Removal

CYLINDER HEAD COMPONENTS FOR REMOVAL AND INSTALLATION

CYLINDER HEADS REMOVAL

1. Remove battery and tray.
2. drain engine coolant.
3. Disconnect accelerator cable.
4. Disconnect A/T throttle cable.
5. Remove air cleaner cap assembly.
(a) Disconnect the MAF meter connector and wire clamp.





(b) Disconnect the air hose from air cleaner cap.
(c) Disconnect the accelerator cable clamp.
(d) Disconnect the PCV hose.
(e) Loosen the air cleaner hose clamp bolt.
(f) Disconnect the 4 air cleaner cap clips.
(g) Remove the air cleaner cap and MAF meter together with the air cleaner hose.

6. With cruise control system
Remove cruise control actuator.

7. Disconnect ground straps
Disconnect the 2 straps.

8. Remove right hand engine mounting stay
Remove the 3 bolts and Right hand engine mounting stay.

9. Disconnect radiator hoses.
10. Disconnect heater hoses
Disconnect the 2 hoses.

11. Disconnect fuel hoses
Disconnect the fuel inlet and return hoses.

CAUTION: Catch leaking fuel in a container.

12. Disconnect pressure hose of hydraulic motor
Remove the bolt, and disconnect the pressure hose from the water inlet.

13. Remove V-bank cover
Using a 5 mm hexagon wrench, remove the 2 nuts and V-bank cover.





14. Remove emission control valve set.

(a) Disconnect these vacuum hoses:





(1) Vacuum hose from VSV for fuel pressure control.
(2) Vacuum hose from fuel pressure regulator.
(3) Vacuum hose from cylinder head rear plate.
(4) Vacuum hose from VSV for ACIS.
(5) Vacuum hose from EGR vacuum modulator.
(6) Vacuum hose from EGR valve.
(7) Vacuum hose from air intake chamber.
(8) Vacuum hose from charcoal canister.

(b) Disconnect these connectors:





(1) VSV connector for ACIS
(2) VSV connector for fuel pressure control
(3) VSV connector for EGR
(4) VSV connector for EVAP

(c) Remove the 2 nuts and emission control valve set.

15. High-tension cord cover and high-tension cords from air intake chamber

(a) Remove the high-tension cord cover and holder grommet.
(b) Remove the high-tension cords.

16. Remove air intake chamber:

(a) Disconnect the brake booster vacuum hose.
(b) Disconnect the PCV hose.
(c) Disconnect the DLC1.
(d) Remove the nut, and disconnect the 2 ground straps.
(e) Remove the bolt, and disconnect the hydraulic motor pressure hose from the air intake chamber.
(f) Remove the bolt, and disconnect the ground strap.
(g) Remove the 2 nuts, and disconnect the PS pressure tube.
(h) Remove the 2 bolts and No.1 engine hanger.
(i) Remove the 2 bolts and air intake chamber stay.
(j) Remove the 4 nuts, No.2 EGR pipe and 2 gaskets.
(k) Disconnect the 2 water bypass hoses.
(l) Disconnect the air assist hose.
(m) Using an 8 mm hexagon wrench, remove the 2 bolts. 2 nuts, air intake chamber and gasket.

17. Remove intake air control valve from air intake chamber:

(a) Remove the 3 nuts and DLC1 clamp.
(b) Remove the intake air control valve by prying a screwdriver between the intake air control valve and air intake chamber.
(c) Remove the gasket.

18. Remove throttle body from air intake chamber
Remove the 2 bolts, 2 nuts, throttle body and gasket.





19. Remove EGR valve and vacuum modulator from air intake chamber
Remove the 3 nuts, EGR valve, vacuum modulator and gasket.

20. Disconnect engine wire from engine left hand side
Remove the 2 nuts, and disconnect the engine wire.

21. Disconnect engine wire from no.3 timing belt cover
Disconnect the 2 clamps and engine wire.

22. Disconnect engine wire from engine rear side
Remove the 2 nuts, and disconnect the engine wire.

23. Disconnect engine wire from engine left hand side
Remove the 5 nuts, and disconnect the engine wire.

24. Remove ignition coils





Remove the 3 bolts and 3 ignition coils from the Left hand cylinder head.

25. Remove spark plugs.
26. Remove front exhaust pipe.





(a) Remove the 2 bolts and stay.
(b) Remove the 2 bolts, and disconnect the bracket.
(c) Remove the 2 bolts and 2 nuts holding the front exhaust pipe to the center exhaust pipe.
(d) Remove the 4 nuts holding the front exhaust pipe to the exhaust manifolds.
(e) Remove the front exhaust pipe and 3 gaskets.

27. Remove timing belt
28. Remove camshaft timing pulleys
29. Remove no.2 idler pulley
30. Remove no.3 timing belt cover
Remove the 6 bolts and belt cover.

31. Remove cylinder head rear plate





(a) Disconnect the vacuum hose from the vacuum tank.
(b) Remove the nut, and disconnect the ground strap.
(c) Remove the bolt and rear plate.

32. Remove water inlet pipe
(a) Remove the bolt and inlet pipe.
(b) Remove the 0-ring.

33. Remove air assist hose and vacuum hose





34. Remove intake manifold, delivery pipes and injectors





Remove the 2 bolts, 2 nuts, 2 plate washers and intake manifold together with the delivery pipes, and injectors.

35. Remove fuel pressure regulator from left hand delivery pipe
Remove the 0-ring from the pressure regulator.

36. Remove fuel pulsation damper and no.1 fuel pipe
Remove the bolt, pulsation damper, No.1 fuel pipe and 2 gaskets.

37. Remove no.2 fuel pipe
Remove the 2 union bolts, No.2 fuel pipe and 4 gaskets.

38. Remove delivery pipes and injectors





(a) Remove the 4 bolts, delivery pipes together with the 6 injectors.

NOTE: Be careful not to drop the injectors when removing the delivery pipes.

(b) Remove the 4 spacers from the intake manifold.
(c) Pull out the 6 injectors from the delivery pipes. Remove the 0-ring and grommet from each injector.

39. Remove water outlet
(a) Remove the 2 bolts, 2 nuts and 2 plate washers.
(b) Disconnect the water bypass hose and remove the water outlet.
(c) Remove the 2 intake manifold gaskets.

40. Remove left hand exhaust manifold
(a) Remove the bolt, two nuts and heat insulator.
(b) Remove the six nuts, exhaust manifold and gasket.
(c) Remove the heated oxygen sensor.
(d) Remove the bolt, nut and exhaust manifold stay.
(e) Remove the 6 nuts, exhaust manifold and gasket.

41. Remove oil dipstick and guide
(a) Remove the bolt holding the dipstick guide to the Left hand cylinder head.
(b) Pull out the dipstick guide together with the dipstick from the No.1 oil pan.
(c) Remove 0-ring from the dipstick guide.

42. Remove ps bracket
Remove the 3 bolts and PS bracket.

43. Remove right hand exhaust manifold
(a) Remove the three nuts and heat insulator.
(b) Remove the six nuts, exhaust manifold and gasket.
(c) Remove the heated oxygen sensor.
(d) Remove the 4 nuts, No.1 EGR pipe and 2 gaskets.
(e) Remove the bolt, nut and exhaust manifold stay.
(f) Remove the 6 nuts, exhaust manifold and gasket.

44. Remove cylinder head covers
Remove the 8 bolts, cylinder head cover and gasket. Remove the 2 cylinder head covers.

45. Remove camshaft position sensor.
46. 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 intake camshaft of Right hand cylinder head
(a) Align the timing marks (2 dot marks) of the camshaft drive and driven gears by turning the camshaft with a wrench.





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





Recommended service bolt:
Thread diameter 6 mm Thread pitch 1.0 mm
Bolt length 16 - 20 mm

HINT: When removing the camshaft, mark certain that the torsional spring force of the sub-gear has been eliminated by the above operation.

(c) Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown.





(d) Remove the 5 bearing caps and intake camshaft.

B. Remove exhaust camshaft of right hand cylinder head
(a) Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown.





(b) Remove the 5 bearing caps, oil seal and exhaust camshaft.

C. Remove intake camshaft of Left hand cylinder head
(a) Align the timing marks (1 dot mark) of the camshaft drive and driven gears by turning the camshaft with a wrench.





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





Recommended service bolt:
Thread diameter 6 mm
Thread pitch 1.0 mm
Bolt length 16 - 20 mm

HINT: When removing the camshaft, make sure that the torsional spring force of the sub-gear has been eliminated by the above operation.

(c) Uniformly loosen and remove the 10 bearing cap bolts. in several passes. in the sequence shown.





(d) Remove the 5 bearing caps and intake camshaft.

D. Remove exhaust camshaft of Left hand cylinder head
(a) Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown.





(b) Remove the 5 bearing caps, oil seal and exhaust camshaft.

HINT:
- Arrange the camshafts in the correct order.
- Arrange the bearing caps in the correct order.

47. 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) Using SST, turn the sub-gear counterclockwise and remove the service bolt.





SST 09960-10010 (09962-01000, 09963-00500)

(c) Using snap ring pliers, remove the snap ring.





(d) Remove these parts:

- Wave washer
- Camshaft sub-gear
- Camshaft gear spring

HINT: Arrange the camshaft sub-gears and gear springs (Right hand and Left hand side).

48. Remove cylinder heads

(a) Using an 8 mm hexagon wrench, remove the cylinder head (recessed head) bolt on each cylinder head, then repeat for the other side, as shown.





(b) Uniformly loosen and remove the 8 cylinder head (12 pointed head) bolts on each cylinder head, in several passes, in the sequence shown, then repeat for the other side, as shown. Remove the 16 cylinder head bolts and plate washers.





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 2 cylinder heads on wooden blocks on a bench.





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

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