Removal

REMOVAL OF CYLINDER HEADS

1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY

CAUTION: Work must be started after approx. 20 seconds or longer from the time the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery.

2. DRAIN ENGINE COOLANT
3. REMOVE SUSPENSION UPPER BRACE
4. DISCONNECT THROTTLE CABLE FROM THROTTLE BODY (A/T)
5. DISCONNECT ACCELERATOR CABLE FROM THROTTLE BODY
6. REMOVE CRUISE CONTROL ACTUATOR AND VACUUM PUMP
7. REMOVE AIR CLEANER HOSE

(a) Disconnect the following hoses:

(1) ISC valve air hose
(2) Vacuum pipe hose

(b) Remove the air cleaner hose.

8. REMOVE ENGINE RH UNDER COVER
9. REMOVE SUSPENSION LOWER CROSSMEMBER
10. REMOVE FRONT EXHAUST PIPE
11. REMOVE ALTERNATOR
12. REMOVE ISC VALVE
13. REMOVE THROTTLE BODY
14. REMOVE EGR PIPE

(a) Loosen the union nut.
(b) Remove the two bolts, EGR pipe and gasket.

15. REMOVE EGR VALVE AND VACUUM MODULATOR

(a) Disconnect the four vacuum pipe hoses.
(b) Remove the two bolts, two nuts, the EGR valve, vacuum modulator assembly and gasket.

16. REMOVE VACUUM PIPE

(a) Disconnect the following hoses:

(1) Four BVSV vacuum hoses
(2) Fuel Pressure VSV hose
(3) A/C control valve vacuum hose

(b) Remove the two bolts and vacuum pipe.

17. REMOVE DISTRIBUTOR

18. REMOVE EXHAUST CROSSOVER PIPE

- Remove the six nuts, two bolts, crossover pipe and two gaskets.

19. DISCONNECT COLD START INJECTOR CONNECTOR
20. REMOVE COLD START INJECTOR TUBE
21. REMOVE AIR INTAKE CHAMBER

(a) Disconnect the following hoses:

(1) PCV hose
(2) Vacuum sensing hose
(3) Fuel pressure VSV hose
(4) A/C control valve vacuum hose
(5) EGR gas temperature sensor connector(CALIF. only)

Fig. 10 Intake Manifold Removal:

(b) Remove the four bolts and two intake chamber stays.
(c) Remove the two bolts, two nuts, intake chamber and two gaskets.

22. REMOVE DELIVERY PIPES AND INJECTORS
23. REMOVE WATER OUTLET

(a) Disconnect the following connector and hose:

(1) Water temperature switch connector
(2) Radiator upper hose

(b) Remove the three nuts, water outlet and gasket.

24. REMOVE WATER BY-PASS OUTLET

(a) Disconnect the following connectors and hose:

(1) Cold start injector time switch connector
(2) Water temperature sensor connector
(3) Heater water by-pass hose

(b) Remove the three nuts, water by-pass outlet and gasket.
(c) Remove the two bolts and crossover pipe heat insulator from the water by-pass outlet.

25. REMOVE CYLINDER HEAD REAR PLATE

- Remove the two bolts and rear plate.

26. REMOVE INTAKE MANIFOLD

(a) Remove the two bolts and No.2 idler pulley bracket stay.

(b) Remove the eight bolts, four nuts, intake manifold and two gaskets.

27. REMOVE RH EXHAUST MANIFOLD

(a) Disconnect the main oxygen sensor connector.

(b) Remove the three nuts and outside heat insulator.

(d) Remove the bolt and inside heat insulator.

28. REMOVE LH EXHAUST MANIFOLD

(a) Remove the two nuts and heat insulator.

(b) Remove the six nuts, exhaust manifold and gasket.

29. REMOVE SPARK PLUGS
30. REMOVE TIMING BELT, CAMSHAFT TIMING PULLEYS AND NO.2 IDLER PULLEY Service and Repair
31. REMOVE NO.3 TIMING BELT COVER

- Remove the six bolts and timing 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 of the timing belt cover.
- Do not allow the belt to come into contact with oil, water or dust.

32. REMOVE CYLINDER HEAD COVERS

- Remove the six nuts, seal washers, cylinder head cover and gasket. Remove the two cylinder head covers.

33. REMOVE SPARK PLUG TUBE GASKETS
- Remove the six tube gaskets.

34. REMOVE CAMSHAFTS

NOTE: Since the thrust clearance of the camshaft is small, the camshaft must be held 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, the following steps should be carried out.

A. Remove exhaust camshaft of RH cylinder head

Fig. 11 Cam Timing Locations:

(a) Align the timing marks (two pointed marks) of the camshaft drive and driven gears by turning the camshaft with a wrench.

Fig. 12 Cam Sub-gear Location:

(b) Secure the exhaust camshaft sub-gear to the driven gear with a service bolt. Recommended service bolt:

Thread diameter 6 mm
Thread pitch 1.0 mm
Bolt length 1 6 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.

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

B. Remove intake camshaft of RH cylinder head

(a) Uniformly loosen and remove the ten bearing cap bolts in several passes in the sequence shown.
(b) Remove the five bearing caps, oil seal and intake camshaft.

C. Remove exhaust camshaft of LH cylinder head

(a) Align the timing marks (one pointed mark) of the camshaft drive and driven gears by turning the camshaft with a wrench.

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

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

D. Remove intake camshaft of LH cylinder head

(a) Uniformly loosen and remove the ten bearing cap bolts in several passes in the sequence shown.
(b) Remove the five bearing caps, oil seal and intake camshaft.

NOTE: Arrange the bearing caps in correct order.

35. DISASSEMBLE EXHAUST CAMSHAFTS

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

NOTE: Be careful not to damage the camshaft.

(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).

NOTE: 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

NOTE: Arrange the camshaft sub-gears and gear springs (RH and LH).

36. REMOVE CYLINDER HEADS

(a) Using a 8 mm hexagon wrench, remove the cylinder head (recessed head) bolts.

(b) Uniformly loosen and remove the cylinder head (12 pointed head) bolts in several passes in the sequence shown.

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

(c) Lift the cylinder head from the dowels on the cylinder block and place the two cylinder heads 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 cylinder block.

- Be careful not to damage the contact surfaces of the cylinder head and cylinder block.