Removal

REMOVAL
1. DRAIN ENGINE COOLANT
2. REMOVE THROTTLE BODY COVER





3. DISCONNECT TIMING BELT FROM CAMSHAFT TIMING PULLEYS

NOTICE:
- Be careful not to drop anything inside the timing belt cover.
- Do not allow the belt to come into correct with oil, water or dust.

4. REMOVE CAMSHAFT TIMING PULLEYS
5. REMOVE CAMSHAFT POSITION SENSOR
6. DISCONNECT PS PUMP FROM ENGINE
7. REMOVE FRONT EXHAUST PIPE
8. REMOVE OIL DIPSTICK AND GUIDE FOR A/T
9. REMOVE IGNITION COILS
10. REMOVE TIMING BELT REAR PLATES
a. Remove the 3 bolts, stud bolt and RH No.1 timing belt rear plates.
b. Disconnect the wire clamp from the LH timing belt rear plate.
c. Remove the 3 bolts, stud bolt and LH No.1 timing belt rear plates.
11. DISCONNECT FUEL INLET HOSE AND FUEL RETURN HOSE
12. DISCONNECT CONNECTORS FROM INTAKE MANIFOLD
a. Disconnect the throttle position sensor connector.
b. Disconnect the accelerator pedal position sensor connector.
c. Disconnect the throttle control motor connector.
d. Disconnect the VSV connector for EVAP.
e. Disconnect the 8 injector connectors.
f. Disconnect the ECT sensor connector.
g. Disconnect the water sender gauge connector.
h. Disconnect the 8 ignition coil connectors.
i. Disconnect the 2 heated oxygen sensor connectors





13. DISCONNECT HOSES FROM INTAKE MANIFOLD
a. Disconnect the vacuum hose from the fuel pressure regulator.
b. Disconnect the PCV hose from the PCV valve on the LH cylinder head.
c. Disconnect the EVAP hose (from charcoal canister) from the VSV for the EVAP.
d. Disconnect the EVAP hose (from charcoal canister) from EVAP pipe on the intake manifold.
e. Disconnect the EVAP hose (from intake air connector) from EVAP pipe on the intake manifold.
f. Disconnect the PS air hose from the intake manifold.
g. w/o Hydraulic brake booster: Disconnect the brake booster tube.
14. REMOVE INTAKE MANIFOLD ASSEMBLY
a. Disconnect the accelerator cable from the throttle body.





b. Disconnect the 2 wire clamps from the throttle body.
c. Disconnect the No.1 water bypass hose (from the front water bypass joint).





d. Disconnect the 2 wire clamps from the wire clamp bracket on the RH delivery pipe.





e. Remove the 3 bolts holding the engine wire protector from the rear water bypass joint, RH and LH cylinder heads.
f. Remove the guide for the A/T bracket from the LH and LH cylinder heads.
g. Remove the 2 ground cables from the RH and LH cylinder heads.





h. Disconnect the DLC1 from the throttle body cover bracket and remove the bracket from the intake manifold.
i. Disconnect the engine wire from the engine hanger and wire bracket.
j. Remove the wire bracket from the intake manifold.
k. Remove the 2 nuts and accelerator cable bracket from the intake manifold.





l. Remove the 6 bolts, 4 nuts, the intake manifold assembly and 2 gaskets.
15. DISASSEMBLE UPPER AND LOWER INTAKE MANIFOLDS
a. Remove the throttle body.





b. Remove the 13 bolts, 3 nuts, upper intake manifold and gasket.
c. Disconnect the EVAP hose from the upper intake manifold, and remove the accelerator cable clamp and VSV for EVAP.
d. w/ Hydraulic brake booster: Remove the plug from the upper intake manifold.
w/o Hydraulic brake booster: Remove the bolt, union, 2 gaskets and brake booster tube from the upper intake manifold.





e. Remove the 2 bolts and EVAP pipe from the intake manifold.





f. Disconnect the fuel return hose from the fuel pressure regulator.
g. Remove the 3 bolts holding the fuel return hose from the lower intake manifold.
h. Remove the fuel pressure regulator, fuel pressure pulsation damper and 2 gaskets.
i. Remove the bolt and rear fuel pipe.
j. Remove the 2 delivery pipes and 8 injectors.
16. REMOVE WATER INLET AND INLET HOUSING ASSEMBLY





17. REMOVE FRONT WATER BYPASS JOINT
Remove the 4 nuts, water bypass joint and 2 gaskets.





18. REMOVE REAR WATER BYPASS JOINT
Remove the 4 nuts, water bypass joint and 2 gaskets.
19. REMOVE ENGINE HANGERS





20. REMOVE CYLINDER HEAD COVERS
Remove the 18 bolts, seal washers, RH and LH cylinder head covers and 2 gaskets.
21. IF NECESSARY, REMOVE SEMI-CIRCULAR PLUGS AND CAMSHAFT HOUSING PLUGS
22. 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, the following steps should be carried out.





a. Check the crankshaft pulley position. Check that the timing mark of the crankshaft pulley is in aligned with the centers of the crankshaft pulley bolt and idler pulley bolt.

NOTICE: Having the crankshaft pulley at the wrong angle can cause the piston head and valve head to come into contact with each other when you remove the camshaft, causing damage. So always set the crankshaft pulley at the correct angle.





b. Remove the RH camshafts.
1. Boring the service bolt hole of the sub-gear upward by turning the hexagon wrench head portion of the exhaust camshaft with a wrench.
2. Secure the sub-gear to the main gear with a service bolt.





Recommended service bolt:

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





3. Set the timing mark (1 dot mark) of the camshaft main gear at approximately 10 angle by turning the hexagon wrench head portion of the exhaust camshaft with a wrench.





4. Uniformly loosen and remove the 22 bearing cap bolts in several passes, in the sequence shown.
5. Remove the oil feed pipe, 9 bearing caps and camshafts.
c. Remove the LH camshafts.





1. Boring the service bolt hole of the sub-gear upward by turning the hexagon wrench head portion of the exhaust camshaft with a wrench.





2. Secure the 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.

3. Align the timing mark (2 dot marks) of the camshaft drive gear by turning the hexagon wrench head portion of the exhaust camshaft with a wrench.





4. Uniformly loosen and remove the 22 bearing cap bolts in several passes, in the sequence shown.
5. Remove the oil feed pipe, 9 bearing caps and camshafts.

HINT: Arrange the bearing caps in correct order.

23. DISASSEMBLE EXHAUST CAMSHAFTS





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 the wave washer.
e. Remove the camshaft sub-gear.
f. Remove the camshaft gear spring.

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

Be careful not to damage the camshaft timing tube.





24. REMOVE OIL SEAL FROM INTAKE CAMSHAFT
25. REMOVE SPARK PLUGS
26. REMOVE CYLINDER HEAD AND EXHAUST MANIFOLD ASSEMBLIES

Cylinder Head Removal Sequence:

a. Uniformly loosen the 10 cylinder head bolts on one side of each cylinder head in several passes, in the sequence shown, then do the other side as shown. Remove the 20 cylinder head bolts and plate washers.

NOTICE:
- Cylinder head warpage or cracking could result from removing bolts in incorrect order.
- Do not drop the plate washer for cylinder head bolt into portion A of the cylinder head. If dropped into portion A, the plate washer will pass through the cylinder head and cylinder block into the oil pan.





b. 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 lift off, pry between the cylinder head and cylinder block with a screwdriver.

NOTICE:
- Be careful not to damage the surfaces contacting the cylinder head and cylinder block.
- The cylinder head should not be tilted so as to secure the valve lifter. If the cylinder head is tilted, remove the valve lifter and check that the adjusting shim is set correctly.





27. REMOVE RH EXHAUST MANIFOLD FROM CYLINDER HEAD
a. Remove the 4 bolts and heat insulator.
b. Remove the 8 nuts, exhaust manifold and gasket.





28. REMOVE LH EXHAUST MANIFOLD FROM CYLINDER HEAD
a. Remove the 4 bolts and heat insulator.
b. Remove the 8 nuts, exhaust manifold and gasket.