Removal/Installation

REMOVAL

Fig. 1 Disconnecting Fuel Pump Relay Coupler:

1. Relieve fuel pressure as follows:
a. Place transmission gear shift lever in Neutral (manual transmission) or Park (automatic transmission). Set parking brake and block drive wheels.
b. Remove main fuse box cover and engine cooling water reservoir.
c. Detach main fuse box from body and disconnect coupler from fuel pump relay, Fig. 1.
d. Remove fuel filler cap to release fuel vapor pressure in tank, reinstall cap.
e. Start engine and run till it stops for lack of fuel. Repeat cranking engine three times for three seconds each time to dissipate fuel pressure in lines.
2. Disconnect battery ground cable, then drain cooling system.
3. Remove air cleaner assembly with AFM outlet hose.
4. Disconnect the following electrical wires:
a. Disconnect Idle Speed Control (ISC) valve connector.
b. Disconnect high tension cord from distributor, then distributor Crank Angle Sensor (CAS) connector.
c. On California models, disconnect Recirculated Exhaust Gas Temperature Sensor (REGTS) and Exhaust Gas Recirculation Vacuum Switching Valve (EGR VSV) connectors.
d. On all models, disconnect Water Temperature Sensor (WTS) and oxygen sensor connectors.
e. Disconnect canister purge VSV connector, then ground wire from intake manifold.
f. Disconnect Throttle Position Sensor (TPS) and fuel injector connectors.
g. Disconnect Water Temperature Gauge (WTG) and radiator fan thermo switch.
h. Ensure all wires are free of clamps on engine.
5. Disconnect vacuum hoses from brake booster and canister purge.
6. Remove accelerator cable from throttle lever and bracket.
7. Remove radiator hose from thermostat housing, heater hose from cylinder head and throttle body hose from throttle body.
8. Remove fuel feed and return hoses from delivery pipe.
9. Remove timing belt as outlined under TIMING BELT & TENSIONER.
10. On DOHC models, remove timing belt inside cover, the exhaust pipe from manifold.
11. On DOHC models, remove alternator adjusting arm stiffener, then intake manifold bracket.
12. Remove cylinder head cover.
13. Using 18 mm hexagon socket, remove cylinder head bolts.
14. Remove cylinder head, intake manifold, exhaust manifold, distributor, fuel delivery pipe and injectors as an assembly. Do not place assembly on flat surface as one valve is in the open position.

INSTALLATION

Fig. 42 Cylinder Head Tightening Sequence:

Fig. 43 Installing Rubber Seal:

1. Install new head gasket with TOP mark on gasket on top and facing crankshaft pulley side.
2. Install cylinder head. Tighten bolts gradually with torque wrench, following sequence in Fig. 42. Tighten all bolts to specifications.
3. On DOHC models, install valve lash adjuster, camshafts and camshaft timing belt pulleys as outlined under CAMSHAFTS & HYDRAULIC VALVE LASH ADJUSTER
4. On SOHC models, install rocker arm shafts, rocker arms, springs and camshaft as outlined under ROCKER ARMS, ROCKER ARM SHAFTS & CAMSHAFT.
5. Install cylinder head cover, then timing belt inside covers. Ensure rubber seal is installed between water pump and cylinder head, Fig. 43.
6. Install distributor to cylinder head.
7. On SOHC models, adjust valve lash as outlined under ADJUSTMENT PROCEDURES/VALVES.
8. Reverse removal procedure to complete installation.