Dissemble

PREPARATION FOR REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY
2. DRAIN COOLANT
3. DISCONNECT EXHAUST PIPE FROM EXHAUST MANIFOLD

4. REMOVE THROTTLE CABLE BRACKET FROM CYLINDER HEAD COVER (A/T)
5. REMOVE ACCELERATOR AND ACTUATOR CABLE BRACKET FROM CYLINDER HEAD COVER
6. DISCONNECT FOLLOWING WIRES AND CABLES:
(a) Ground strap from the cylinder head
(b) Oxygen sensor wire

(c) High-tension cord from the ignition coil
(d) Distributor connector
(e) Temp. switch wire (for A/T)
(f) Solenoid resistor wire connector
(g) Knock sensor wire connector
7. DISCONNECT FOLLOWING HOSES:

(a) Brake booster vacuum hose
(b) Actuator vacuum hose (with cruise control system)
(c) Fuel hose from the intake manifold
(d) EGR valve vacuum hose

8. DISCONNECT RADIATOR UPPER HOSE FROM THERMOSTAT HOUSING
9. DISCONNECT TWO HEATER HOSES
REMOVAL OF CYLINDER HEAD
1. REMOVE AIR INTAKE CONNECTOR

(a) Disconnect the No.1 air hose from the air intake connector.
(b) Remove the two clamp bolts.
(c) Loosen the throttle body hose clamp and remove the air intake connector and the connector pipe.
2. DISCONNECT FOLLOWING HOSES:
(a) No. 1 water by-pass hose from ISC valve.

(b) No. 2 water by-pass hose from throttle body.
(c) Two PCV hoses from the cylinder head cover.
(d) Fuel hose from the fuel hose support.
(e) Label and disconnect the emission control hoses from the throttle body and air intake chamber to allow removal of the cylinder head.
3. REMOVE AIR INTAKE CHAMBER STAY

4. REMOVE VACUUM PIPE SUBASSEMBLY
Remove the bolts and remove the vacuum pipe and ground strap.
5. REMOVE DISTRIBUTOR FROM CYLINDER HEAD
(a) Remove the high-tension cord clip bolt, leaving the wires attached to the clips.
(b) Disconnect the high tension cord by pulling on the plug boot.

(c) Remove the distributor holding bolt.
(d) Remove the distributor from the cylinder head with the cap and wires.
6. REMOVE SPARK PLUGS

7. DISCONNECT FOLLOWING WIRES:
(a) Cold start injector wire
(b) Water temp. sensor wire
(c) Start injection time switch wire
(d) Water temp. sending unit wire
(e) Throttle position sensor wire connector
(f) ISC valve wire connectors
8. DISCONNECT COLD START INJECTOR FUEL HOSE FROM DELIVERY PIPE
9. REMOVE AIR INTAKE CHAMBER
(a) Remove the five bolts and two nuts.
(b) Loosen the nut of the EGR pipe.

10. DISCONNECT EFI WIRE HARNESS FROM ECU
(a) Remove the glove box.
(b) Remove the ECU.
(c) Disconnect the three connectors.
(d) Pull out the ECU wire harness out through the cowl panel.
11. REMOVE PULSATION DAMPER AND NO.1 FUEL PIPE
12. REMOVE WATER OUTLET HOUSING
(a) Loosen the clamp and disconnect the water by-pass hose.

(b) Remove the two bolts and remove the outlet housing.
13. REMOVE INTAKE MANIFOLD

Remove the eight bolts and two nuts holding the intake manifold and remove the intake manifold and gasket.
14. REMOVE POWER STEERING PUMP FROM BRACKET
(a) Remove the PS pump pulley with the drive belt.

(b) Remove the PS pump stay.
(c) Remove the PS pump from the bracket.
(d) Lay the PS pump to one side without disconnecting the hoses.
15. REMOVE EXHAUST MANIFOLD

(a) Remove the five nuts and the two heat insulators.
(b) Remove seven nuts and the exhaust manifold.
16. REMOVE TIMING BELT AND CAMSHAFT TIMING PULLEYS
17. SET NO.1 CYLINDER TO TDC/COMPRESSION
18. REMOVE NO.3 TIMING BELT COVER
Remove the five bolts and remove the cover and gasket.
19. RELIEVE TIMING BELT TENSION
(a) Loosen the idler pulley set bolt a little and shift the idler pulley to the alternator side with a screwdriver and wrench.
(b) Finger tighten the set bolt and then relieve the timing belt tension.
20. REMOVE TIMING BELT FROM CAMSHAFT TIMING PULLEYS
21. REMOVE CAMSHAFT TIMING PULLEYS
Using SST to hold the pulley, remove the pulley set bolt, timing pulley, and match pin. SST 09278-54012

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

NOTE: The exhaust and intake sides each use a different type of pulley they are not interchangeable.

22. REMOVE OIL PRESSURE REGULATOR
(a) Remove the two bolts and the timing belt cover stay.

(b) Remove the three bolts and the oil pressure regulator and gasket.
18. REMOVE NO.2 TIMING BELT COVER
Remove the three bolts and two nuts and the No.2 timing belt cover and gasket.
19. REMOVE CYLINDER HEAD BOLTS

Using SST, remove the fourteen head bolts gradually in two or three passes and in the numerical order shown. SST 09043-38100

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

20. REMOVE CYLINDER HEAD
Lift the cylinder head from the dowels on the cylinder block and place the head on wooden blocks on a bench. If the cylinder head is difficult to lift off, pry with a screwdriver between the head and block saliences.

CAUTION: Be careful not to damage the cylinder head and block surfaces on the cylinder head gasket side.

21. REMOVE EGR COOLER

DISASSEMBLY OF CYLINDER HEAD
1. REMOVE CYLINDER HEAD COVERS

Remove the two cylinder head covers by loosening the screws.
2. REMOVE NO.1 AND NO.2 CAMSHAFT HOUSINGS WITH CAMSHAFT
Remove No.1 and No.2 camshaft housings by loosening the nuts (front side) and bolts.

CAUTION: Loosen each camshaft housing nut and bolt a little at a time in the sequence shown in the figure.

3. REMOVE ROCKER ARMS AND LASH ADJUSTERS

Remove the rocker arms and lash adjusters from the cylinder head.
NOTE: Arrange the rocker arms and lash adjusters in order.

4. REMOVE VALVES
(a) Using SST, compress the valve spring until the two keepers can be removed. SST 09202-43013

(b) Remove the valve keepers, retainers, springs and valves.

NOTE: Keep valves in order for reinstallation in the same manner.

(c) Remove the valve stem oil seals.
(d) Using a small screwdriver or magnet, remove the valve spring seats