Removal and Installation

REMOVAL

CAUTION:
- After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads.
- When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting surfaces with new engine oil.
- Apply new engine oil to bolt threads and seat surfaces when installing cylinder head, camshaft sprockets, crankshaft pulley, and camshaft brackets.
- Before disconnecting fuel hose, release fuel pressure.

Upper Timing Chain





1. Drain coolant from drain plug on water pipe and radiator drain cock.
2. Remove vacuum hoses, fuel hoses, wires, harness and connectors and so on.
3. Remove the following parts:
- Generator and bracket
- Air duct
- Upper radiator hose
- Cooling fan assembly
- Front exhaust tube





4. Remove the following:
- Intake manifold collector supports
- Intake manifold
- Exhaust manifold with warm-up three way catalyst





5. Set No. 1 piston at TDC on its compression stroke.





6. Remove distributor.
7. Set a suitable transmission jack under aluminum oil pan and remove front engine mounting.





8. Remove rocker cover.
- Remove in numerical order as shown.



9. Remove cam sprockets.
- For retiming during cylinder head removal/installation, apply paint marks to upper timing chain and cam sprockets.





- The stoppers on camshaft sprocket cover prevent upper timing chain from disengaging idler sprocket.





10. Remove camshaft brackets and camshafts.
- Mark these parts' original positions for reassembly.





11. Remove cylinder head bolts in numerical order.
- Removing bolts in incorrect order could result in warped or cracked cylinder head.
- Loosen cylinder head bolts in two or three steps.

12. Remove camshaft sprocket cover.
13. Remove upper chain tensioner.
14. Remove upper timing chain.



15. Remove idler sprocket bolt.
- For retiming during cylinder head removal/installation apply paint marks to lower timing chain and idle sprocket.





- The stoppers on front cover prevent lower timing chain fro disengaging crankshaft sprocket.





16. Remove cylinder head and cylinder head gasket.

INSTALLATION

CAUTION:
- After removing timing chain, do not turn crankshaft and camshaft separately, or valves will strike piston heads.
- When installing camshafts, chain tensioners, oil seals, or other sliding parts, lubricate contacting surfaces with new engine oil.
- Apply new engine oil to bolt threads and seat surfaces when installing cylinder head, camshaft sprockets, crankshaft pulley, and camshaft brackets.





Liquid gasket application places

1. Install new cylinder head gasket, cylinder head and cylinder head bolts.
- Apply new engine oil to bolt threads and seat surfaces.



- Be sure to install washers between bolts and cylinder head.

2. Slightly tighten the cylinder head bolts.
- This is necessary to avoid damaging cylinder head gasket.

3. Install upper timing chain and chain tensioner.
- Set upper timing chain on the idler sprocket, aligning mating marks.





4. Install cam sprocket cover.
- Apply a continuous bead of liquid gasket to camshaft sprocket cover.
- Be careful not to damage cylinder head gasket.
- Be careful upper timing chain does not slip or jump off idler sprocket.





5. Tighten cylinder head bolts in the order shown using the following procedure:





a. Tighten all bolts to 29 Nm (3.0 kg-m, 22 ft. lbs.).
b. Tighten all bolts to 79 Nm (8.1 kg-m, 59 ft. lbs.).
c. Loosen all bolts completely.
d. Tighten all bolts to 25 to 34 Nm (2.5 to 3.5 kg-m, 18 to 25 ft. lbs.).
e. Turn all bolts 86 to 91 degrees clockwise.

If an angle wrench is not available, mark all cylinder head bolts on the side facing engine front. Then, turn each cylinder head bolt 86 to 91 degrees clockwise.





6. Install camshafts and camshaft brackets in the order shown using the following procedure:
a. Set camshafts and camshaft brackets.
b. Tighten all bolts to 2 Nm (0.2 kg-m, 17 inch lbs.).
c. Tighten all bolts to 9.0 to 11.8 Nm (0.92 to 1.2 kg-m, 79.9 to 1134.2 inch lbs.).
- Apply new engine oil to bolt threads and seat surfaces.

7. Install camshaft sprockets.





- Set upper timing chain on camshaft sprockets, aligning mating marks.








8. Install distributor.
- Make sure that No. 1 piston is set at TDC and that distributor rotor is set at No. 1 cylinder spark position.
9. Install rocker cover gasket.
- Apply liquid gasket to rocker cover rubber gasket, cylinder head and camshaft sprocket cover.





10. Install rocker cover using the following procedure:
a. Tighten nuts and bolts (1)-(5)-(6)-(4) in that order to 4 Nm (0.4 kg-m, 35 inch lbs.).
b. Tighten nuts and bolts (1) to (11) in numerical order to 8 to 11 Nm (0.8 to 1.1 kg-m, 69 to 95 inch lbs.).

11. Install all spark plugs with high-tension cords.
12. Install vacuum hoses, fuel tubes, wires, harness and connectors and so on.