Removal and Installation

CYLINDER HEAD COMPONENTS (7M-GE) COMPONENTS (7M-GTE)
PREPARATION FOR REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE TERMINAL OF BATTERY E
2. DRAIN COOLANT
3. DISCONNECT EXHAUST PIPE FROM EXHAUST MANIFOLD
4. DISCONNECT FOLLOWING CABLE:
(a) Cruise control cable
(b) Accelerator cable
(c) (A/T) Throttle cable
5. DISCONNECT GROUND STRAP FROM ENGINE REAR SIDE

6. (7M-GE)
REMOVE NO.1 AIR CLEANER HOSE WITH INTAKE AIR CONNECTOR PIPE

(7M-GTE)
REMOVE NO.4 AIR CLEANER PIPE WITH NO.1 AND NO.2 AIR CLEANER HOSE
7. DISCONNECT FOLLOWING HOSES:
(b) Charcoal canister hose
(c) Brake booster hose
8. REMOVE RADIATOR INLET HOSE

9. DISCONNECT HEATER INLET HOSE

REMOVAL OF CYLINDER HEAD
1. REMOVE ALTERNATOR
(a) Disconnect the No.3 PCV hose.
(b) Remove the drive belt.
(c) Remove the alternator and adjusting bar.

2. (7M-GTE)
REMOVE PS RESERVOIR TANK
Remove the two bolts, nut and reservoir tank with bracket.
3. (7M-GTE)
REMOVE CAM POSITION SENSOR

4. REMOVE AIR INTAKE CHAMBER WITH CONNECTOR
(a) Remove the PCV pipe.
(b) Disconnect following wires:
- (7M-GE)
Cold start injector connector
- Throttle position sensor connector
- ISC valve connector
(c) Disconnect following hoses:
- BVSV hose from throttle body
- EGR hoses from throttle body
- Vacuum transmitting pipe hose from intake chamber
- Pressure regulator hose
- PS air hose
- VSV hoses (for FPU)
- (7M-GE) Diaphragm hose
(d) Disconnect following hoses:
- (7M-GTE)
Auxiliary air pipe hose from vacuum transmitting pipe hose
No.1 water by-pass hose from ISC valve
- (7M-GE)
No.3 water by-pass hose from throttle body
- (7M-GTE)
No.3 water by-pass hose from water by-pass pipe

(e) Remove the EGR pipe mounting bolts.
(f) Remove the manifold stay mounting bolts.

(g) (7MGE)
Remove the throttle body bracket.

(7M-GTE)
Remove the ISC pipe.

(h) (7M-GTE)
Remove the air intake connector mounting bolt.

(i) (7M-GE)
Remove the air intake connector bracket mounting bolts.
(j) Remove the cold start injector tube.
(k) Remove the EGR vacuum modulator from the bracket.
(l) Disconnect the engine wire from the clamps of intake chamber.
(m) Remove the two nuts, five bolts, vacuum transmitting pipes and intake chamber with connector and gasket.
(n) (7M-GTE) Disconnect the cold start injector connector.
5. (7M-GTE) REMOVE IGNITION COIL WITH BRACKET
6. REMOVE ENGINE WIRE
(a) Disconnect following wires:
- Oxygen sensor connector
- Oil pressure sender gauge connector
- Water temp. sensor connector
- Water temp. sender gauge connector
- Cold start injector time switch connector
- (7M-GE) Distributor connector Injector connectors
- Three VSV connectors
- Knock sensor connector(s)
- Ground strap from intake manifold
- Check connector
- Solenoid resister connector
- (7M-GE) Ignition coil connector
- (7M-GTE) Igniter connectors
- Noise filter connector
- Main relay connector
- Starter connector (terminal 50)
- Transmission connectors
(b) Remove the engine wire from the four clamps.

7. REMOVE PULSATION DAMPER, VSV AND NO.1 FUEL PIPE

8. REMOVE NO.3 FUEL PIPE
(a) Disconnect the fuel hose from the fuel support.
(b) Remove the bolt, union bolt, NO.3 fuel pipe and gaskets.

9. (7M-GTE) REMOVE AUXILIARY AIR PIPE
10. (7M-GE) REMOVE HIGH-TENSION CORDS AND DISTRIBUTOR
11. (7M-GE) REMOVE OIL DIPSTICK
12. (7M-GTE)
REMOVE TURBOCHARGER

13. REMOVE EXHAUST MANIFOLD
(a) (7M-GTE) Remove the five nuts and heat insulators.

(b) (7M-GTE) Remove the three bolts and exhaust manifold stay.

14. REMOVE WATER OUTLET HOUSING
(a) (7M-GE)
Remove the union bolts, union with No.4 water bypass hose and gaskets.
(b) Disconnect the No.6 water by-pass hose from the water by-pass pipe.

15. REMOVE CYLINDER HEAD COVERS
(a) Remove the accelerator link.
(b) Remove the No.1 and No.2 cylinder head covers.
(c) Remove the heater hose clamp.

(d) Using SST, remove the No.3 cylinder head cover. SST 09923-00010
16. REMOVE SPARK PLUGS
17. REMOVE TIMING BELT AND CAMSHAFT TIMING PULLEYS
18. REMOVE CYLINDER HEAD
(a) Using SST, remove the head bolts gradually in three passes and in the numerical order shown. SST 09043-38100

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

(b) Lift the cylinder head from the dowels on the cylinder block. As the cylinder head is lifted, separate the No.5 water by-pass hose from the union.
(c) Place the head on wooden blocks on a bench.
If the cylinder head is difficult to lift off, pry with a screwdriver between the cylinder head and block projection.

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

DISASSEMBLY OF CYLINDER HEAD
1. REMOVE NO.2 TIMING BELT COVER
2. REMOVE ALTERNATOR BRACKET
3. REMOVE HEATER INLET HOSE
4. REMOVE HEATER UNION

5. REMOVE DELIVERY PIPE WITH INJECTORS
(a) Remove the three bolts, and then remove the delivery pipe with the injectors.

NOTE: When removing the delivery pipe, be careful not to drop the injectors.

(b) Remove the six insulators and three spacers from the cylinder head.

6. REMOVE INTAKE MANIFOLD
Remove the four nuts, seven bolts, EGR valve, VSV, intake manifold and gasket.
7. REMOVE NO.2 ENGINE HANGER AND GROUND STRAP

8. REMOVE EGR COOLER

9. REMOVE BEARING CAPS AND CAMSHAFTS
(a) Loosen each bearing cap bolt a little at a time and in the sequence shown in the figure.
(b) Remove the camshaft bearing caps, oil seal and camshaft.

10. REMOVE VALVE LIFTERS WITH SHIMS
Arrange the valve lifters and shims in order.

11. REMOVE VALVES
(a) Using SST, press the valve spring and remove the two keepers. SST 09202-70010
(b) Remove the spring retainer, valve spring, seat and valve.
(c) Pry out the oil seal.

NOTE: Arrange the valves, seats valve springs and retainers in order.