Removal

CYLINDER HEAD

COMPONENTS:

REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
2. REMOVE ENGINE UNDER COVER ASSEMBLY
a. w/engine under cover assembly
3. REMOVE ENGINE UNDER COVER NO. 1
4. REMOVE ENGINE UNDER COVER No. 2
a. w/engine under cover No. 2
5. DRAIN ENGINE COOLANT
6. DRAIN ENGINE OIL
7. REMOVE FRONT WHEEL RH
8. REMOVE FR WIPER ARM RH
9. REMOVE FR WIPER ARM LH
10. REMOVE COWL TOP VENTILATOR LOUVER SUB-ASSEMBLY
11. REMOVE WINDSHIELD WIPER LINK ASSEMBLY
12. REMOVE COWL TOP PANEL SUB-ASSEMBLY OUTER
13. REMOVE V-BANK COVER SUB-ASSEMBLY
14. REMOVE AIR CLEANER CAP SUB-ASSEMBLY
15. REMOVE AIR CLEANER FILTER ELEMENT SUB-ASSEMBLY
16. REMOVE AIR CLEANER INLET No. 2
17. REMOVE AIR CLEANER CASE
18. REMOVE EMISSION CONTROL VALVE SET
19. REMOVE INTAKE AIR SURGE TANK
20. DISCONNECT FUEL PIPE SUB-ASSEMBLY NO. 1

21. DISCONNECT HEATER INLET WATER HOSE
a. Lock the hose clamp as shown in the illustration.
b. Disconnect the heater inlet water hose.
22. REMOVE INTAKE MANIFOLD

a. Remove the nut and disconnect the ground cable.
b. Disconnect the 6 fuel injector connectors.

c. In order to remove the intake manifold, using several steps, remove the 9 bolts and 2 nuts in the sequence shown in the illustration.
23. DISCONNECT RADIATOR HOSE INLET

24. REMOVE WATER OUTLET
a. Disconnect the radiator hose inlet.
b. Disconnect the engine coolant temperature sensor connector.
c. Remove the clamp.
d. Remove the 2 bolts, 2 nuts and 2 washers.
e. Lock the hose clamp as shown in the illustration and remove the water outlet together with water by-pass hose No. 1.
f. Remove the 2 gaskets from the 2 cylinder heads.
25. REMOVE FRONT FENDER APRON SEAL RH
26. REMOVE V (COOLER COMPRESSOR TO CRANKSHAFT PULLEY) BELT NO. 1
27. REMOVE VANE PUMP V BELT
28. REMOVE ENGINE MOVING CONTROL ROD
29. REMOVE ENGINE MOUNTING STAY No. 2 RH
30. REMOVE GENERATOR BRACKET No. 2
31. REMOVE CRANKSHAFT PULLEY
SST 09213-54015 (91651-60855), 09330-00021, 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05031)
32. REMOVE TIMING BELT NO. 1 COVER
33. REMOVE TIMING BELT No. 2 COVER
34. REMOVE ENGINE MOUNTING BRACKET RH
35. REMOVE TIMING BELT GUIDE No. 2
36. REMOVE TIMING BELT
37. REMOVE TIMING BELT IDLER SUB-ASSEMBLY No. 2
38. REMOVE CAMSHAFT TIMING PULLEY
SST 09960-10010 (09962-01000, 09963-01000), 09249-63010
39. REMOVE TIMING BELT NO. 3 COVER
40. SEPARATE VANE PUMP ASSEMBLY
41. REMOVE PROPELLER SHAFT (for 4WD)
SST 09325-20010
42. REMOVE EXHAUST PIPE SUB-ASSEMBLY FRONT NO. 3
43. REMOVE EXHAUST MANIFOLD HEAT INSULATOR NO. 1
44. REMOVE MANIFOLD STAY

45. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY
a. Disconnect the heated oxygen sensor connector.
b. Using several steps, loosen and remove the 6 nuts in the sequence shown in the illustration.
c. Remove the exhaust manifold RH and the gasket from the cylinder head RH.
46. SEPARATE EXHAUST PIPE ASSEMBLY FRONT
47. REMOVE MANIFOLD CONVERTER INSULATOR NO. 3
48. REMOVE EXHAUST MANIFOLD HEAT INSULATOR No. 2

49. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY No. 2
a. Disconnect the heated oxygen sensor connector.
b. Using several steps, loosen and remove the 6 nuts and bolt in the sequence shown in the illustration.
c. Remove the exhaust manifold converter No. 2 and the gasket from the cylinder head LH.

50. REMOVE OIL LEVEL GAGE GUIDE
a. Remove the bolt which is used to secure the oil level gage guide from the cylinder head LH.
b. Pull out the oil level gage guide and the oil level gage together from the cylinder block.
c. Remove the O-ring from the oil level gage guide.
51. REMOVE IGNITION COIL ASSEMBLY
52. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY
53. REMOVE CYLINDER HEAD COVER SUB-ASSEMBLY LH
54. REMOVE CAMSHAFT
55. REMOVE No. 2 CAMSHAFT
56. REMOVE NO. 3 CAMSHAFT SUB-ASSEMBLY
57. REMOVE NO. 4 CAMSHAFT SUB-ASSEMBLY
58. REMOVE CYLINDER HEAD SUB-ASSEMBLY

a. Disconnect the VVT sensor connector.
b. Disconnect the camshaft timing oil control valve connector.
c. Remove the nut and disconnect the engine wire harness clamp.

d. Using a socket hexagon wrench 8, remove the hexagon bolt.

e. Using several steps, loosen the 8 cylinder head bolts uniformly in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

NOTICE:
^ Be careful not to drop washers into the cylinder head.
^ Head warpage or cracking could result from removing bolts in an incorrect order.

59. REMOVE CYLINDER HEAD LH

a. Disconnect the VVT sensor connector.
b. Disconnect the camshaft timing oil control valve connector.
c. Remove the bolts and disconnect the ground cable.
d. Remove the bolt and the wire harness clamp bracket.
e. Remove the bolt and separate the water inlet. (TMMWV MADE)

f. Using a socket hexagon wrench 8, remove the hexagon bolt.

g. Using several steps, loosen the 8 cylinder head bolts uniformly in the sequence shown in the illustration. Remove the 8 cylinder head bolts and plate washers.

NOTICE:
^ Be careful not to drop the washers into the cylinder head.
^ Head warpage or cracking could result from removing bolts in an incorrect order.

60. REMOVE CYLINDER HEAD GASKET
61. REMOVE CYLINDER HEAD GASKET No. 2