Cylinder Head Removal

REMOVAL

1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY
2. DRAIN ENGINE COOLANT
3. (A/T)
DISCONNECT THROTTLE CABLE AND BRACKET FROM THROTTLE BODY
4. DISCONNECT ACCELERATOR CABLE AND BRACKET FROM THROTTLE BODY AND AIR INTAKE CHAMBER
5. REMOVE CRUISE CONTROL ACTUATOR AND BRACKET
6. REMOVE AIR CLEANER HOSE
7. REMOVE ALTERNATOR
8. REMOVE OIL PRESSURE GAUGE, ENGINE HANGERS AND ALTERNATOR UPPER BRACKET
9. RAISE VEHICLE

CAUTION: Be sure the vehicle 18 securely supported.

10. REMOVE RH FRONT WHEEL
11. REMOVE ENGINE RH UNDER COVER
12. REMOVE SUSPENSION LOWER CROSSMEMBER
13. DISCONNECT EXHAUST PIPE FROM CATALYTIC CONVERTER
14. REMOVE EXHAUST MANIFOLD AND CATALYTIC CONVERTER ASSEMBLY

(a) Disconnect the oxygen sensor connector.
(b) Remove the six bolts and manifold upper heat insulator.

(d) Remove the six nuts, the exhaust manifold and catalytic converter assembly.
15. SEPARATE EXHAUST MANIFOLD AND CATALYTIC CONVERTER

Remove the following parts:
(1) Five bolts
(2) Manifold lower heat insulator
(3) Eight bolts
(4) Two catalytic converter heat insulators

(5) Three bolts and two nuts
(6) Exhaust manifold
(7) Gasket
(8) Retainer
(9) Cushion
(10) Catalytic converter
16. REMOVE DISTRIBUTOR
17. REMOVE WATER OUTLET

(a) Disconnect the following connectors and hoses:
(1) Water temperature sender gauge connector
(2) Water temperature sensor connector
(3) Cold start injector time switch connector
(4) Radiator upper hose
(5) Water hoses
(6) Emission control vacuum hoses
(b) Remove the two bolts, water outlet and gasket.
18. REMOVE WATER BY-PASS PIPE

(a) Disconnect the water hoses.
(b) Remove the two bolts, two nuts, water by-pass pipe, gasket and 0-ring.
19. REMOVE EXHAUST GAS RECIRCULATION (EGR) VALVE AND MODULATOR

(a) Remove the vacuum hoses.
(b) Loosen the union nut of the EGR pipe, and remove two bolts, EGR modulator and gasket.
(c) Remove the bolt and EGR valve.
20. REMOVE THROTTLE BODY
21. REMOVE COLD START INJECTOR PIPE
22. REMOVE AIR TUBE

(a) Disconnect the following air hoses:
(1) Air intake chamber air hose
(2) Throttle body air hose
(3) (w/ PS) PS pump air hoses
(b) Remove the two bolts and air tube.
23. REMOVE INTAKE MANIFOLD

(a) Remove the two bolts and manifold stay.

(b) Disconnect the vacuum sensing hose.
(c) Remove the six bolts, two nuts, intake manifold and gasket.
24. REMOVE DELIVERY PIPE AND INJECTORS
25. REMOVE SPARK PLUGS
26. REMOVE CAMSHAFT TIMING PULLEY
27. REMOVE NO.1 IDLER PULLEY AND TENSION SPRING
28. REMOVE NO.3 TIMING BELT COVER

Remove the four bolts and belt cover.

NOTE:
- Support the belt so the meshing of the crankshaft timing pulley and timing belt does not shift.
- Be careful not to drop anything inside the timing belt cover.
- Do not allow the belt to come into contact with oil, water or dust.

29. REMOVE CYLINDER HEAD COVER

Remove the four nuts, grommets, head cover and gasket

NOTE: Arrange the grommets in correct order, so that they can be reinstalled into their original positions. This minimizes any possibility of oil leakage due to reuse of grommets.

30. REMOVE INTAKE AND EXHAUST CAMSHAFTS

NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be help level while it is being removed. To assist you in this, the following steps should be carried out. Should the camshaft be removed without being kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, due do the camshaft catching in this portion of the cylinder head, causing it seize or break.

A. Remove exhaust camshaft

(a) Set the knock pin of the intake camshaft at 10-45 ° BTDC of camshaft angle.

NOTE: The above angle helps to lift the exhaust camshaft level and evenly by pushing No.2 and No.4 cylinder cam lobes of the exhaust camshaft to their valve lifters.

(b) Secure the exhaust camshaft sub-gear to main 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.

(e) Uniformly loosen and remove bearing cap bolts 3 to 8 in several passes, in the sequence shown.

NOTE: Do not remove the No.3 bearing cap bolts at this stage.

(f) Remove the No.1, No.2 and No.4 bearing cap.

(g) Alternately loosen and remove No.3 bearing cap bolts 9 and 10.

NOTE:

- As bearing cap bolts 9 and 10 are loosened, check that the camshaft is being lifted out straight and level.
- If the camshaft is not being lifted out straight and level, tighten bearing cap bolts 9 and 10. Then reverse the order of above steps from (f) to (a) and reset the knock pin of the intake camshaft at 10-45° BTDC, and repeat the steps from (b) and (g) once again.

CAUTION: Do not pry on or attempt to force the camshaft with a tool or other object.

(h) Remove the No.3 bearing cap and exhaust camshaft.
B. Remove intake camshaft

(a) Set the knock pin of the intake camshaft at 80-115 ° BTDC of camshaft angle.

NOTE: The above angle allows No.1 and No.3 cylinder cam lobes of the intake camshaft to push their valve lifters evenly.

(b) Remove the front bearing cap bolts 1 and 2.
(C) Remove the front bearing cap and oil seal.

CAUTION: If the front bearing cap is not removable hand, do not try to remove by force but leave as it without bolts.

(d) Uniformly loosen and remove bearing cap bolts 3 to 8 in several pass, in the sequence shown.

NOTE: Do not remove the No.2 bearing cap bolts at this stage.

(e) Remove the No.1, No.3 and No.4 bearing caps.

(f) Alternately loosen and remove No.2 bearing cap bolts 9 and 10.

NOTE:
- As bearing cap bolts 9 and 1O are loosened, check that the camshaft is being lifted out straight and level, after breaking adhesion on the front bearing cap.

- If the camshaft is not being lifted out straight and level, retighten bearing cap bolts 9 and 10. Reverse the order of above steps from (f) to (a) and reset the knock pin of the intake camshaft at 80-115° BTDC, and repeat steps from (b) to (f) once again.

CAUTION: Do not pry on or attempt to force the camshaft with a tool or other object.

(g) Remove the No.2 bearing cap and camshaft.
31. DISASSEMBLE EXHAUST CAMSHAFT

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

(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).

CAUTION: 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 sub-gear
(3) Camshaft gear spring
32. IF NECESSARY, REMOVE SPARK PLUG TUBES
Using a pipe wrench, remove the four spark tubes.
33. REMOVE CYLINDER HEAD

(a) Using SST, uniformly loosen and remove the ten cylinder head bolts in several passes, in the sequence shown.

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

(b) Lift the cylinder head from the dowels on the cylinder block and place the head on wooden blocks on a bench.

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

CAUTION: Be careful not to damage the cylinder head and cylinder block surfaces of cylinder head gasket side.