Removal
REMOVAL
1. DRAIN ENGINE COOLANT
2. DISCONNECT THESE CABLES:
- (M/T) Disconnect the accelerator cable from the throttle body.
- (A/T) Disconnect the accelerator and throttle cables from the throttle body.
- (w/ Cruise Control System)
Remove the actuator cover, and disconnect the cruise control cable from the actuator.
3. REMOVE AIR CLEANER CAP, MAF METER AND RESONATOR ASSEMBLY
a) Disconnect the 3 wire clamps for the engine wire.
b) Disconnect the MAF meter connector.
c) Disconnect the air hose from the air cleaner cap.
d) Loosen the air cleaner hose clamp.
e) Loosen the 4 clips, and remove the air cleaner cap, MAF meter and resonator assembly.
4. REMOVE INTAKE AIR CONNECTOR
a) Disconnect these hoses and clamp:
(1) Air hose for IAC
(2) Vacuum sensing hose
(3) Wire clamp for engine wire
b) Loosen the hose clamp, and remove the 2 bolts and intake air connector.
5. REMOVE OIL DIPSTICK GUIDE
a) Remove the bolt, dipstick guide and engine wire bracket.
b) Remove the O-ring from the dipstick guide.
6. REMOVE DRIVE BELT FOR PS PUMP
Loosen the lock bolt and adjusting bolt, and remove the drive belt.
7. REMOVE DRIVE BELT IDLER PULLEY FOR PS PUMP
Remove the 3 bolts and idler pulley.
8. REMOVE PS PUMP AND BRACKET
a) Using SST, remove the nut and PS pump pulley.
SST 09960-10010 (09962-01000, 09963-01000)
b) Disconnect the 2 air hoses from the throttle body and air intake chamber.
c) Remove the 2 bolts, and disconnect the PS pump.
HINT: Put aside the pump and suspend it.
d) Remove the 4 bolts and PS pump bracket.
9. REMOVE PCV HOSES
10. REMOVE IGNITION COILS
a) Disconnect high-tension cords at the rubber boot from the cylinder head.
NOTICE: Pulling on or bending the cords may damage the conductor inside.
b) Disconnect the ignition coil connectors.
c) Remove the 4 bolts and 2 ignition coils.
11. DISCONNECT ENGINE WIRE
a) Disconnect these connectors and clamps:
(1) (w/ A/C)
A/C compressor connector
(2) Oil pressure sensor connector and clamp
(3) Engine coolant temperature sender gauge connector
(4) 4 engine wire clamps and engine wire
(5) ECT sensor connector
(6) EGR gas temperature sensor connector
(7) VSV connector for EGR
b) Disconnect the 2 vacuum hoses from the VSV for EGR and clamp.
c) Disconnect the bolt and ground strap from the cowl top panel.
d) Remove the 2 bolts, and disconnect the engine wire from air the intake chamber.
e) Disconnect the 2 engine wire clamps and engine wire.
f) Disconnect these connectors:
(1) Throttle position sensor connector
(2) IAC valve connector
(3) Crankshaft position sensor connector
(4) Knock sensor connector
g) Disconnect the DLC1 from the bracket.
h) Disconnect the engine wire clamp.
12. REMOVE EGR PIPE
Remove the 4 nuts, bolt, EGR pipe and 2 gaskets.
13. REMOVE INTAKE CHAMBER STAY
Remove the 2 bolts and intake chamber stay.
14. REMOVE AIR INTAKE CHAMBER ASSEMBLY
a) Disconnect these hoses:
- EVAP hose from throttle body
- Brake booster vacuum hose from union
- Water bypass hose from water bypass pipe
- Water bypass hose from cylinder head rear cover
b) Remove the 3 bolts, 2 nuts, air intake chamber assembly and gasket.
15. DISCONNECT INJECTOR CONNECTORS
16. REMOVE FUEL INLET PIPE
Remove the 2 union bolts, 4 gaskets and fuel inlet pipe.
17. REMOVE FUEL RETURN PIPE
a) Disconnect these hoses: Fuel return hose from fuel pressure regulator Fuel return hose from fuel return pipe
b) Remove the 2 bolts and fuel return pipe.
18. REMOVE DELIVERY PIPE AND INJECTORS
a) Remove the 2 bolts and delivery pipe together with the 4 injectors.
NOTICE: Be careful not to drop the injectors when removing the delivery pipe.
b) Remove the 4 insulators from the 4 spacers.
c) Pull out the 4 injectors from the delivery pipe.
d) Remove the O-ring and grommet from each injector.
e) Using a screwdriver, pry out the 4 spacers.
19. REMOVE INTAKE MANIFOLD
Remove the 3 bolts, 2 nuts, intake manifold and gasket.
20. REMOVE FRONT EXHAUST PIPE
21. REMOVE EXHAUST MANIFOLD
a) Remove the 2 bolts, 2 nuts and heat insulator.
b) Remove the 6 nuts, exhaust manifold and gasket.
22. REMOVE WATER OUTLET
a) Disconnect the upper radiator hose.
b) Remove the 2 bolts, water outlet and gasket.
c) Remove the camshaft position sensor.
23. REMOVE CYLINDER HEAD REAR COVER
Remove the 3 bolts, cylinder head rear cover and gasket.
24. REMOVE SPARK PLUGS
25. REMOVE FRONT ENGINE HANGER
26. REMOVE ENGINE WIRE BRACKETS
Remove the 4 bolts, 4 wire brackets and ground strap.
27. REMOVE CYLINDER HEAD COVER
Remove the 10 bolts, seal washers, cylinder head cover and gasket.
28. SET NO.1 CYLINDER TO TDC/COMPRESSION
a) Turn the crankshaft pulley clockwise and align its groove with the "0" mark on the timing chain cover.
b) Check that the timing marks (1 and 2 dots) of the camshaft drive and driven gears are in straight line on the cylinder head surface as shown in the illustration. If not, turn the crankshaft 1 revolution (360°) and align the marks as above.
29. REMOVE CHAIN TENSIONER
Remove the 2 nuts, chain tensioner and gasket.
30. REMOVE SEMI-CIRCULAR PLUGS
31. REMOVE CAMSHAFT TIMING GEAR
a) Place the matchmarks on the camshaft timing gear and No.1 timing
b) Hold the intake camshaft with a wrench and remove the bolt.
c) Remove the camshaft timing gear and chain from the intake camshaft and leave on the slipper and damper.
32. REMOVE CAMSHAFTS
NOTICE:
Since the thrust clearance of the camshaft is small, the camshaft must be kept 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, these steps should be carried out.
a) Bring the service bolt hole of the driven sub-gear upward by turning the hexagon wrench head portion of the exhaust 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 (0.63 - 0.79 inch)
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 exhaust camshaft.
HINT: If the camshaft is not being lifted out straight and level, reinstall the No.3 bearing cap with the 2 bolts. Then alternately loosen and remove the bearing cap bolts with the camshaft gear pulled up.
NOTICE: Do not pry on or attempt to force the camshaft with a tool or other object.
e) Uniformly loosen and remove the 10 bearing cap bolts, in several passes, in the sequence shown.
f) Remove the 5 bearing caps and intake camshaft.
HINT: If the camshaft is not being lifted out straight and level, reinstall the No.3 bearing cap with the 2 bolts. Then alternately loosen and remove the 2 bearing cap bolts with the camshaft gear pulled up.
NOTICE: Do not pry on or attempt to force the camshaft with a tool or other object.
33. DISASSEMBLE EXHAUST CAMSHAFT
a) Mount the hexagon wrench head portion of the camshaft in a vise.
NOTICE: Be careful not to damage the camshaft.
b) Using SST, turn the sub-gear clockwise, 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
34. REMOVE CYLINDER HEAD
a) Remove the 2 bolts in front of the head before the other head bolts are removed.
b) Uniformly loosen and remove the 10 cylinder head bolts, in several passes, in the sequence shown.
NOTICE: Cylinder head warpage or cracking could result from re moving bolts In incorrect order.
c) Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head 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.