes, in the sequence shown.
(d) Remove the four bearing caps, oil seal and intake camshaft.
NOTE: Arrange the bearing caps in correct order.