Removal and Replacement

REPLACEMENT
1. DISCHARGE FUEL SYSTEM PRESSURE
2. DISCONNECT BATTERY NEGATIVE TERMINAL
3. REMOVE FRONT WHEEL RH
4. REMOVE ENGINE UNDER COVER RH
5. REMOVE CYLINDER HEAD COVER NO.2
6. DRAIN ENGINE COOLANT
7. SEPARATE EXHAUST PIPE ASSY FRONT (2WD DRIVE TYPE)
8. SEPARATE EXHAUST PIPE ASSY FRONT (4WD DRIVE TYPE)
9. REMOVE MANIFOLD STAY (2WD DRIVE TYPE)
10. REMOVE MANIFOLD STAY (4WD DRIVE TYPE)
11. REMOVE FAN AND GENERATOR V BELT
12. SEPARATE VANE PUMP ASSY
13. REMOVE GENERATOR ASSY
14. REMOVE ENGINE MOUNTING INSULATOR RH
15. REMOVE IGNITION COIL ASSY
16. REMOVE CYLINDER HEAD COVER SUB-ASSY
17. REMOVE V-RIBBED BELT TENSIONER ASSY
18. REMOVE ENGINE MOUNTING BRACKET RH
19. REMOVE WATER PUMP ASSY
20. SEPARATE CRANKSHAFT POSITION SENSOR
21. SET NO. 1 CYLINDER TO TDC/COMPRESSION
22. REMOVE CRANKSHAFT PULLEY
SST 09960-10010 (09962-01000, 09963-01000)
23. REMOVE CHAIN TENSIONER ASSY NO. 1
24. REMOVE TIMING CHAIN OR BELT COVER SUB-ASSY
25. REMOVE TIMING CHAIN OR BELT COVER OIL SEAL
26. REMOVE CRANKSHAFT POSITION SENSOR PLATE NO. 1
27. REMOVE CHAIN TENSIONER SLIPPER
28. REMOVE CHAIN SUB-ASSY
29. REMOVE CHAIN VIBRATION DAMPER NO. 1
30. REMOVE AIR CLEANER HOSE NO. 1 (2WD DRIVE TYPE)

a) Disconnect the VSV connector.
b) Remove the clamp of the engine wire.
c) Disconnect the fuel vapor feed hose No.1 from the VSV.
d) Disconnect the fuel vapor feed hose No. 3 from the VSV.

e) Loosen the 2 hose clamp bolts, then remove the air cleaner hose No. 1.
31. REMOVE AIR CLEANER HOSE NO. 1 (4WD DRIVE TYPE)
a) Loosen the 2 hose clamp bolts, then remove the air cleaner hose No. 1.
32. REMOVE OIL LEVEL GAGE SUB-ASSY
33. SEPARATE ACCELERATOR CONTROL CABLE ASSY (4WD DRIVE TYPE)
34. REMOVE INTAKE MANIFOLD (2WD DRIVE TYPE)

a) Remove the 2 clamps of the engine wire from the clamp bracket.

b) Disconnect the throttle control motor connector.

c) Disconnect the water by-pass hose from the throttle body.
d) Disconnect the water by-pass hose No. 2 from the throttle body.

e) Disconnect the union to check valve hose from the intake manifold.

f) Remove the 4 bolts, 2 nuts and 2 clamp brackets.
g) Remove the intake manifold and throttle body.
h) Remove the gasket from the intake manifold.
35. REMOVE INTAKE MANIFOLD (4WD DRIVE TYPE)

a) Remove the 2 clamps of the engine wire from the clamp bracket.

b) Disconnect the throttle position sensor connector.
c) Disconnect the idle air control valve connector.

d) Disconnect the water by-pass hose from the throttle body.
e) Disconnect the water by-pass hose No. 2 from the throttle body.

f) Disconnect the union to check valve hose from the intake manifold.

g) Remove the 4 bolts, 2 nuts and 2 clamp brackets.
h) Remove the intake manifold and throttle body.
i) Remove the gasket from the intake manifold.
36. REMOVE CAMSHAFT TIMING OIL CONTROL VALVE ASSY

a) Remove the bolt, then remove the camshaft timing oil control valve.
37. REMOVE CAMSHAFT

a) Using several steps, uniformly loosen and remove the 19 bearing cap bolts in the sequence shown in the illustration.
b) Remove the 9 bearing caps, then remove the 2 camshafts from the cylinder head.
38. DISCONNECT FUEL TUBE SUB-ASSY
SST 09268-21010
39. REMOVE CYLINDER HEAD SUB-ASSY
a) Disconnect the engine wire.

1) Disconnect the 4 fuel injector connectors.

2) Disconnect the oil pressure switch connector.

3) Disconnect the crankshaft position sensor connector.
4) Disconnect the knock sensor connector.

5) Disconnect the camshaft position sensor connector.

6) Disconnect the engine coolant temperature sensor connector.
7) Disconnect the radio setting condenser connector.
8) Disconnect the 2 engine earths.
9) Remove the clamp from the clamp bracket.
10) Disconnect the heated oxygen sensor connector.

b) Disconnect the radiator hose inlet.
c) Disconnect the heater inlet water hose.
d) Remove the bolt, then separate the water by-pass pipe No. 1.

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

NOTICE:
- Be careful not to drop the plate washers into the cylinder head.
- Head warpage or cracking could result from removing the bolts in the wrong order.

f) Remove the cylinder head.
40. REMOVE CYLINDER HEAD GASKET
41. INSPECT CYLINDER HEAD SET BOLT

a) Using vernier calipers, measure the length of the cylinder head bolts from the seat to the end.
Standard length: 146.8 to 148.2 mm (5.780 to 5.835 inch)
Maximum length: 148.5 mm (5.846 inch)
If the bolt length is greater than maximum, replace the cylinder head set bolt.
42. INSTALL CYLINDER HEAD GASKET

a) Place a new cylinder head gasket on the cylinder block surface with the Lot No. stamp upward.

NOTICE:
- Make sure that the cylinder head gasket is mounted in the correct direction.
- Place the cylinder head gently in order to avoid damaging the gasket.

43. INSTALL CYLINDER HEAD SUB-ASSY

HINT: The cylinder head bolts should be tightened in 2 successive steps.

a) Apply a light coat of engine oil to the threads of the cylinder head bolts.

b) Using several steps, uniformly install and tighten the 10 cylinder head bolts and plate washers with a bi-hexagon wrench 10 mm in the sequence shown in the illustration.
Torque: 49 Nm (500 kgf-cm, 36 ft. lbs.)

c) Mark the front of the cylinder head bolts with paint.
d) Retighten the cylinder head bolts 90° in the same sequence as step (b).
e) Check that the paint mark of each bolt is at a 90° angle to the front.
f) Install the water by-pass pipe No. 1 with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
g) Connect the heater inlet water hose.
h) Connect the radiator hose inlet.
i) Connect the engine wire.
1) Connect the heated oxygen sensor connector.
2) Install the clamp onto the clamp bracket.
3) Connect the 2 engine earths.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
4) Connect the radio setting condenser connector.
5) Connect the engine coolant temperature sensor connector.
6) Connect the camshaft position sensor connector.
7) Connect the knock sensor connector.
8) Connect the crankshaft position sensor connector.
9) Connect the oil pressure switch connector.
10) Connect the 4 fuel injector connectors.
44. CONNECT FUEL TUBE SUB-ASSY
45. INSTALL CAMSHAFT
a) Apply a light coat of engine oil to the camshaft journals.

b) Place the 2 camshafts on the cylinder head as shown in the illustration.

c) Examine the front marks and numbers and check that the sequence order is as shown in the illustration. Then tighten the bolts.
Torque:
23 Nm (235 kgf-cm, 17 ft. lbs.) for bearing cap No. 1
13 Nm (133 kgf-cm, 10 ft. lbs.) for bearing cap No. 3

HINT:
- Bearing Cap No.1 = Nos. 9-11 in illustration
- Bearing Cap No.3 = Nos. 1-8 in illustration

46. INSTALL CAMSHAFT TIMING OIL CONTROL VALVE ASSY
a) Apply a light coat of engine oil to a new O-ring, then install it onto the camshaft timing oil control valve.

b) Install the camshaft timing oil control valve with the bolt.
Torque: 9.0 Nm (92 kgf-cm, 80 inch lbs.)
47. INSTALL INTAKE MANIFOLD (2WD DRIVE TYPE)
a) Install a new gasket onto the intake manifold.

b) Install the intake manifold and throttle body with the 2 brackets, 4 bolts and 2 nuts.
Torque: 30 Nm (306 kgf-cm, 22 ft. lbs.)
c) Connect the union to check valve hose to the intake manifold.
d) Connect the water by-pass hose No. 2 to the throttle body.
e) Connect the water by-pass hose to the throttle body.
f) Connect the idle speed control valve connector.
g) Connect the throttle position sensor connector.
h) Install the 2 clamps of the engine wire onto the clamp bracket.
49. INSTALL ACCELERATOR CONTROL CABLE ASSY (4WD DRIVE TYPE)
50. INSTALL OIL LEVEL GAGE SUB-ASSY
51. INSTALL AIR CLEANER HOSE NO. 1 (2WD DRIVE TYPE)
a) Install the air cleaner hose No. 1 with the 2 hose clamp bolts.
b) Connect the fuel vapor feed hose No. 3 to the VSV.
c) Connect the fuel vapor feed hose No. 1 to the VSV.
d) Install the clamp of the engine wire.
e) Connect the VSV connector.
52. INSTALL AIR CLEANER HOSE NO. 1 (4WD DRIVE TYPE)
a) Install the air cleaner hose No. 1 with the 2 hose clamp bolts.
53. INSTALL CHAIN VIBRATION DAMPER NO. 1
54. INSTALL CHAIN SUB-ASSY
SST 09223-22010
55. INSTALL CHAIN TENSIONER SLIPPER
56. INSTALL CRANKSHAFT POSITION SENSOR PLATE NO. 1
57. INSTALL TIMING CHAIN OR BELT COVER OIL SEAL
SST 09223-22010
58. INSTALL TIMING CHAIN OR BELT COVER SUB-ASSY
59. INSTALL CHAIN TENSIONER ASSY NO. 1
60. INSTALL CRANKSHAFT PULLEY
SST 09960-10010 (09962-01000, 09963-01000)
61. INSTALL CRANKSHAFT POSITION SENSOR
62. INSTALL WATER PUMP ASSY
63. INSTALL ENGINE MOUNTING BRACKET RH
64. INSTALL V-RIBBED BELT TENSIONER ASSY
65. INSTALL CYLINDER HEAD COVER SUB-ASSY
66. INSTALL IGNITION COIL ASSY
67. INSTALL ENGINE MOUNTING INSULATOR RH
68. INSTALL GENERATOR ASSY
69. INSTALL VANE PUMP ASSY
70. INSTALL FAN AND GENERATOR V BELT
71. INSTALL MANIFOLD STAY (2WD DRIVE TYPE)
72. INSTALL MANIFOLD STAY (4WD DRIVE TYPE)
73. INSTALL EXHAUST PIPE ASSY FRONT (2WD DRIVE TYPE)
74. INSTALL EXHAUST PIPE ASSY FRONT (4WD DRIVE TYPE)
75. ADD ENGINE COOLANT
76. INSTALL BATTERY NEGATIVE TERMINAL
Torque: 5.4 Nm (55 kgf-cm, 48 inch lbs.)
77. CHECK FOR ENGINE COOLANT LEAKAGE
78. CHECK FOR ENGINE OIL LEAKAGE
79. CHECK FOR FUEL LEAKAGE
80. CHECK FOR EXHAUST GAS LEAKAGE
81. INSPECT IGNITION TIMING
SST 09843-18040
82. INSPECT ENGINE IDLING SPEED
83. INSPECT COMPRESSION
SST 09992-00500
84. INSPECT CO/HC
85. INSTALL CYLINDER HEAD COVER NO.2
86. INSTALL ENGINE UNDER COVER RH
87. INSTALL FRONT WHEEL RH
Torque: 103 Nm (1,050 kgf-cm, 76 ft. lbs.)