Removal/Installation

REMOVAL
1. Relieve fuel system pressure as outlined under Technician Safety Information.
2. Disconnect battery ground cable, then drain coolant system into appropriate container.
3. Remove air cleaner assembly with AFM outlet hose.
4. Disconnect following electrical wires:
a. Disconnect Idle Speed Control (ISC) valve connector.
b. Disconnect high tension cord from distributor, then the 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. Disconnect Water Temperature Sensor (WTS) and oxygen sensor connectors.
e. Disconnect canister purge VSV connector, then the 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.
10. Remove timing belt inside cover, then the exhaust pipe from manifold.
11. Remove cylinder head cover.
12. Using 18 mm hexagon socket, remove cylinder head bolts.
13. 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
1. Install new head gasket with TOP mark on gasket on top and facing crankshaft pulley side.

Fig. 20 Cylinder Head Tightening Sequence:

2. Install cylinder head, then using sequence shown in Fig. 20, torque cylinder head bolts in two or three steps to 48-54 ft. lbs.
3. Install valve lash adjuster, camshafts and camshaft timing belt pulleys as outlined under Camshaft, Engine.

Fig. 21 Water Pump Rubber Seal Installation:

4. Install cylinder head cover, then the timing belt inside covers. Ensure rubber seal is installed between water pump and cylinder head, Fig. 21.
5. Install distributor to cylinder head.
6. Reverse procedure to install.