Removal

REMOVAL
1. Remove engine RH fender apron seal.
2. Drain engine coolant.
3. Remove air cleaner cap assembly and air filter.
4. Remove front exhaust pipe.
5. Remove RH engine mounting stay.
6. Remove V-Bank cover.
a. Using a 5 mm hexagon wrench, remove the 2 nuts.





b. Disconnect the 2 clips, and remove the cover.
7. Remove high-tension cord set.
8. Remove air intake chamber assembly.
a. Disconnect these cables and connectors:
- Accelerator cable
- A/T throttle cable
- Throttle position sensor connector
- A/C valve connector
- EGR gas temperature sensor connector
- EGR valve position sensor connector
- Vacuum Control Valve (VSV) connector for Acoustic Control Induction System (ACIS)
- VSV connector for EVAP
- VSV connector for EGR
- DLC1 from bracket on intake air control valve
b. Remove the 2 nuts, and disconnect the PS pressure tube from the blow engine hanger.





c. Disconnect the hoses, cables, strap and clamp:
1) PCV hose from PCV valve on RH cylinder head
2) Ground strap and cable from intake air control valve for ACIS
3) Ground cable from air intake chamber





4) Brake booster vacuum hose from air intake chamber
5) 2 water bypass hoses from throttle body
6) Air assist hose from throttle body
7) EVAP hose from pipe on emission control valve set
8) 2 vacuum hoses from vacuum tank for ACIS
9) Engine wire clamp from emission control valve set





d. Remove the 2 bolts and No.1 engine hanger.
e. Remove the 2 bolts and air intake chamber stay.
f. Remove the 4 nuts, No.2 EGR pipe and 2 gaskets.





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





9. Remove intake manifold assembly.
a. Disconnect the 6 injector connectors.
b. Disconnect these hoses:
1) Fuel inlet hose from fuel filter

CAUTION: Perform disconnecting operations of the fuel tube connector (quick type) after observing the precaution.

2) Heater hose from intake manifold





c. Remove the 9 bolts, 2 nuts, 2 plate washers, the intake manifold, delivery pipes and injectors assembly.





10. Remove water outlet.
a. Disconnect these connectors, (strap) and hoses:
- ECT sender gauge connector
- ECT sensor connector
- Ground strap (connector)
- Radiator hose
- Engine coolant reservoir hose
b. Remove the 2 bolts, 2 nuts and 2 plate washers.
c. Disconnect the water bypass hose, and remove the water outlet.
d. Remove the 2 gaskets.
11. Remove generator drive belt.
12. Remove PS pump.
13. Remove ignition coils.
14. Remove spark plugs.





15. Remove timing belt.
16. Remove camshaft timing pulleys.
17. Remove No.2 idler pulley.
18. Remove No.3 timing belt cover.
a. Disconnect the 3 engine wire clamps from the timing belt cover.
b. Remove the 6 bolts and timing belt cover.





19. Disconnect engine wire protector from rear side.
Remove the 2 nuts, and disconnect the engine wire protector from the RH cylinder head and water inlet.





20. Disconnect engine wire and protector from RH side.
Remove the 5 nuts, and disconnect the engine wire and protector from the RH cylinder head cover.





21. Disconnect engine wire protector from LH side.
Remove the 2 bolts, and disconnect the engine wire protector from the LH cylinder head cover.





22. Disconnect cylinder head rear plate from LH cylinder head.
a. Remove the nut, and disconnect the ground strap.
b. Remove the bolt, and disconnect the rear plate.
23. Disconnect water inlet pipe from LH cylinder head and water inlet.
a. Remove the bolt, and disconnect the inlet pipe from the water inlet.
b. Remove the O-ring from the inlet pipe.





24. Remove NO.1 EGR pipe.
Remove the 4 nuts, EGR pipe and 2 gaskets.





25. Remove RH exhaust manifold.
a. Disconnect these connectors:
- (California)
- A/F sensor (bank 1 sensor 1) connector
- (Except California)
- Oxygen sensor (bank 1 sensor 1) connector
b. Remove the bolt, nut and exhaust manifold stay.
c. Remove the 6 nuts, exhaust manifold and gasket.





26. Remove PS pump bracket.
Remove the 3 bolts and pump bracket.





27. Remove LH exhaust manifold.
a. Disconnect these connectors:
- (California)
- A/F sensor (bank 2 sensor 1) connector
- (Except California)
- Oxygen sensor (bank 2 sensor 1) connector
b. Remove the bolt, nut and exhaust manifold stay.
c. Remove the 6 nuts, exhaust manifold and gasket.
28. Remove camshaft position sensor.





29. Remove oil dipstick and guide.
a. Remove the bolt holding the dipstick guide to the LH cylinder head.
b. Pull out the dipstick guide together with the dipstick from the No.1 oil pan.
c. Remove the O-ring from the dipstick guide.





30. Remove cylinder head covers.
Remove the 8 bolts, cylinder head cover and gasket. Remove the 2 cylinder head covers.
31. Remove camshafts of RH cylinder head.

NOTICE: 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 the intake camshaft.
1) Align the timing marks (2 dot marks) of the camshaft drive and driven gears by turning the camshaft with a wrench.





2) 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.





3) Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown.
4) Remove the 5 bearing caps and intake camshaft.





b. Remove the exhaust camshaft.
1) Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown.
2) Remove the 5 bearing caps, oil seal and exhaust camshaft.
32. Remove camshafts of LH cylinder head.

NOTICE: 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 the intake camshaft.
1) Align the timing marks (1 dot mark) of the camshaft drive and driven gears by turning the camshaft with a wrench.





2) 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.





b. Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown.
c. Remove the 5 bearing caps and intake camshaft.





d. Remove the exhaust camshaft
1) Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown.
2) 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.





33. Disassemble exhaust camshafts.
a. Mount the hexagonal wrench head portion of the camshaft in a vise.

NOTICE: 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 sugars and gear springs (RH and LH side).





34. Remove cylinder meads.
a. Using an 8 mm hexagon wrench, remove the cylinder head (recessed head) bolt on each cylinder head, then peat 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.

NOTICE: 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.

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