Cylinder Head Removal
REMOVAL
1. REMOVE RIGHT-HAND ENGINE UNDER COVER
2. DRAIN ENGINE COOLANT
3. A/T only: DISCONNECT THROTTLE CABLE FROM THROTTLE BODY
4. DISCONNECT ACCELERATOR CABLE FROM THROTTLE BODY
5. REMOVE AIR CLEANER CAP AND CASE
6. REMOVE GENERATOR
7. REMOVE FRONT EXHAUST PIPE
a. Using a 14 mm deep socket wrench, remove the 2 bolts holding the front exhaust pipe to the front TWC.
b. Remove the 2 bolts holding the front exhaust pipe to the TWC w/ pipe.
c. Remove the front exhaust pipe and 2 gaskets.
8. REMOVE EXHAUST MANIFOLD AND HEAT INSULATOR ASSEMBLY
a. Disconnect these connectors:
^ California: Air Fuel Ratio (A/F) sensor connector
^ Except California: Oxygen sensor (bank 1 sensor 1) connector
b. Remove the 4 bolts and manifold upper heat insulator.
c. California: Remove the 2 bolts and Right-Hand exhaust manifold stay.
d. Remove the 2 bolts and Left-Hand exhaust manifold stay.
e. Remove the 6 nuts, the exhaust manifold and heat insulator assembly.
9. California: REMOVE A/F SENSOR FROM EXHAUST MANIFOLD
10. Except California: REMOVE OXYGEN SENSOR (BANK 1 SENSOR 1) FROM EXHAUST MANIFOLD
11. REMOVE HEAT INSULATOR
a. Remove the 3 bolts and lower heat insulator.
b. Remove the 4 bolts, 2 nuts and 2 heat insulators
12. REMOVE THROTTLE BODY
13. REMOVE IGNITION COILS, NO.2 INTAKE MANIFOLD STAY AND HIGH-TENSION CORDS ASSEMBLY
a. Disconnect the 2 ignition coil connectors.
b. Disconnect the 4 high-tension cords from the 2 clamps on the cylinder head cover.
c. Disconnect the 4 high-tension cords from the spark plugs.
d. Disconnect the wire clamp from the manifold stay.
e. Remove the 2 nuts, 2 bolts, 2 ignition coils, manifold stay and 4 high-tension cords assembly.
14. DISCONNECT OIL PRESSURE SWITCH CONNECTOR
15. REMOVE WATER OUTLET
a. Disconnect these connectors:
^ ECT sensor connector
^ ECT sender gauge connector
b. Disconnect these hoses from the water outlet:
1) Radiator hose
2) Water bypass pipe hose
3) Heater water hose
c. Remove the 2 nuts, water outlet and gasket.
16. REMOVE WATER BYPASS PIPE
a. Remove the bolt, 2 nuts and oil cooler heat protector.
b. Disconnect these hoses:
^ IAC valve water bypass hose from water bypass pipe
^ Heater water hose from water bypass pipe
^ 2 oil cooler water bypass hoses from oil cooler
c. Remove the nut and disconnect the wire protector.
d. Remove the 2 bolts and 2 nuts.
e. Disconnect the water bypass pipe from the water pump cover, and remove the water bypass pipe.
f. Remove the gasket and O-ring.
17. DISCONNECT HOSES AND GROUND STRAP
Disconnect these hoses and ground strap:
1) Vacuum sensor hose from gas filter on intake manifold
2) Brake booster vacuum hose from intake manifold
3) Ground strap from intake manifold
18. DISCONNECT FUEL INLET HOSE FROM FUEL FILTER
Remove the union bolt and 2 gaskets, and disconnect the inlet hose from the fuel filter.
19. REMOVE EGR VALVE AND VACUUM MODULATOR
a. Disconnect the 2 vacuum hoses from the Vacuum Switching Valve (VSV) for the EGR.
b. Disconnect the vacuum modulator from the clamp on the intake manifold.
c. Loosen the union nut of the EGR pipe, and remove the 2 nuts, the EGR valve, vacuum modulator, vacuum hoses assembly and gasket.
20. DISCONNECT PS IDLE-UP AIR HOSES FROM AIR TUBE
21. DISCONNECT KNOCK SENSOR CONNECTOR
22. DISCONNECT GROUND CABLE
Remove the bolt, and disconnect the ground cable from the intake manifold.
23. REMOVE VSV FOR EGR
24. REMOVE CYLINDER HEAD COVER
a. Remove the 2 bolts and accelerator cable bracket.
b. Disconnect the Positive Crankcase Ventilation (PCV) hose from the intake manifold.
c. Disconnect the engine wire protector from the 2 mounting bolts of the No.2 timing belt cover in the sequence shown.
d. Remove the 4 nuts, grommets, head cover and gasket.
HINT: Arrange the grommets in the correct order, so that they can be reinstalled into their original positions. This minimizes any possibility of oil leakage due to reuse of the grommets in different positions.
25. DISCONNECT ENGINE WIRE
a. Remove the 2 bolts, and disconnect the engine wire protector from the Left-Hand side of the intake manifold.
b. Disconnect the 4 injector connectors.
C. W/ A/C: Disconnect the A/C compressor connector.
d. Disconnect the crankshaft position sensor connector.
e. Disconnect the 3 clamps from the No.2 timing bet cover and generator drive belt adjusting bar.
f. Disconnect the camshaft position sensor connector.
g. Disconnect the engine wire protector from the 2 brackets on the front side of the intake manifold.
h. Remove these parts:
^ Right-Hand scuff plate
^ Right-Hand cowl side trim
^ Right-Hand Floor carpet center cover
i. Disconnect the wire and connectors:
^ 2 ECM connectors
^ 2 connectors from connectors on bracket
^ Connector from J/B No.4
j. Disconnect the wire clamp from the bracket.
k. Pull out the engine wire from the cabin.
l. Take out the engine wire between the cylinder head and intake manifold.
26. DISCONNECT TIMING BELT FROM CAMSHAFT TIMING PULLEY
27. REMOVE CAMSHAFT TIMING PULLEY
28. REMOVE NO.1 IDLER PULLEY AND TENSION SPRING
29. REMOVE NO.3 TIMING BELT COVER
Remove the 3 bolts and timing belt cover.
NOTICE:
^ Support the timing belt, so the meshing of the 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.
30. REMOVE EXHAUST 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. Set the knock pin of the intake camshaft at 10 - 45° BTDC of camshaft angle.
HINT: The above angle allows No.2 and No.4 cylinder cam lobes of the exhaust camshaft to push their valve lifters evenly.
b. 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 inch)
HINT: When removing the camshaft, make sure that the torsional spring force of the sub gear has been eliminated by the above operation.
c. Remove the 2 bolts and rear bearing cap.
d. Uniformly loosen and remove the 6 bolts on the No.1, No.2 and No.4 bearing caps, in several passes, in the sequence shown.
NOTICE: Do not remove the No.3 bearing cap bolts at this stage.
e. Remove the No.1,No.2 and No.4 bearing caps.
f. Alternately loosen and remove the 2 bolts on the No.3 bearing cap.
HINT:
^ As the 2 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 2 No.3 bearing cap bolts. Then do steps f. to a. and reset the knock pin of the intake camshaft at 10 - 45°BTDC, and repeat steps b. to f. once again.
NOTICE: Do not pry on or attempt to force the camshaft with a tool or other object.
g. Remove the No.3 bearing cap and exhaust camshaft.
31. REMOVE INTAKE CAMSHAFT
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. Set the knock pin of the intake camshaft at 80 - 115° BTDC of camshaft angle.
HINT: The above angle allows the No.1 and No.3 cylinder cam lobes of intake camshaft to push their valve lifters evenly.
b. Remove the 2 bolts, front bearing cap and oil seal.
c. Uniformly loosen and remove the 6 bolts on the No.1, No.3 and No.4 bearing caps, in several passes, in the sequence shown.
NOTICE: Do not remove the No.2 bearing cap bolts at this stage.
d. Remove the No.1, No.3 and No.4 bearing caps.
e. Alternately loosen and remove the 2 bolts on the No.2 bearing cap.
HINT:
^ As the 2 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 2 No.2 bearing cap bolts. Do steps e. to a. and reset the knock pin of the intake camshaft at 80 - 115° BTDC, and repeat steps b. to e. once again.
NOTICE: Do not pry on or attempt to force the camshaft with a tool or other object.
f. Remove the No.2 bearing cap and camshaft.
32. DISASSEMBLE EXHAUST CAMSHAFT
a. Mount the camshaft in a vise.
NOTICE: Be careful not to damage the camshaft.
b. Insert service bolt A into the service hole of the camshaft sub gear.
c. Using a screwdriver, turn the sub gear clockwise, and remove service bolt B.
NOTICE: Be careful not to damage the camshaft.
d. Using snap ring pliers, remove the snap ring.
e. Remove these parts:
1) Wave washer
2) Camshaft sub gear
3) Camshaft gear spring
33. REMOVE CYLINDER HEAD AND INTAKE MANIFOLD ASSEMBLY
a. Uniformly loosen and remove the 10 cylinder head bolts in several passes, in the sequence shown.
NOTICE: 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.
HINT: If the cylinder head is difficult to the lift off, pry between the cylinder head and cylinder block with a screwdriver.
NOTICE: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.
34. REMOVE AIR TUBE
a. Disconnect the air hose from the intake manifold.
b. Remove the 2 bolts, hose clamp and air tube.
35. REMOVE INTAKE MANIFOLD
Remove the 6 bolts, 2 nuts and intake manifold and gasket.
36. REMOVE AIR HOSE FOR AIR ASSIST SYSTEM
Disconnect the air hose from the cylinder head port, and remove the air hose.
37. REMOVE DELIVERY PIPE AND INJECTORS
38. REMOVE OIL PRESSURE SWITCH