Cylinder Head - Removal

1. Discharge fuel system pressure

2. Disconnect cable from negative battery terminal

3. Remove front wiper arm head cap (for hatchback)

4. Remove front wiper arm head cap (for sedan)

5. Remove front wiper arm and blade assembly lh (for hatchback)

6. Remove front wiper arm and blade assembly lh (for sedan)

7. Remove front wiper arm and blade assembly rh (for hatchback)

8. Remove front wiper arm and blade assembly rh (for sedan)

9. Remove hood to cowl top seal (for hatchback)

10. Remove cowl side ventilator sub-assembly lh (for sedan)

11. Remove cowl side ventilator sub-assembly rh (for sedan)

12. Remove cowl top ventilator louver sub-assembly (for hatchback lhd)

13. Remove cowl top ventilator louver lh (for hatchback lhd)

14. Remove cowl top ventilator louver sub-assembly (for hatchback rhd)

15. Remove cowl top ventilator louver lh (for hatchback rhd)

16. Remove cowl top ventilator louver sub-assembly (for sedan rhd)

17. Remove cowl top ventilator louver sub-assembly (for sedan lhd)

18. Remove front wiper motor and link (for hatchback)

19. Remove front wiper motor and link (for sedan)

20. Remove cowl to register duct sub-assembly no. 2 (for hatchback)

21. Remove front air shutter seal rh (for sedan)

22. Remove cowl top panel outer (for hatchback)

23. Remove cowl top panel outer (for sedan)

24. Remove battery

25. Remove battery tray

26. Remove front wheel rh

27. Remove engine under cover rh

28. Remove engine under cover sub-assembly (for rough road area specification vehicles)

29. Drain engine oil

30. Drain engine coolant

31. Remove cylinder head cover no. 2

32. Remove air cleaner cap sub-assembly with air cleaner hose no. 1

33. Disconnect radiator hose no. 3

34. Disconnect reserve tank hose

35. Remove water filler sub-assembly

36. Disconnect water by-pass hose no. 2

37. Disconnect water by-pass hose

38. Disconnect throttle with motor body connector

39. Disconnect ventilation hose

40. Disconnect union to connector tube hose

41. Remove oil level gauge sub-assembly

42. Remove intake manifold

43. Remove oil level gauge guide

44. Disconnect fuel tube sub-assembly

45. Disconnect booster vacuum tube

46. Disconnect camshaft position sensor connector

47. Disconnect engine coolant temperature sensor connector

48. Disconnect heated oxygen sensor connector

49. Disconnect heater water hose inlet a

50. Separate water by-pass pipe no. 1

51. Disconnect wire harness

52. Separate exhaust pipe assembly front

53. Remove manifold support bracket

54. Remove fan & generator v belt

55. Remove generator assembly

56. Remove ignition coil no. 1

57. Remove ventilation hose

58. Remove ventilation hose no. 2

59. Remove cylinder head cover sub-assembly (for rhd)

60. Remove cylinder head cover sub-assembly (for lhd)

61. Remove engine mounting insulator sub-assembly rh

62. Remove crankshaft damper sub-assembly

63. Remove crankshaft position sensor

64. Remove camshaft timing oil control valve assembly

65. Remove water pump pulley

66. Remove water pump assembly

67. Remove transverse engine engine mounting bracket

68. Remove oil pump assembly

69. Remove oil pump seal

70. Remove chain tensioner assembly no. 1

71. Remove chain tensioner slipper

72. Remove chain vibration damper no. 1

73. Remove chain sub-assembly

74. Remove camshaft

75. Remove cylinder head sub-assembly

76. Remove cylinder head gasket

77. Remove exhaust manifold heat insulator no. 1

78. Remove exhaust manifold

79. Remove harness bracket

80. Remove booster vacuum tube

81. Remove camshaft position sensor

82. Remove engine coolant temperature sensor

83. Remove water by-pass hose

84. Remove harness bracket

85. Remove fuel delivery pipe sub-assembly

86. Remove fuel injector assemmbly

87. Remove delivery pipe no. 1 spacer

88. Remove injector vibration insulator

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1. Using a screwdriver with its tip wrapped in protective tape, disengage the claw and remove the 2 front wiper arm head caps.

1. Using a screwdriver with its tip wrapped in protective tape, disengage the claw and remove the 2 front wiper arm head caps.

1. Operate the wiper, then stop the windshield wiper motor in the automatic stop position.

2. Remove the nut and front wiper arm.

1. Operate the wiper, then stop the windshield wiper motor in the automatic stop position.

2. Remove the nut and front wiper arm.

HINT:

Use the same procedure as for the LH side.

HINT:

Use the same procedure as for the LH side.

1. Disengage the 7 clips and remove the hood to cowl top seal.

1. Using a screwdriver with its tip wrapped in protective tape, disengage the 3 claws and remove the cowl side ventilator sub-assembly LH.

HINT:

Use the same procedure as for the LH side.

1. Disengage the 2 hooks and remove cowl top ventilator louver center No. 1.

2. Disconnect the washer hose.

3. Disengage the 11 claws and clip.

4. Disconnect the washer hose and remove the cowl top ventilator louver sub-assembly.

1. Remove the 2 clips.

2. Disengage the 4 claws and remove the cowl top ventilator louver LH.

1. Disconnect the washer hose.

2. Disengage the 10 claws and clip and remove the cowl top ventilator louver sub-assembly.

1. Remove the clip.

2. Disengage the 4 claws and remove the cowl top ventilator louver LH.

1. Disengage the 2 clips, the 6 claws and the 10 hooks.

2. Remove the cowl top ventilator louver sub-assembly.

3. Disconnect the washer hoses.

4. Disengage the 5 hooks.

1. Disengage the 3 clips, the 4 claws and the 8 hooks.

2. Remove the cowl top ventilator louver sub-assembly.

3. Disconnect the washer hoses.

4. Disengage the 5 hooks.

1. Remove the 2 bolts.

2. Slide the wiper link. Disengage the meshing of the rubber pin, then disconnect the connector and remove the front wiper motor and link.

1. Remove the 2 bolts.

2. Slide the wiper link. Disengage the meshing of the rubber pin, then disconnect the connector and remove the front wiper motor and link.

1. Disengage the claw and remove cowl to register duct sub-assembly No. 2.

1. Disengage the 3 claws and remove the front air shutter seal.

1. Disengage the wire harness clamp.

2. Remove the 9 bolts and remove the cowl top panel outer.

NOTICE:

To avoid the danger of being burned, do not remove the radiator cap sub-assembly while the engine and radiator assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.

1. Loosen the radiator drain cock plug.

2. Remove the radiator cap sub-assembly.

3. Loosen the cylinder block drain cock plug, then drain the coolant.
   

   
   
   
   

1. Remove the 4 nuts and cylinder head cover No. 2.

1. Disconnect fuel vapor feed hose No. 1 and fuel vapor feed hose No. 2 from the vacuum switching valve assembly.

2. Disconnect the vacuum switching valve assembly connector and wire harness clamp.

3. Disconnect ventilation hose No. 2.

4. Disconnect the wire harness clamp and mass air flow meter connector.

5. Loosen the hose clamp, unlock the air cleaner assembly clamp and remove air cleaner cap sub-assembly with air cleaner hose No. 1.

1. Disconnect radiator hose No. 3.

1. Disconnect the reserve tank hose.

1. Separate radiator hose No. 1 from the cylinder head.

2. Remove the 2 nuts and remove the water filler sub-assembly.

1. Disconnect water by-pass hose No. 2.

1. Disconnect the water by-pass hose.

1. Separate the wire harness clamp.

2. Remove the nut and separate the throttle with motor body connector.

1. Disconnect the ventilation hose.

1. Disconnect the union to connector tube hose.

1. Separate the wire harness clamps shown in the illustration.

2. Remove the 3 bolts and 2 nuts and remove the intake manifold.

1. Remove the wire harness clamp and the bolt and remove the oil level gauge guide.

1. Remove the fuel pipe clamp.

2. Pinch the retainer of the fuel tube connector, then pull out the fuel tube connector to disconnect the fuel tube from the fuel delivery pipe sub-assembly.

   NOTICE:

   1. Remove any dirt and foreign matter from the fuel tube connector before performing this work.
      
   2. Do not allow any scratches or foreign matter on the parts when disconnecting as the fuel tube connector has the O-ring that seals the pipe.
      
   3. Perform this work by hand. Do not use any tools.
      
   4. Do not forcibly bend, twist or turn the nylon tube.
      
   5. Protect the disconnected parts by covering them with vinyl bags after disconnecting the fuel tube.
      
   6. If the fuel tube connector and pipe are stuck, push and pull to release them.
      

1. Disconnect the booster vacuum tube.

1. Disconnect the camshaft position sensor connector.

1. Disconnect the engine coolant temperature sensor connector.

1. Remove the bolts and separate the sensor bracket.

2. Disconnect the heated oxygen sensor connector.

1. Disconnect heater water inlet hose A.

1. Remove the bolt and separate water by-pass pipe No. 1.

1. Remove the 2 bolts and disconnect the wire harness.

1. Remove the 2 bolts and 2 compression springs and separate the exhaust pipe assembly front.

1. Remove the 3 bolts and remove the manifold support bracket.

1. Loosen bolts A and B.

2. Release the fan and generator V belt tension and remove the fan and generator V belt.

1. Remove the terminal cap.

2. Separate the connector and harness clamp.

3. Remove the nut and remove terminal B.

4. Remove fan belt adjusting slider fixing bolts A and B and remove the fan belt adjusting slider.

5. Remove fixing bolt B and remove the generator.

1. Disconnect the 4 ignition coil connectors.

2. Remove the 4 bolts and 4 ignition coils.

1. Disconnect the ventilation hose.

1. Disconnect ventilation hose No. 2.

1. Disconnect the fuel injector connectors.

2. Disconnect the connector and 3 wire harness clamps shown in the illustration and disconnect the engine wire harness.

3. Remove the 9 bolts, 2 nuts and 2 seal washers and then remove the cylinder head cover sub-assembly.

1. Disconnect the fuel injector connectors.

2. Disconnect the connector and 3 wire harness clamps shown in the illustration and disconnect the engine wire harness.

3. Remove the bolt and remove the wire harness bracket.

4. Remove the 9 bolts, 2 nuts and 2 seal washers and remove the cylinder head cover sub-assembly.

1. Place a wooden block on a jack underneath the engine.

2. Remove the 5 bolts and nut and remove the engine mounting insulator sub-assembly RH.

1. Set cylinder No. 1 to TDC/compression.
   

   1. Turn the crankshaft damper sub-assembly, and align its timing notch with timing mark "0" of the oil pump.

   3. Check that the timing marks on the camshaft timing sprocket and the camshaft timing gear are all facing upward as shown in the illustration.
      If not, turn the crankshaft 1 complete revolution (360°) and align the marks as above.

2. Using 2 SSTs, loosen the bolt while holding the crankshaft damper sub-assembly.

   SST

   09213-14010 (91651-60865)
   09330-00021
   

   NOTICE:

   Check the SST installation positions when installing them, to avoid the SST fixing bolts from coming into contact with the oil pump assembly.

3. Remove the SSTs and the bolt.

4. Remove the crankshaft damper sub-assembly.

1. Disconnect the crankshaft position sensor connector.

2. Remove the bolt and remove the crankshaft position sensor.

1. Disconnect the camshaft timing oil control valve assembly connector.

2. Remove the bolt and nut and remove the camshaft timing oil control valve assembly.

3. Remove the O-ring from the camshaft timing oil control valve assembly.

1. Using SST, hold the water pump pulley.

   SST

   09960-10010 (09962-01000, 09963-00700)
   

2. Remove the 3 bolts and remove the water pump pulley.

1. Remove the 3 bolts and 2 nuts and remove the water pump assembly and gasket.

1. Remove the 4 bolts and remove the transverse engine engine mounting bracket.

1. Remove the 15 bolts and the nut.

2. Using a screwdriver with its tip wrapped in protective tape, prize the oil pump assembly to remove it.

   NOTICE:

   Do not damage the contact surfaces of the oil pump assembly or oil pan sub-assembly.

3. Remove the 2 O-rings from the cylinder block and oil pan sub-assembly.

1. Using a screwdriver with its tip wrapped in protective tape, remove the oil pump seal.

NOTICE:

1. Do not rotate the crankshaft with the chain tensioner removed.
   
2. When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40 ° from the TDC first.
   

1. Pull up the stopper plate and hold it with its lock released.

2. Unlock the plunger of the tensioner and push it in to the end.

3. Pull down the stopper plate with the plunger pushed to the end and lock the plunger.

4. Insert a 3 mm (0.12 in.) diameter bar into the hole in the stopper plate and lock the plunger.

5. Remove the 2 bolts and remove chain tensioner assembly No. 1.

1. Remove the chain tensioner slipper.

1. Remove the 2 bolts and remove chain vibration damper No. 1.

NOTICE:

When rotating the camshaft with the timing chain removed, rotate the crankshaft counterclockwise 40° from the TDC first.

1. Using several steps, loosen and remove the 19 bearing cap bolts uniformly in the sequence shown in the illustration, and then remove camshaft bearing cap No. 1 and camshaft bearing cap No. 2.

   NOTICE:

   Loosen each bolt uniformly while keeping the camshaft level.

2. Remove the camshaft and camshaft No. 2.

1. Using several steps, loosen and remove the 10 cylinder head bolts uniformly with an 8 mm bi-hexagon wrench in the sequence shown in the illustration. Remove the 10 cylinder head bolts and the plate washers.

   NOTICE:

   1. Do not drop the washers into the cylinder head.
      
   2. Head warpage or cracking could result from removing the bolts in the wrong order.
      

1. Remove the cylinder head gasket.

1. Remove the 4 bolts and remove exhaust manifold heat insulator No. 1.

1. Remove the 3 bolts and 2 nuts and remove the exhaust manifold.

1. Remove the bolt and remove the harness bracket.

1. Remove the 2 bolts and remove the booster vacuum tube.

1. Remove the bolt and remove the camshaft position sensor.

1. Using SST, remove the engine coolant temperature sensor connector.

   SST

   09817-33190
   

1. Remove the water by-pass hose.

1. Remove the bolt and remove the harness bracket.

1. Remove the 3 bolts and remove the fuel delivery pipe sub-assembly together with the 4 fuel injectors.

   NOTICE:

   Do not drop the fuel injectors when removing the fuel delivery pipe sub-assembly.

1. Pull the 4 fuel injector assemblies out of the fuel delivery pipe sub-assembly.

1. Remove the 2 delivery pipe No. 1 spacers.

1. Remove the 4 injector vibration insulators.