- Disconnect negative battery cable. Drain cooling system. Disconnect accelerator cable, throttle valve cable (A/T models) and cruise control cable.
WARNING:
To prevent air bag deployment (if equipped), disconnect negative battery cable at least 60 seconds before working on vehicle.
- Remove air cleaner hose and intake air pipes. Disconnect necessary electrical connections, coolant hoses, control cables, fuel lines and vacuum hoses. Remove alternator.
- On turbo models, remove power steering fluid reservoir. On all models, remove PCV tubing with hoses. Remove support braces and air intake connector. See Figure.
- Place suitable container under cold start injector fuel line. Cover fuel line connection using shop towel. Slowly loosen fuel line union bolt to release fuel pressure. Once fuel pressure is released, remove union bolts, gaskets and cold start injector fuel line.
- Remove EGR pipe retaining bolts. On non-turbo models, remove EGR vacuum modulator from bracket. On all models, remove necessary piping, retaining bolts/nuts, air intake chamber and gasket. See Figure.
- Remove fuel pipes from delivery pipe, fuel pressure regulator or pulsation damper, and fuel filter. Disconnect spark plug wires.
- Remove retaining bolt and distributor (non-turbo models) or camshaft position sensor (turbo models). Remove oil dipstick and necessary piping to access valve covers. Disconnect exhaust pipe from exhaust manifold or turbocharger outlet elbow (if equipped).
- On turbo models, remove turbocharger (if necessary). See TURBOCHARGER under REMOVAL & INSTALLATION. Remove ignition coil assembly and bracket.
- On all models, remove retaining nuts, exhaust manifold and gasket. Remove coolant outlet housing (if necessary). Remove No. 1, No. 2 and No. 3 valve covers, and gaskets. See Figure.
- Remove spark plugs. Remove timing belt and camshaft timing pulleys. See TIMING BELT .
CAUTION:
Cylinder head bolts must be removed in proper sequence to prevent cylinder head warpage.
- Using Hex Adapter (09043-38100), loosen cylinder head bolts in sequence using several steps. See Figure and Figure
. Remove cylinder head bolts. Lift cylinder head upward, and disconnect coolant by-pass hose from union. Remove cylinder head and gasket.
NOTE:
If cylinder head removal is difficult, pry between cylinder head and projected area near front of cylinder block. DO NOT damage sealing surfaces on cylinder block and cylinder head.
- Remove No. 2 timing belt cover, delivery pipe, insulators and spacers from cylinder head. DO NOT allow injectors to fall from delivery pipe during removal.
- Remove retaining bolts/nuts, intake manifold and gasket, and EGR cooler. See Figure. Remove bolt and heater union, which heater coolant line connects to, from rear of cylinder head. Remove camshafts. See CAMSHAFT under REMOVAL & INSTALLATION.