Removal
REMOVAL
1. REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. DISCONNECT UPPER RADIATOR HOSE FROM WATER OUTLET
4. REMOVE AIR CLEANER, MAP METER AND INTAKE AIR CONNECTOR PIPE ASSEMBLY
5. REMOVE DRIVE BELT
6. DISCONNECT PS PUMP WITHOUT DISCONNECTING HOSES
a) Disconnect these hoses:
- PS air hose from No.4 timing belt cover
- PS air hose from air intake chamber
b) Remove the 2 bolts and pump rear stay.
c) Remove the 2 bolts, and disconnect the vane pump from the pump bracket.
HINT: Put aside the vane pump, and suspend it.
7. DISCONNECT FRONT EXHAUST PIPE FROM EXHAUST MANIFOLD
a) Disconnect the wire grommet of the heated oxygen sensor (bank 2 sensor 2) from the floor.
b) Remove the 3 bolts and nuts holding the front exhaust pipe to the exhaust manifold.
c) Remove the 2 bolts and pipe support bracket.
d) Disconnect the front exhaust pipe from the exhaust manifold, and remove the 2 gaskets.
8. REMOVE EXHAUST MANIFOLD
a) Disconnect the 3 heated oxygen sensor connectors.
b) Remove the clamps and case clamp.
c) Using a 14 mm deep socket wrench, remove the 8 nuts, exhaust manifold and 2 gaskets.
9. REMOVE WATER BYPASS OUTLET AND NO.1 WATER BYPASS PIPE
10. REMOVE THROTTLE BODY AND INTAKE AIR CONNECTOR ASSEMBLY
11. REMOVE OIL DIPSTICK AND GUIDE FOR ENGINE
12. REMOVE OIL DIPSTICK AND GUIDE FOR A/T
13. REMOVE AIR INTAKE CHAMBER
14. REMOVE VACUUM CONTROL VALVE SET AND NO.2 VACUUM PIPE
a) Disconnect the VSV connector for the ACIS.
b) Remove the 3 nuts, vacuum control valve set and No.2 vacuum pipe.
15. REMOVE NO.3 TIMING BELT COVER
16. REMOVE IGNITION COILS AND HIGH-TENSION CORD SET ASSEMBLY
17. REMOVE SPARK PLUGS
18. DISCONNECT ENGINE WIRE FROM CYLINDER HEAD
a) Disconnect the ground strap from the cylinder head.
b) Disconnect the 2 water bypass hoses from the hose clamps on the cylinder head and oil filter bracket.
c) Disconnect the heated oxygen sensor (bank 2 sensor 1) connector from the hose clamp.
d) Remove the 2 bolts and hose clamps.
e) Disconnect these connectors:
- Heated oxygen sensor (bank 1 sensor 1) connector
- Crankshaft position sensor connector
f) Remove the bolt and clamp bracket, and disconnect the engine wire from the water pump.
g) Disconnect the 2 ground terminals from the intake manifold.
h) Disconnect the 2 engine wire clamps from the clamp brackets on the intake manifold.
i) Remove the 2 bolts and clamp brackets.
j) Disconnect these connectors:
- ECT sensor connector
- ECT sender gauge connector
- 2 knock sensor connectors
- Oil pressure switch connector
- Oil level sensor connector
- Starter connector
- 6 injector connectors
- Camshaft position sensor connector
- Camshaft timing oil control valve connector
k) Using a 5 mm hexagon wrench, remove the bolt holding the engine wire protector to the No.2 cylinder head cover.
l) Remove the 4 nuts, and disconnect the engine wire protector from the intake manifold.
19. REMOVE FUEL PRESSURE PULSATION DAMPER
20. REMOVE INTAKE MANIFOLD ASSEMBLY
a) Disconnect the starter wire from the manifold stay.
b) Remove the 2 bolts and manifold stay.
c) Remove the 7 bolts, 2 nuts, intake manifold and delivery pipe assembly and gasket.
21. REMOVE NO.1 AND NO.2 CYLINDER HEAD COVERS
a) Remove the 12 bolts and 4 nuts.
b) Remove the cylinder head covers and gaskets.
22. DISCONNECT TIMING BELT FROM CAMSHAFT TIMING PULLEYS
NOTICE:
- Support the timing belt, so that the measuring of the crankshaft timing pulley and timing belt does not shift.
- Be careful not to drop anything inside the timing belt cover.
- Do not allow the timing belt to come into contact with oil, water or dust.
23. REMOVE CAMSHAFT TIMING PULLEYS
a) Remove the exhaust camshaft timing pulley. Hold the hexagon portion of the camshaft with a wrench, and remove the pulley bolt and camshaft pulley.
b) Remove the VVT-i (intake camshaft timing) pulley.
24. REMOVE NO.4 TIMING BELT COVER
Remove the 4 bolts and timing belt cover.
25. REMOVE CAMSHAFTS
a) Using a 5 mm hexagon wrench, the 2 No.3 camshaft bearing cap bolts.
b) Uniformly loosen and remove the 4 camshaft bearing cap bolts.
c) Using a screwdriver, pry out the Nos.1, 3 camshaft bearing caps and oil seals.
NOTICE: Be careful not to damage the cap. Tape the screwdriver tip.
d) Uniformly loosen and remove the 12 camshaft bearing cap bolts, in several passes, in the sequence shown.
e) Remove the 6 No.2 camshaft bearing caps and camshaft. Remove the intake and exhaust camshafts.
26. REMOVE CYLINDER HEAD ASSEMBLY
a) Using a 10 mm bi-hexagon wrench, uniformly loosen and remove the 14 cylinder head bolts, in several passes, in the sequence shown.
NOTICE: Cylinder head warpage or cranking could result from removing in incorrect order.
b) Remove the 14 plate washers.
c) Lift the cylinder head from the dowels on the cylinder block.
d) Disconnect the heater hose from the heater union.
e) Place the head on wooden blocks on a bench.
If the cylinder head is difficult to lift off, pry with a screwdriver between the cylinder head and block projection.
NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.