Removal and Disassembly

REMOVAL
1. Release fuel pressure.
2. Remove timing belt.
Refer to Timing Belt service procedures.








3. Drain coolant by removing drain plugs from both sides of cylinder block.





4. Separate ASCD and accelerator control wire from intake manifold collector.
5. Remove intake manifold collector from engine. The following parts should be disconnected to remove intake manifold collector.
a. Harness connectors for: IACV-AAC valve, Throttle position sensor, Throttle position switch, Ignition coil, Power transistor, EGRC-solenoid valve, and EGR temperature sensor.
b. Water hoses from collector
c. Heater hoses
d. PCV hose from RH rocker cover
e. Vacuum hoses for: EVAP canister, Master brake cylinder and Pressure regulator.
f. Purge hose from EVAP canister
g. EGR tube
h. Earth harnesses
i. Air duct hose





6. Remove fuel feed and fuel return hoses from injector fuel tube assembly.
7. Disconnect all injector harness connectors.
8. Remove injector fuel tube assembly.





9. Remove intake manifold from engine. The following parts should be disconnected to remove intake manifold.
a. Engine coolant temperature switch harness connector
b. Thermal transmitter harness connector
c. Water hose from thermostat housing





10. Remove both camshaft sprockets.
11. Remove rear timing belt cover.
12. Remove distributor and ignition wires.
After pulling out distributor from cylinder head, do not rotate distributor rotor.
13. Remove harness clamp from RH rocker cover.
14. Remove front exhaust tube from exhaust manifold.





15. Remove compressor and power steering pump.
16. Remove alternator.
17. Remove compressor and alternator bracket.





18. Remove both rocker covers.





19. Remove cylinder head with exhaust manifold.
- A warped or cracked cylinder head could result from removing in incorrect order.
- Cylinder head bolts should be loosened in two or three steps.

DISASSEMBLY

CAUTION:
- When installing sliding parts such as rocker arms, camshaft and oil seal, be sure to apply new engine oil on their sliding surfaces.
- When tightening cylinder head bolts and rocker shaft bolts, apply new engine oil to thread portions and seat surfaces of bolts.



- If hydraulic valve lifter is kept on its side, there is a risk of air entering it. After removal, always set hydraulic valve lifter straight up, or when laying it on its side, have it soak in new engine oil.
- Do not disassemble hydraulic valve lifter.
- Attach tags to valve lifters so as not to mix them up.





1. Remove exhaust manifolds from cylinder head.





2. Remove rocker shafts with rocker arms.
Bolts should be loosened in two or three steps.
3. Remove hydraulic valve lifters and lifter guide.
- Hold hydraulic valve lifters with wire so that they will not drop from lifter guide.
4. Remove oil seal and camshaft.
- Before removing camshaft, measure camshaft end play.





5. Remove valve components with Tool.
6. Remove valve oil seals with Tool or suitable tool.