Valve Cover: Service and Repair
REMOVAL1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY
CAUTION: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.(w/Airbag)
2. DRAIN ENGINE COOLANT
3. DISCONNECT ACCELERATOR CABLE FROM THROTTLE LINKAGE
4. DISCONNECT THROTTLE CABLE FROM THROTTLE LINKAGE (A/T)
5. REMOVE AIR CLEANER CAP, VOLUME AIR FLOW METER AND AIR CLEANER HOSE
(a) Disconnect the volume air flow meter
(b) Disconnect the coil cord clamp.
(c) Disconnect the air hoses.
(d) Loosen the air cleaner hose clamp bolt.
(e) Disconnect the air cleaner cap clips.
(f) Remove the air cleaner cap and volume air flow meter together with the air cleaner hose.
6. REMOVE V-BANK COVER
- Using a 5 mm hexagon wrench, remove the two nuts and V-bank cover
7. REMOVE EMISSION CONTROL VALVE SET
(a) Disconnect the EGR gas temp. sensor connector clamp from the emission control valve set. (Calif. only)
(b) Disconnect the two vacuum hoses of the fuel pressure control VSV.
(c) Disconnect the two vacuum hoses of the IACV VSV,
(d) Disconnect the two VSV connectors.
(e) Remove the two bolts and emission control valve set.
8. DISCONNECT HOSES
(a) Brake booster vacuum hose
(b) PS air hose
(c) PCV hose
(d) IACV vacuum hose
9. DISCONNECT GROUND STRAPS
- Remove the nut and disconnect the two ground straps.
10. DISCONNECT COLD START INJECTOR CONNECTOR
11. DISCONNECT COLD START INJECTOR PIPE (No.2 FUEL PIPE)
(a) Put a suitable container or shop towel under the injector pipe.
(b)Remove the union bolt and two gaskets, and disconnect the injector pipe.
HINT: Slowly loosen the union bolt.
12. REMOVE NO.1 ENGINE HANGER AND AIR INTAKE CHAMBER STAY
(a) Remove the two bolts and No.1 engine hanger.
(b) Remove the two bolts and air intake chamber stay.
13. REMOVE EGR PIPE
(a) Loosen the union nut.
(b) Remove the two bolts and EGR pipe.
14. DISCONNECT HYDRAULIC MOTOR PRESSURE PIPE
- Remove the bolt and disconnect the hydraulic pressure pipe from the air intake chamber.
15. REMOVE AIR INTAKE CHAMBER
(a) Disconnect the three emission control vacuum hoses.
(b) Disconnect the two water by-pass hoses.
(c) Disconnect the EGR gas temp. sensor connector. (Calif. only)
(d) Disconnect the throttle position sensor connector.
(e) Disconnect the IAC valve connector.
(f) Disconnect the IAC valve air hose.
(g) Disconnect the PS air hose.
(h) Using 8 mm hexagon wrench, remove the two bolts, nuts air intake chamber and gasket.
16. DISCONNECT LH ENGINE WIRE HARNESS
(a) Disconnect the following connectors:
(1) Three injector connectors
(2) Engine oil level sensor connector
(3) Oil pressure switch connector
(4) A/C compressor connector
(5) Generator connector and wire
(6) Engine Coolant temp. sensor connector (for hydraulic cooling fan)
(b) Remove the two bolts, and disconnect the five clamps and LH engine wire harness.
17 .DISCONNECT RH ENGINE WIRE HARNESS
(a) Disconnect the following connectors:
(1) Three injector connectors
(2) Engine coolant temperature sender gauge connector
(3) Oxygen sensor connector
(4) PS pump connector
(b) Remove the two bolts, and disconnect the two clamps and RH engine wire harness.
18. DISCONNECT HIGH TENSION CORDS FROM SPARK PLUGS
19.REMOVE CYLINDER HEAD COVERS
- Remove the six nuts, seal washers, cylinder head cover and gasket. Remove the two cylinder head covers.
INSTALL
1. REVERSE PROCEDURE TO INSTALL NOTING THE FOLLOWING TORQUE AND PROCEDURES:
2. REINSTALL CYLINDER HEAD COVERS
(a) Apply seal packing to the cylinder heads as shown in the illustration. Seal packing:Part No.08826-00080 or equivalent
(b) Install the gasket to the cylinder head cover.
(c) Install the cylinder head cover with the six seal washers and nuts. Uniformly tighten the nuts in several passes. Install the two cylinder head covers.
Torque: 5.9 N.m (60 kgf.cm. 52 in.lb)
3. REINSTALL AIR INTAKE CHAMBER
(a) Using 8 mm hexagon wrench, install a new gasket and the air intake chamber with the two bolts and nuts.
Torque: 43 N.m (440 kgf.cm, 32 ft.lb)
4. REINSTALL EGR PIPE
- Install a new gasket, sleeve ball and the EGR pipe with the two bolts and union nut.
Bolt Torque: 18 N.m (185 kgf.cm. 13 ft.lb)
Union nut Torque: 76 N.m (800 kgf.cm, 58 ft.lb)
5. REINSTALL NO.1 ENGINE HANGER AND AIR INTAKE CHAMBER STAY
(a) Install the air intake chamber stay with the two bolts.
Torque: 39 N.m (400 kgf.cm. 29 ft.lb)
(b) Install the No.1 engine hanger with the two bolts.
Torque: 39 N.m (400 kgf.cm, 29 ft.lb)
6. RECONNECT COLD START INJECTOR PIPE (NO.2 FUEL PIPE)
- Connect the injector pipe with the two new gaskets and union bolt.
Torque: 15 N.m (150 kgf.cm, 11 ft.lb)
7. RECONNECT GROUND STRAPS
- Connect the two ground straps with the nut.
Torque: 13 N.m (130 kgf.cm, 9 ft.lb)