Cylinder Head Removal

1. Disconnect cable from negative terminal of battery. Set engine at No.1 TDC.

CAUTION (With Airbag): To avoid accidental air bag deployment work must be started after approx. 30 seconds or longer from the time the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery.

2. Drain engine coolant.
3. (A/T) Disconnect throttle cable from throttle body.
4. Disconnect accelerator cable from throttle body.
5. Remove air cleaner cap, resonator and air cleaner hose.
a. Disconnect the air intake temperature sensor connector.
b. Disconnect the cruise control actuator cable from the clamp on the resonator and air cleaner cap.
c. Loosen the air cleaner hose clamp bolt.
d. Disconnect the four air cleaner cap clips.
e. Disconnect the air cleaner hose from the throttle body, and remove the air cleaner cap together with the resonator and air cleaner hose.
6. Remove generator.
7. Remove distributor.





8. Disconnect front exhaust pipe.














9. Disconnect the oxygen sensor connectors,remove the upper heat insulator, two manifold stays and the exhaust manifold and three-way catalytic converter assembly.
10. Disconnect oil pressure switch connector.
11. Disconnect engine wire (for oxygen sensor(s)) from engine hanger.
12. Remove water outlet.
a. Disconnect the following connectors:
1. Engine coolant temperature sender gauge connector.
2. Engine coolant temperature sensor connector.





b. Disconnect the following hoses:
1. Upper radiator hose.
2. Water by-pass pipe hose.
3. Heater water hose.
4. Idle Air Control (IAC) water by-pass hose.
5. Two Evaporative Emission Control (EVAP) Thermal Vacuum Valve (TVV) vacuum hoses.





c. Remove the two bolts, water outlet and gasket.





13. Remove water by-pass pipe.
a. Disconnect the following hoses:
1. IAC water by-pass hose.
2. Heater water hose.
3. (With Oil Cooler)
Two oil cooler water by-pass hoses.





b. Remove the two bolts, two nuts, water by-pass pipe and gasket.
c. Remove the 0-ring from the water by-pass hose.
14. Remove throttle body.
a. Disconnect the throttle position sensor connector.
b. Disconnect the IAC valve connector.





c. Disconnect the following hoses from the throttle body.
1. PCV hose.
2. Two vacuum hoses from EGR vacuum modulator.
3. Vacuum hose from EVAP Vacuum Switching Valve (VSV).





d. Remove the four throttle body mounting bolts.





e. Disconnect the hoses from the throttle body, and remove the throttle body.
1. Water by-pass hose from water outlet.
2. Water by-pass hose from water by-pass pipe.
3. Air hose from air tube.





15. Remove EGR valve and vacuum modulator
a. Disconnect the EGR gas temperature sensor connector.
b. Remove the following hoses:
1. Two vacuum hoses from EGR VSV (Hoses No.1 and 2).
2. Vacuum hose from charcoal canister (Hose No.3).
3. Disconnect the EGR gas temperature sensor connector (Connector (e)).
c. Disconnect the vacuum hose clamp.





d. Loosen the union nut of the EGR pipe and remove the two bolts, EGR valve, vacuum modulator, vacuum hoses assembly and gasket.





16. Disconnect vacuum hoses.
a. Vacuum sensor hose from air intake chamber.
b. Brake booster vacuum hose from air intake chamber.
c. Vacuum sensing hose.
17. (With A/C) Disconnect A/C magnet switch VSV connector.





18. Remove air tube
a. Disconnect the following hoses:
1. (With A/C) Air hose from A/C Air Switching Valve (ASV).
2. Two air hoses from Power Steering pump.





b. Remove the three bolts, wire clamp and air tube.





19. Disconnect engine wire ground strap from intake manifold.
20. Disconnect knock sensor and EGR VSV connectors.
21. Remove EGR VSV.





22. Remove intake manifold.
a. Remove the four bolts, wire bracket, No.1 air intake chamber and manifold stays.
b. Remove the bolt, vacuum hose bracket, and disconnect the engine wire.





c. Remove the six bolts, two nuts, intake manifold and gasket.





d. Disconnect the two wire clamps from the wire brackets on the intake manifold.





23. Remove delivery pipe and injectors.
a. Disconnect the injector connectors.
b. Loosen the pulsation damper, and disconnect the fuel inlet hose.
c. Disconnect fuel return hose.





d. Remove the two bolts and delivery pipe together with the four injectors.

CAUTION: Be careful not to drop the injectors when removing the delivery pipe.

e. Remove the four insulators and two spacers from the cylinder head.
f. Pull out the four injectors from the delivery pipe.
g. Remove the 0-ring and grommet from each injector.





24. Remove camshaft timing pulley.
25. Remove the bolt, No. 1 idler pulley and tension spring.





26. Remove the four bolts and No.3 timing belt cover.





NOTE:
^ Support the timing belt, so the meshing of crankshaft timing pulley and timing belt does not shift.
^ Be careful not to drop anything inside the timing belt cover.
^ Do not allow the belt to come into contact with oil, water or dust.





27. Remove the two engine hangers and ground strap.
28. Remove generator bracket
29. Remove oil pressure switch.





30. Remove the four nuts, grommets, cylinder head cover and gasket.





NOTE: Arrange the grommets in correct order. so that they can be reinstalled into their original positions This minimizes any possibility of oil leakage due reuse of grommets.





31. Remove high - tension cords clamp and PCV valve.
32. Remove camshafts.

CAUTION: 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. Remove exhaust camshaft.
1. Set the knock pin of the intake camshaft at 10-45° BTDC of camshaft angle.

NOTE: The above angle allows No.2 and No.4 cylinder cam lobes of the exhaust camshaft to push their valve lifters evenly.





2. Secure the exhaust camshaft sub-gear to drive 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 in.)

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





3. Remove the two bolts and rear bearing cap.





4. Uniformly loosen and remove the six bolts on the No. 1, No.2 and No.4 bearing caps in several passes in the sequence shown.

NOTE: Do not remove the No.3 bearing cap bolts at this stage.

5. Remove the No.1, No.2 and No.4 bearing caps.





6. Alternately loose and remove the two bolts on the No.3 bearing cap.

NOTE:
^ As the two No.3 bearing cap bolts are loosened, make sure that the camshaft is lifted out straight and level.
^ If the camshaft is not being lifted out straight and level, retighten the two No.3 bearing cap bolts. Then reverse the order of above steps from (f) to (a) and reset the knock pin of the intake camshaft at 10-45° BTDC, and repeat steps from (b) to (f) once again.

CAUTION:Do not pry on or attempt to force the camshaft with a tool or other object.

7. Remove the No.3 bearing cap and exhaust camshaft.





B. Remove intake camshaft.
1. Set the knock pin of the intake camshaft at 80-115° BTDC of camshaft angle.

NOTE: The above angle allows the No.1 and No.3 cylinder cam lobes of intake camshaft to push their valve lifters evenly.





2. Remove the two bolts, front bearing cap and oil seal.





3. Uniformly loosen and remove the six bolts on the No. 1, No.3 and No.4 bearing caps in several passes in the sequence shown.

NOTE: Do not remove the No.2 bearing cap bolts at this stage.

d. Remove the No.1, No.3 and No.4 bearing caps.





5. Alternately loosen and remove the two bolts on the No.2 bearing cap.

NOTE:
^ As the two No.2 bearing cap bolts are loosened, make sure that the camshaft is lifted out straight and level, after breaking adhesion on the front bearing cap.
^ If the camshaft is not being lifted out straight and level, retighten the two No.2 bearing cap bolts. Reverse the order of above steps from (e) to (a) and reset the knock pin of the intake camshaft at 8O-1l5° BTDC, and repeat steps from (b) to (e) once again.

CAUTION: Do not pry on or attempt to force the camshaft with a tool or other object.

6. Remove the No,2 bearing cap and camshaft.





33. Remove cylinder head.

a. Using SST 09011-38121, uniformly loosen and remove the ten cylinder head bolts in several passes, in the sequence shown.

CAUTION: Cylinder head warpage or cracking could result from removing bolts in incorrect order.





b. Lift the cylinder head from the dowels on the cylinder block, and place the cylinder head on wooden blocks on a bench.

NOTE: If the cylinder head is difficult to lift off, pry between the cylinder head and cylinder block with a screwdriver.

CAUTION: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.