Valve Cover: Service and Repair

REMOVAL

1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY

CAUTION:Work must be started after approx. 30 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.(w/Airbag)

2. DRAIN ENGINE COOLANT
3. DISCONNECT RADIATOR INLET HOSE

4. DISCONNECT ACCELERATOR CABLE
5. DISCONNECT THROTTLE CABLE
6. REMOVE AIR CLEANER CAP, VOLUME AIR FLOW METER AND AIR CLEANER HOSE

(a) Disconnect the volume air flow meter connector and clamp.
(b) Disconnect the accelerator cable clamp.
(c) Disconnect the PCV hose.
(d) Loosen the air cleaner hose clamp bolt.
(e) Disconnect the air cleaner cap clips.
(f) Remove the air cleaner cap and volume air flow meter together with the air cleaner hose.

7. REMOVE V-BANK COVER
- Using a 5 mm hexagon wrench, remove the two nuts and V-bank cover

8. REMOVE EMISSION CONTROL VALVE SET

(a) Disconnect the following vacuum hoses:

(1) Vacuum hose from fuel pressure control VSV
(2) Vacuum hose from fuel pressure regulator
(3) Vacuum hose from cylinder head rear plate
(4) Vacuum hose from intake air control valve VSV
(5) Vacuum hose from EGR vacuum modulator
(6) Vacuum hose from EGR valve

(b) Disconnect the following connectors:

(1) Intake air control valve connector
(2) Fuel pressure connector
(3) EGR VSV connector

(a) Disconnect the following hoses:

(1) Brake booster vacuum hose
(2) PCV hose
(3) Intake air control valve vacuum hose

(b) Disconnect the data link connector 1.
(c) Remove the nut and disconnect the 2 ground straps.

(d) Remove the bolt and disconnect the hydraulic motor pressure hose from the air intake chamber.
(e) Remove the bolt, and disconnect the ground strap.
(f) Disconnect the RH oxygen sensor connector clamp from the PS pressure tube.

(g) Remove the 2 nuts, and disconnect the PS pressure tube.
(h) Disconnect the 2 PS air hoses.

(i) Remove the 2 bolts and No.1 engine hanger.
(j) Remove the 2 bolts and air intake chamber stay.

(k) Remove the 4 nuts, EGR pipe and 2 gaskets.

(l) Disconnect the following connectors:

(1) Throttle position sensor connector
(2) IAC valve connector
(3) EGR gas temperature sensor connector
(4) A/C idle-up connector

(m) Disconnect the following vacuum hoses:

(1) 2 vacuum hoses from TVV
(2) Vacuum hose from cylinder head rear plate

(3) Vacuum hose from charcoal canister

(n) Disconnect the following hoses:

(1) 2 water bypass hoses
(2) Air assist hose

(o) Using an 8 mm hexagon wrench, remove the 2 bolts, 2 nuts, air intake chamber and gasket.

10. DISCONNECT ENGINE WIRE FROM ENGINE LH SIDE

(a) Disconnect the following connectors:

(1) 3 injector connectors
(2) 3 ignition coil connectors

(b) Remove the 2 nuts, and disconnect the engine wire.

11. DISCONNECT ENGINE WIRE FROM NO.3 TIMING BELT COVER
- Remove the bolt and 3 clamps. and disconnect the engine wire.

12. DISCONNECT ENGINE WIRE FROM ENGINE REAR SIDE

- Remove the 2 nuts, and disconnect the engine wire.

13. DISCONNECT ENGINE WIRE FROM ENGINE RH SIDE

(a) Disconnect the following connectors:

(1) 3 injector connectors
(2) 3 ignition coil connectors

(b) Remove the 5 nuts, and disconnect the engine wire.

14. REMOVE IGNITION COILS

- Remove the 6 bolts and 6 ignition coils from the RH and LH cylinder heads.

HINT: Arrange the ignition coils in the correct order.

15. REMOVE SPARK PLUGS

- Using a 16 mm plug wrench, remove the 6 spark plugs from the RH and LH cylinder heads.

16. REMOVE CYLINDER HEAD COVERS

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

INSTALL

1. REVERSE PROCEDURE TO INSTALL NOTING THE FOLLOWING TORQUE AND PROCEDURES:
2. REINSTALL CYLINDER HEAD COVERS

(a) Apply seal packing to the cylinder heads as shown in the illustration. Seal packing:Part No.08826-00080 or equivalent
(b) Install the gasket to the cylinder head cover.
(c) Install the cylinder head cover with the eight bolts. Uniformly tighten the nuts in several passes. Install the two cylinder head covers.

Torque: 8 N.m (80 kgf.cm. 69 in.lb)

3. REINSTALL SPARK PLUGS

Torque: 18 N.m (180 kgf.cm. 13 ft.lb)

4. REINSTALL IGNITION COILS

Torque: 8 N.m (80 kgf.cm. 69 in.lb)

5. REINSTALL AIR INTAKE CHAMBER

(a) Using 8 mm hexagon wrench, install a new gasket and the air intake chamber with the two bolts and nuts.

Torque: 43 N.m (440 kgf.cm, 32 ft.lb)

4. REINSTALL EGR PIPE
- Install 2 new gaskets and the EGR pipe with the four nuts.

Bolt Torque: 12 N.m (120 kgf.cm. 9 ft.lb)

5. REINSTALL NO.1 ENGINE HANGER AND AIR INTAKE CHAMBER STAY

(a) Install the air intake chamber stay with the two bolts.

Torque: 19.5 N.m (200 kgf.cm. 14 ft.lb)

(b) Install the No.1 engine hanger with the two bolts.

Torque: 39 N.m (400 kgf.cm, 29 ft.lb)