Removal and Installation

REMOVAL
WARNING: FUEL SUPPLY TUBES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVED BEFORE SERVICING OF THE FUEL SYSTEM IS BEGUN OR PERSONAL INJURY OR DAMAGE TO VEHICLE MAY OCCUR. A VALVE IS PROVIDED OK] THE FUEL INJECTION SUPPLY MANIFOLD FOR THIS PURPOSE.

CAUTION: The fuel system is normally pressurized to 255-314 kPa (37-46 psi). The fuel pressure is 268.9-310 kPa (39-45 psi) with the pressure regulator hose disconnected.

1. Remove fuel pressure relief valve cap from the fuel pressure relief valve.
2. With the tool fitting open, attach the Fuel Pressure Gauge T80L-9974-B to the fuel pressure relief valve, making sure the fitting is fully seated.
3. Open the valve on the side of gauge and drain fuel into an appropriate container until fuel pressure is fully relieved.
4. Disconnect the battery ground cable.
5. Drain the cooling system.
6. Remove the air intake system.
7. Remove the power steering hose bracket bolts from the valve cover.
8. Disconnect the power steering pressure (PSP) switch electrical connector.





9. Remove the two power steering pump drive belt idler pulley shield bolts. Remove the power steering pump drive belt idler pulley shield.
10. Remove the accessory drive belts.
11. Remove the power steering pump through bolt and lock bolt and position the power steering pump out of the way.
12. Remove the exhaust manifold.
13. Carefully remove the valve cover.
14. Remove the timing belt.





15. Remove the two intake manifold support bolts and remove the intake manifold support.
16. Disconnect the distributor electrical connector.





17. Disconnect the following electrical connectors from the water hose connection:
^ Engine coolant temperature sensor (ECT sensor)
^ Water temperature indicator sender unit





18. Remove the four water hose connection bolts-and then remove the water hose connection from the cylinder head and discard the water hose connection gasket.
19. Disconnect and position the front fuel tubes aside.

CAUTION: Plug the front fuel tubes once they have been removed from the fuel injection supply manifold to prevent fuel leakage.

NOTE: Label the front fuel tubes during the removal procedure to ease installation.

20. Disconnect and position aside all engine wiring connectors.
^ The following electrical connectors should be disconnected:
^ Idle switch
^ Throttle position sensor (TP sensor)
^ Idle air control valve (IAC valve)
^ Fuel charging wiring (includes four fuel injector electrical connectors)
^ EGR solenoid vacuum valve
^ Generator electrical connector





21. Disconnect the vacuum hose from the vacuum fitting on the RH side of the intake manifold.
22. Disconnect the vacuum hose connecting the evaporative emissions canister (EVAP canister) to the metal vacuum tube.
23. Disconnect the accelerator cable.





24. Disconnect the brake vacuum booster hose from the LH side of the intake manifold.
25. Remove the distributor.
26. Remove the camshafts.





27. Remove the cylinder head bolts in three steps, in the sequence shown.
28. Remove the cylinder head from the engine.
29. Remove and discard the head gasket.
30. If necessary, remove the intake manifold.

INSTALLATION
1. If removed, install the intake manifold.
2. Be sure the cylinder head and the cylinder block gasket surfaces are clean.
3. Install a new head gasket.





4. Measure the length of each cylinder head bolt before reinstalling. If the cylinder head bolt length is longer than 105.5 mm (4 inches) then replace the cylinder head bolt with a new one.

Install the cylinder head. Tighten the cylinder head bolts in two steps to 18-22 Nm (13-16 ft. lbs.) in the sequence shown.








5. After the initial tightening, apply a paint mark to the cylinder head bolts and turn the cylinder head bolts 90 +/- 5 degrees in the sequence shown. Turn all the cylinder head bolts another 90 +/- 5 degrees in the sequence shown.
6. Install the camshafts.

Install the distributor.

CAUTION: Ensure none of the camshaft lobes are located directly on the hydraulic lash adjusters (HLA).

8. Connect the brake vacuum booster hose from the LH side of the intake manifold.
9. Connect the accelerator cable.
10. Connect the vacuum hose connecting the EVAP canister to the metal vacuum tube.
11. Connect the vacuum hose to the vacuum fitting on the RH side of the intake manifold.
12. Connect the following engine wiring connectors:
^ Generator electrical connector
^ EGR solenoid vacuum valves
^ Fuel charging wiring (includes four fuel injector electrical connectors)
^ IAC valve
^ TP sensor

13. Connect the front fuel tubes to the fuel injection supply manifold.
14. Connect the distributor connector.
15. Install the timing belt.
16. Install the intake manifold support. Tighten the intake manifold support bolts to 38-51 Nm (28-38 ft. lbs.).
17. Install the valve cover.
18. Install the exhaust manifold.
19. Install and adjust the generator drive belt.
20. Loosely install the power steering pump through bolt.
21. Loosely install the power steering pump lock bolt.
22. Connect the PSP switch electrical connector.
23. Install and adjust the power steering drive belt.
24. Tighten the power steering pump through bolt to 43-61 Nm (32-45 ft. lbs.).
25. Tighten the power steering pump lock bolt to 31-46 Nm (23-34 ft. lbs.).
26. Install the power steering pump drive belt idler pulley shield. Tighten the power steering pump drive belt idler pulley shield bolts to 7-9 Nm (61-86 inch lbs.).
27. Install the power steering hose brackets to the valve cover. Tighten the power steering hose bracket bolts to 8-10 Nm (71-88 inch lbs.).
28. Position a new water hose connection gasket on the water hose connection and install the water hose connection.
29. Tighten the four water hose connection bolts to 19-25 Nm (14-18 ft. lbs.).
30. Connect the following items to the water hose connection:
^ ECT sensor electrical connector
^ Water temperature indicator sender unit electrical connector
31. Install the air intake system.
32. Fill the cooling system and check for leaks.
33. Install the fuel pressure relief valve cap. Tighten the fuel pressure relief valve cap to 1 Nm (8 inch lbs.).
34. Turn the ignition switch ON/OFF several times without starting engine to check for fuel leaks.

Check all connections at the fuel injection supply manifolds, hose and tube fittings for leakage.

CAUTION: The fuel system is normally pressurized to 255-314 kPa (37-46 psi). The fuel pressure is 268.9-310 kPa (39-45 psi) with the vacuum line disconnected.

35. Connect the battery ground cable.