FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
Courtesy of Operation CHARM: Car repair manuals for everyone.

Removal and Disassembly






REMOVAL
1. Release fuel pressure.
2. Drain coolant from radiator and drain plug of block.
3. Remove the following parts.
- Power steering drive belt.
- Power steering pump, idler pulley and power steering brackets.
- Vacuum hoses of swirl control valve and pressure control solenoid valve.
- Accelerator wire bracket.
4. Disconnect EGR tube from exhaust manifold.
5. Remove bolts which hold intake manifold collector to intake manifold.
6. Remove bolts which hold intake manifold to cylinder head while raising collector upwards.
7. Remove rocker cover.

NOTE: When removing rocker cover, do not hit rocker cover against rocker arm.





8. Set No. 1 piston at TDC on its compression stroke.





NOTE: Make sure No. 1 cylinder is at TDC by looking at the distributor rotor position.





9. Loosen the camshaft sprocket bolt and support the timing chain by using the chain stopper tool No. KV10105800, or equivalent, as shown in figure.





10. Remove camshaft sprocket

NOTE: For retiming during installation, apply paint marks to timing chain at mating marks of crankshaft sprocket and camshaft sprocket.





11. Remove front timing cover to cylinder head bolts.

Loosening Sequence:





12. In numerical order, loosen cylinder head bolts in two or three steps and remove cylinder head.

CAUTION: A warped or cracked cylinder head could result from removing bolts in an incorrect order.

DISASSEMBLY
1. Remove rocker shaft assembly.

Loosening Sequence:





NOTE:
- Evenly loosen as shown in figure.
- Bolts should be loosened in two or three steps.








CAUTION:
- Hydraulic valve lifters are installed in each rocker arm. If hydraulic valve lifter is kept on its side, even when installed in rocker arm, there is a risk of air entering it. When rocker arms are removed, stand them straight up or soak them in new engine oil.
- Do not disassemble hydraulic valve lifter.
- Attach tags to valve lifters so as not to mix them up.

2. Measure camshaft end play, then remove camshaft.





3. Remove valve components with the valve spring compressor tool No. KV10109210, or equivalent.
4. Remove valve oil seals.