Removal and Replacement

CYLINDER HEAD











































REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

3. REMOVE HOOD SUB-ASSEMBLY
4. REMOVE FRONT WHEEL RH
5. REMOVE ENGINE UNDER COVER RH
6. REMOVE ENGINE UNDER COVER LH
7. REMOVE FRONT FENDER APRON SEAL RH
8. REMOVE NO. 1 ENGINE COVER SUB-ASSEMBLY
9. REMOVE FRONT WIPER ARM HEAD CAP
10. REMOVE FRONT WIPER ARM LH
11. REMOVE FRONT WIPER ARM RH
12. REMOVE HOOD TO COWL TOP SEAL
13. REMOVE COWL TOP VENTILATOR LOUVER LH
14. REMOVE WIPER LINK ASSEMBLY
15. REMOVE OUTER COWL TOP PANEL SUB-ASSEMBLY
16. REMOVE COWL BODY MOUNTING BRACKET LOWER LH
17. DRAIN ENGINE COOLANT
18. DRAIN ENGINE OIL
19. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
20. REMOVE THROTTLE BODY ASSEMBLY
21. REMOVE FUEL DELIVERY PIPE SUB-ASSEMBLY





22. REMOVE INTAKE MANIFOLD
(a) Disconnect the 2 water by-pass hoses from the throttle body.
(b) Remove the 5 bolts, 2 nuts, intake manifold and gasket.
23. REMOVE NO. 1 INTAKE MANIFOLD INSULATOR
24. REMOVE FRONT EXHAUST PIPE ASSEMBLY
25. REMOVE OIL DIPSTICK





26. REMOVE OIL DIPSTICK GUIDE
(a) Remove the bolt and guide.
(b) Remove the O-ring from the guide.





27. REMOVE MANIFOLD STAY
(a) Remove the bolt, nut and stay.





28. REMOVE NO. 2 MANIFOLD STAY
(a) Remove the bolt, nut and stay.





29. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
(a) Disconnect the air fuel ratio sensor connector.





(b) Remove the 3 bolts, nut and heat insulator.





30. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
(a) Remove the 5 nuts, manifold converter and gasket.
31. REMOVE FAN AND GENERATOR V BELT
32. REMOVE GENERATOR ASSEMBLY
33. REMOVE VANE PUMP ASSEMBLY
34. REMOVE ENGINE MOUNTING INSULATOR RH
35. REMOVE IGNITION COIL ASSEMBLY
36. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
37. REMOVE V-RIBBED BELT TENSIONER ASSEMBLY
38. REMOVE CRANKSHAFT POSITION SENSOR
39. REMOVE OIL PAN SUB-ASSEMBLY





40. SET NO. 1 CYLINDER TO TDC/COMPRESSION
(a) Turn the crankshaft pulley until its groove and the timing mark "0" of the timing chain cover are aligned.
(b) Check that each timing mark of the camshaft timing gears is aligned with each timing mark located on the No. 1 and No. 2 bearing caps as shown in the illustration.
If not, turn the crankshaft by 1 revolution (360°) to align the timing marks as above.





41. REMOVE NO. 2 CAMSHAFT
(a) Place paint marks on the chain and camshaft timing gears.





(b) Remove the bolt.
(c) Disconnect the wire harness protector clamp.





(d) Remove the 2 nuts, tensioner and gasket.





(e) While holding the camshaft with a wrench, loosen the camshaft timing set bolt.





(f) Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
(g) Remove the 5 bearing caps.





(h) While holding the No. 2 camshaft by hand, remove the camshaft timing sprocket set bolt.
(i) Remove the camshaft timing sprocket from the No. 2 camshaft with the timing chain wrapped on the sprocket.
(j) Remove the camshaft timing sprocket from the timing chain.





42. REMOVE CAMSHAFT
(a) Using several steps, uniformly loosen and remove the 10 bearing cap bolts in the sequence shown in the illustration.
(b) Remove the 5 bearing caps.
(c) Remove the camshaft and camshaft timing gear while holding the timing chain by hand.





(d) Tie the timing chain with a string as shown in the illustration.

NOTICE: Be careful not to drop anything inside the timing chain cover.

43. REMOVE CRANKSHAFT PULLEY
44. REMOVE TIMING CHAIN COVER SUB-ASSEMBLY
45. REMOVE NO. 1 CRANKSHAFT POSITION SENSOR PLATE
46. REMOVE TIMING CHAIN GUIDE
47. REMOVE CHAIN TENSIONER SLIPPER
48. REMOVE CHAIN SUB-ASSEMBLY
49. REMOVE NO. 1 CHAIN VIBRATION DAMPER
50. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY





51. REMOVE CAMSHAFT TIMING GEAR ASSEMBLY
(a) Clamp the camshaft in a vise, and make sure that the camshaft timing gear does not rotate.
(b) Cover all the oil ports with vinyl tape except the advance side port shown in the illustration.





(c) Apply air pressure of 100 kPa (1.0 kgf/cm2, 14 psi) to the oil path, then turn the camshaft timing gear to the advance direction (counterclockwise) by hand.

CAUTION: Cover the paths with a shop rag to avoid oil splashes.

HINT: Depending on the air pressure, the camshaft timing gear will turn to the advance angle side without applying force by hand. Also, under the condition that the pressure can hardly be applied because of air leakage from the port, there may be the case that the lock pin can hardly be released.





(d) Remove the flange bolt of the camshaft timing gear.

NOTICE:
^ Be sure not to remove the other 4 bolts.
^ When reusing the camshaft timing gear, release the straight pin lock first, then install the gear.





52. REMOVE NO. 2 CAMSHAFT BEARING
(a) Remove the camshaft bearing.





53. REMOVE CYLINDER HEAD SUB-ASSEMBLY
(a) Disconnect the radiator hose inlet.





(b) Disconnect the radio setting condenser connector.
(c) Disconnect the engine oil pressure switch connector.
(d) Disconnect the engine coolant temperature sensor connector.
(e) Disconnect the camshaft position sensor connector.
(f) Remove the bolt and ground cable.





(g) Using several steps, uniformly loosen and remove the 10 cylinder head bolts and 10 plate washers with a 10 mm bi-hexagon wrench in the sequence shown in the illustration.

NOTICE:
^ Be careful not to drop the plate washers into the cylinder head.
^ Head warpage or cracking could result from removing the bolts in the wrong order.

54. REMOVE CYLINDER HEAD GASKET