Removal

Various Engine Compartment Components:

Timing Belt Components:

Air Intake Chamber, Intake Manifold:

Exhaust System (Except California):

Exhaust System (California Only):

Cylinder Head And Related Components:

REMOVAL
1. REMOVE ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. REMOVE FRONT EXHAUST PIPE
4. REMOVE MAF METER, RESONATOR AND AIR CLEANER ASSEMBLY
5. REMOVE HIGH-TENSION CORDS WITH IGNITION COILS AND SPARK PLUGS
6. DISCONNECT CABLES
a. w/Cruise control: Disconnect the wise control actuator cable.
b. Disconnect the accelerator cable.
c. A/T: Disconnect the throttle cable.
7. DISCONNECT HEATER HOSE AND UPPER RADIATOR HOSE
8. REMOVE GENERATOR
9. REMOVE INTAKE CHAMBER STAY
a. A/T: Remove the bolt, 2 nuts, oil filler tube and No.1 throttle cable clamp.
b. Remove the 2 bolts and intake chamber stay.
10. REMOVE AIR INTAKE CHAMBER ASSEMBLY





a. Disconnect the throttle position sensor connector.
b. Disconnect the IAC valve connector.
c. Disconnect the 2 PCV hoses.
d. Disconnect the 2 water bypass hoses.
e. Disconnect the air assist hose.





f. Remove the 3 bolts, 2 nuts, the air intake chamber assembly and gasket.
11. REMOVE INTAKE AIR CONNECTOR
a. Remove the bolt holding the engine wire to the intake air connector.
b. Disconnect the 2 fuel return hoses from the intake air connector.
c. Disconnect the brake booster vacuum hose from the intake air connector.
d. Disconnect vacuum sensing hose from the fuel pressure regulator.
e. Remove the bolt holding the ground strap to the intake air connector.
f. Disconnect the DLC1 from the bracket.
g. Remove the 3 bolts, 2 nuts, intake air connector and gasket.





12. DISCONNECT ENGINE WIRE
a. Disconnect the oil pressure sensor connector.
b. Disconnect the crankshaft position sensor connector.
c. Disconnect the 6 Injector connectors.
d. Disconnect the ECT sender gauge connector.
e. Disconnect the ECT sensor connector.
f. Disconnect the knock sensor connector.
g. Disconnect the camshaft position sensor connector.
h. Disconnect the 3 engine wire clamps.
i. Remove the 3 bolts, and disconnect the engine wire from the cylinder head.





13. REMOVE CAMSHAFT POSITION SENSOR
14. REMOVE NO.3 TIMING BELT COVER
Remove the 6 bolts and timing belt cover.





15. REMOVE FUEL PRESSURE REGULATOR
16. REMOVE INTAKE MANIFOLD ASSEMBLY
a. Disconnect the fuel inlet hose.
b. Remove the 2 bolts and intake manifold stay.
c. Remove the 8 bolts, 4 nuts, 4 plate washers, intake manifold, the delivery pipes and injectors assembly and 2 gaskets.
17. REMOVE PS PUMP BRACKET
18. REMOVE OIL DIPSTICK AND GUIDE
a. Remove the 2 bolts holding the dipstick guide to the generator bracket.
b. Pull out the dipstick guide together with the dipstick from the oil pan.
d. Remove the O-ring from the dipstick guide.
19. REMOVE GENERATOR BRACKET





20. REMOVE EXHAUST CROSSOVER PIPE
Remove the 6 nuts, crossover pipe and 2 gaskets.
21. REMOVE LH AND RH EXHAUST MANIFOLDS
a. Remove the 6 nuts, exhaust crossover pipe and 2 gaskets.
b. Remove the 12 nuts, LH, RH exhaust manifolds and 2 gaskets.





22. REMOVE CYLINDER HEAD COVERS
Remove the 8 bolts, seal washers, cylinder head cover and gasket. Remove the 2 cylinder head covers.
23. REMOVE SEMI-CIRCULAR PLUGS





24. 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, these steps should be carried out.





a. Remove the exhaust camshaft of the RH cylinder head.
1. Boring the service bolt hole of the driven sub-gear upward by turning the hexagon wrench head portion of the exhaust camshaft with a wrench.
2. Align the timing marks (2 dot marks) of the camshaft drive and driven gears by turning the camshaft with a wrench.
3. Secure the exhaust camshaft sub-gear to the main gear with a service bolt.





Recommended service bolt:

HINT: When removing the camshaft, mark certain that the torsional spring force of the sub-gear has been eliminated by the above operation.





b. Uniformly loosen and remove the 8 bearing cap bolts, in several passes, in the sequence shown.
c. Remove the 4 bearing caps and exhaust camshaft.
25. REMOVE INTAKE CAMSHAFT OF RH CYLINDER HEAD





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





c. Remove the exhaust camshaft of the 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, these steps should be carried out.





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:

HINT: When removing the camshaft, make sure that the torsional spring force of the sub-gear has been eliminated by the above operation.





d. Uniformly loosen and remove the 8 bearing cap bolts, in several passes, in the sequence shown.
e. Remove the 4 bearing caps and exhaust camshaft.

HINT:
- Arrange the camshafts in the correct order.
- Arrange the bearing caps in the correct order.





f. Remove the intake camshaft of the LH cylinder head.
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 intake camshaft.
26. 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 clockwise, and remove the service bolt.
SST 09960-10010 (09962-01000, 09963-00600)





c. Using snap ring pliers, remove the snap ring.
d. Remove the wave washer, camshaft sub-gear and gear spring.

HINT: Arrange the camshaft sub-gears and gear springs (RH and LH sides).

27. REMOVE CYLINDER HEADS





a. Remove the bolt and disconnect the ground strap.
b. Using an 8 mm hexagon wrench, remove the cylinder head (recessed head) bolt on each cylinder head, then repeat for the other side as shown.





c. 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 incorrect order.





d. 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.
- Arrange the cylinder heads in the correct order.

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