Removal (Except 2000 California Models)
- Release fuel pressure. See FUEL PRESSURE RELEASE . Drain cooling system.
- Disconnect control cables at throttle body and cruise control actuator (if equipped). Remove air cleaner cap and airflow meter with air cleaner hose. Remove intake air connector and A/C idle-up valve (if equipped).
- Remove power steering pump drive belt. Remove power steering pump idler pulley. Remove nut and pulley from power steering pump.
- Remove bolts and power steering pump with hoses attached, and secure aside. Remove bolts and power steering pump bracket from cylinder head.
- Disconnect PCV hoses. Disconnect spark plug wires at spark plugs. Remove ignition coils. Remove bolts, coolant outlet and gasket from front of cylinder head. Remove bolts, cylinder head rear cover and gasket from rear of cylinder head.
- Disconnect necessary coolant hoses, vacuum hoses and engine wiring connectors. Remove EGR pipe and gaskets. Remove EGR valve and vacuum modulator with gasket (if necessary).
- Remove intake manifold brace from bottom of air intake chamber. Remove air intake chamber and gasket from intake manifold.
- Disconnect electrical connectors at injectors. Remove union bolts, fuel inlet pipe and gaskets. Disconnect fuel lines, and remove fuel return pipe.CAUTION: DO NOT allow injectors to fall from delivery pipe when removing delivery pipe.
- Remove delivery pipe bolts. Remove delivery pipe with injectors. Remove insulators on top of spacers in cylinder head.
- Remove injectors from delivery pipe (if necessary). Remove intake manifold and gasket. Remove front exhaust pipe from exhaust manifold.
- Remove heat insulator from exhaust manifold. Remove exhaust manifold and gasket. Remove bolts and No. 1 and 2 engine hangers from cylinder head.
- Remove valve cover and gasket. Remove spark plugs. Remove camshafts. See CAMSHAFT . Rotate crankshaft clockwise (viewed from front of engine) so cylinder No. 1 (front cylinder) is at TDC on compression stroke. Ensure timing mark on crankshaft pulley aligns with "0" mark on front cover.
- Ensure timing marks on camshaft gears align. See Figure. If timing marks do not align, rotate crankshaft clockwise 1 full revolution (360 degrees).CAUTION: To prevent cylinder head warpage, loosen cylinder head bolts in proper sequence.
- Remove 2 cylinder head-to-front cover bolts, located on cylinder head, in front of camshaft sprocket area. Loosen cylinder head-to-cylinder block bolts in sequence using several steps. See Fig 1.
- Remove cylinder head-to-cylinder block bolts with washers, cylinder head and cylinder head gasket. Note location of adjusting shims and valve lifters for reassembly reference. Remove adjusting shims and valve lifters from cylinder head (if necessary).