Removal

CYLINDER HEAD

COMPONENTS:

REMOVAL
1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

3. REMOVE AIR CLEANER
4. REMOVE NO. 2 CYLINDER HEAD COVER
5. REMOVE FRONT WHEEL RH
6. REMOVE ENGINE UNDER COVER RH
7. DRAIN ENGINE OIL
8. DRAIN ENGINE COOLANT
9. DISCONNECT ENGINE WIRE
10. DISCONNECT ACCELERATOR CONTROL CABLE
11. DISCONNECT FUEL TUBE

12. DISCONNECT UNION TO CHECK VALVE HOSE
a) Disconnect the union to check valve hose for the brake booster.
13. DISCONNECT RADIATOR HOSE INLET
a) Disconnect the radiator hose inlet from the union.
14. DISCONNECT NO. 1 WATER BY-PASS PIPE
a) Remove the bolt and disconnect the water by-pass pipe.
15. DISCONNECT HEATER WATER INLET HOSE
a) Disconnect the heater water inlet hose from the No. 2 water by-pass pipe.

16. REMOVE WATER FILLER
a) Disconnect the radiator inlet hose.
b) Disconnect the No. 3 radiator hose.
c) Disconnect the radiator reservoir hose.
d) Remove the 2 bolts and water filler.

17. DISCONNECT FRONT EXHAUST PIPE
a) Remove the 2 bolts and 2 compression springs which are installed on the front side of the exhaust pipe.
18. REMOVE NO. 1 EXHAUST MANIFOLD HEAT INSULATOR
a) Remove the 4 bolts and exhaust manifold heat insulator.

19. REMOVE MANIFOLD SUPPORT BRACKET
a) Remove the 3 bolts and manifold support bracket.
20. REMOVE EXHAUST MANIFOLD
a) Remove the 3 bolts, 2 nuts, exhaust manifold and gasket.

21. REMOVE INTAKE MANIFOLD
a) Using several steps, remove the 3 bolts and 2 nuts in the sequence shown in the illustration. Then remove the intake manifold.
b) Remove the gasket from the intake manifold.

22. REMOVE OIL DIPSTICK GUIDE
a) Remove the bolt and dipstick guide.
23. REMOVE IGNITION COIL
24. REMOVE GENERATOR V BELT
25. REMOVE VANE PUMP V BELT
26. REMOVE GENERATOR
27. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSEMBLY
28. DISCONNECT VENTILATION HOSE
29. DISCONNECT NO. 2 VENTILATION HOSE
30. REMOVE CYLINDER HEAD COVER
31. REMOVE WATER PUMP PULLEY
32. REMOVE TIMING CHAIN COVER
33. REMOVE WATER PUMP
34. REMOVE CRANKSHAFT PULLEY
35. REMOVE CRANKSHAFT POSITION SENSOR
36. REMOVE ENGINE MOUNTING INSULATOR RH
37. REMOVE ENGINE MOUNTING BRACKET RH
38. REMOVE NO. 1 CHAIN TENSIONER
39. REMOVE CHAIN TENSIONER SLIPPER
40. REMOVE NO. 1 CHAIN VIBRATION DAMPER
41. REMOVE CHAIN
42. REMOVE FUEL DELIVERY PIPE
43. REMOVE FUEL INJECTOR

44. REMOVE CAMSHAFT
a) Using several steps, uniformly loosen and remove the 19 bearing cap bolts in the sequence shown in the illustration, and then remove the 9 bearing caps, and the No. 1 and No. 2 camshafts.

NOTICE: Loosen each bolt uniformly, keeping the camshaft level.

45. REMOVE CAMSHAFT TIMING GEAR
a) Turn the camshaft timing gear at the most advanced angle.
b) Remove the flange bolt and camshaft timing gear.

NOTICE:
^ Be careful not to remove the other 4 bolts.
^ If reusing the camshaft timing gear, unlock the lock pin inside the camshaft timing gear first.

46. REMOVE CAMSHAFT TIMING SPROCKET
a) Clamp the camshaft in a vise.
b) Remove the flange bolt and camshaft timing sprocket.

NOTICE: Be careful not to damage the camshaft.

47. REMOVE CYLINDER HEAD
a) Using several steps, uniformly loosen and remove the 10 cylinder head bolts with an 8 mm bi-hexagon wrench in the sequence shown in the illustration. Remove the 10 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 the incorrect order.

48. REMOVE CYLINDER HEAD GASKET