Cylinder Head Removal

REMOVAL OF CYLINDER HEAD
1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY
2 DRAIN COOLANT
3. RAISE VEHICLE

NOTICE: Be sure the vehicle is securely supported.

4. DISCONNECT EXHAUST PIPE FROM EXHAUST MANIFOLD
5. REMOVE NO.1 AIR CLEANER HOSE WITH INTAKE AIR CONNECTOR PIPE
6. REMOVE PCV PIPE WITH HOSES
7. REMOVE ACCELERATOR LINK BRACKET
8. REMOVE AIR INTAKE CONNECTOR
9. REMOVE VACUUM TRANSMITTING PIPE AND AIR INTAKE CONNECTOR BRACKETS
10. DISCONNECT GROUND STRAP FROM ENGINE RH REAR SIDE
11. DISCONNECT RADIATOR INLET HOSE
12. DISCONNECT HEATER INLET HOSE
13. DISCONNECT NO.3 PCV HOSE
14. REMOVE ALTERNATOR

(a) Disconnect Connector And Wire From Alternator
(b) Remove Drive Belt

(c) Remove the adjusting lock bolt, pivot bolt, nut and alternator.
15. REMOVE AIR INTAKE CHAMBER
(a) Disconnect the following connectors:
- Throttle position sensor connector
- ISC valve connector
(b) Disconnect the following hoses:
- BVSV hose from throttle body
- EGR hoses from throttle body
- Vacuum transmitting pipe hoses from intake chamber
- Pressure regulator hose
- PS air hose
- No.1 water by-pass hose from intake manifold (for ISC)
- No.3 water by-pass hose from water by-pass pipe (for Throttle body)

(c) Remove the two bolts and manifold stay.
(d) Remove the cold start injector tube.
(e) Put a suitable container or shop towel under the cold start injector.

(f) Remove the union bolt and two gaskets, and disconnect the injector tube.

HINT: Slowly loosen the union bolt.

(g) Remove the union bolt, two gaskets and fuel tube.
(h) Remove the mount bolts of the EGR pipe.

(i) Remove the EGR vacuum modulator from bracket.
(j) Disconnect the engine wire harness from the clamps of the air intake chamber.

(k) Remove the bolt holding the vacuum transmitting pipe to the No.2 fuel pipe stay.
(l) Remove the two nuts, five bolts, vacuum transmitting pipes and air intake chamber and gasket.
(m) Disconnect the cold start injector connector.
16. DISCONNECT ENGINE WIRE
(a) Disconnect the following connectors and wire:
- Oxygen sensor connector
- Oil pressure sender gauge connector
- Water temp. sensor connector Water temp. sender gauge connector
- Cold start injector time switch connector
- Distributor connector
- Igniter connector
- Noise filter connector
- Injector connectors
- VSV connector
- Knock sensor connector
- (California Specification Vehicles) EGR gas temp. sensor connector
- Ground strap from intake manifold
- Starter connector (terminal 50)
- Transmission connectors
- A/C compressor connector
- Check connector
- Connector from relay block
(b) Disconnect the engine wire from each clamp.

17. REMOVE NO.1 FUEL PIPE
18. REMOVE NO.2 FUEL PIPE

(a) Disconnect the fuel hose from the No.2 fuel pipe.
(b) Remove the bolt, union bolt, No.2 fuel pipe and gaskets.
19. REMOVE DISTRIBUTOR

(a) Remove Water Proof Cover
(b) Disconnect High-tension Cords From Spark Plugs And Ignition Coil
(c) Disconnect Distributor Connector
(d) Set No.1 Cylinder To TDC/Compression

(e) Turn the crankshaft counterclockwise approximately 120°.
(f) Turn the crankshaft again approximately 10° to 40° clockwise so that the timing belt cover TDC mark and the crankshaft pulley TDC mark are aligned.
(g) REMOVE DISTRIBUTOR

(h) Remove the hold-down bolt.

(i) Pull out the distributor from the cylinder head.
(j) Remove the oil filler cap.
(k) Look through oil filler hole and turn the crankshaft clockwise until the cam nose can be seen.
20. REMOVE OIL DIPSTICK

21. REMOVE EXHAUST MANIFOLD
Remove the seven nuts, exhaust manifold and gasket.

22. REMOVE WATER OUTLET HOUSING
(a) Remove the union bolts, unions with No.4 water bypass hose and gaskets.
(b) Disconnect the No.6 water by-pass hose from the water by-pass pipe.

23. REMOVE CYLINDER HEAD COVERS
(a) Remove the No.1 and No.2 cylinder head covers.

(b) Using SST, remove the No.3 cylinder head cover. SST 09923-00010
24. REMOVE SPARK PLUGS
25. REMOVE TIMING BELT AND CAMSHAFT TIMING PULLEYS

(a) Remove Alternator Drive Belt, Fan With Fluid Coupling And Water Pump Pulley

(b) Loosen the four nuts holding the fluid coupling to the water pump.
(c) Loosen the pivot bolt, adjusting bolt and nut, and remove the drive belt.
(d) Remove the four nuts, fluid coupling, water pump pulley and fan shroud.
(e) Remove PS Belt
(f) REMOVE NO.3 TIMING BELT COVER

(g) Remove the five bolts, nut and No.3 timing belt cover with the gasket.
(h) Set No.1 Cylinder To TDC/compression

(i) Turn the crankshaft pulley and align its groove with the "O" mark on the No.1 timing belt cover.

(j) Check that the alignment marks on the camshaft timing pulleys and No.2 timing belt cover are aligned. If not, turn the crankshaft pulley one complete revolution.
(k) Remove Timing Belt From Camshaft Timing Pulleys

HINT: If reusing the timing belt, draw a direction arrow on the belt (in direction of engine revolution).

(l) Loosen the mount bolt of the idler pulley and shift it left as far as it will go with a screwdriver and wrench.
(m) Temporarily tighten the mount bolt and thus relieve the timing belt tension.
(n) Remove the timing belt from the camshaft timing pulley.

HINT:

- Support the 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 and dust.

(o) Remove Camshaft Timing Pulleys

Using SST to hold the pulley, remove the pulley bolt, timing pulley and straight pin. SST 09278-54012

HINT: Place the matchmarks on the camshaft timing pulley where the straight pin inserted.

NOTICE: Do not make use of the timing belt tension when removing and installing the pulley set bolts.

(p) Remove Crankshaft Pulley

(q) Using SST to hold the crankshaft pulley, loosen the pulley mount bolt. SST 09213-5401 5 (91651-60855) and 09330-00021
(r) Remove SST and pulley bolt.

(s) Using SST, remove the pulley. SST 09213-54015 (91651-60855) and 09213-60017 (09213-00020, 09213-00030, 09213-00040)
26. REMOVE CYLINDER HEAD

(a) Using SST, uniformly loosen and remove the cylinder head bolts in several passes, in the sequence shown. SST 09043-38100

NOTICE: Head warpage or cracking could result from removing in incorrect order.

(b) Lift the cylinder head from the dowels on the cylinder block. As the cylinder head is lifted, separate the No.5 water by-pass hose from the union.

(c) Place the head on wooden blocks on a bench. If the cylinder head is difficult to lift off, pry with a screwdriver between the cylinder head and block projection.

NOTICE: Be careful not to damage the cylinder head and block surface on the cylinder and head gasket side.

DISASSEMBLY OF CYLINDER HEAD

1. REMOVE NO.2 TIMING BELT COVER
2. REMOVE ALTERNATOR BRACKET
3. REMOVE HEATER INLET HOSE

4. REMOVE DELIVERY PIPE WITH INJECTORS
(a) Remove the three bolts, and then remove the delivery pipe with the injectors.

NOTICE: Be careful not to drop the injectors.

(b) Remove the six insulators and three collars from the cylinder head.
5. REMOVE INTAKE MANIFOLD

Remove the four nuts, seven bolts, EGR valve, VSV, intake manifold and gasket.
6. REMOVE NO.2 ENGINE HANGER AND GROUND STRAP

7. REMOVE HEATER UNION
8. REMOVE EGR COOLER

9. REMOVE BEARING CAPS AND CAMSHAFTS
(a) Uniformly loosen and remove the bearing cap bolts in several passes, in the sequence shown.
(b) Remove the camshaft bearing caps, oil seal and camshaft.

10. REMOVE VALVE LIFTERS WITH SHIMS
Arrange the valve lifters and shims in correct order.
11. REMOVE VALVES

(a) Using SST, press the valve spring and remove the two keepers. SST 09202-70010
(b) Remove the spring retainer, valve spring1seat and valve.

HINT: Arrange the valve, spring seat, valve spring and retainer in correct order.