Cylinder Head Assembly: Service and Repair

1. Disable airbag system as described under MAINTENANCE PROCEDURE/AIRBAG SYSTEM DISARMING.
2. Drain coolant.
3. Disconnect accelerator cable and throttle cable, if equipped, from throttle body.
4. Remove cruise actuator and vacuum pump. Refer to ENGINE.
5. Remove air cleaner hose.
6. Remove engine righthand undercover.
7. On all models, remove front exhaust pipe.
8. Remove alternator, ISC valve and throttle body.
9. Remove EGR pipe, then the EGR valve and vacuum modulator.
10. Remove vacuum pipe.
11. Remove distributor.
12. Remove exhaust crossover pipe.
13. Disconnect cold start injector connector. Remove cold start injector tube.

Fig. 10 Intake Manifold Removal:

14. Remove air intake chamber as follows:
a. Disconnect PCV, vacuum sensing, fuel pressure, air conditioner control valve, and EGR temperature sensor hoses.
b. Remove intake chamber stays.
c. Remove intake chamber and gaskets.
15. Remove delivery pipes and injectors, Fig. 10.
16. Remove water outlet.
17. Disconnect injector time switch, water temperature sensor, and heater by-pass hose. Remove water bypass outlet.
18. Remove cylinder head rear plate.
19. Remove idler pulley bracket stay, then the intake manifold.
20. Remove righthand exhaust manifold.
(a) Remove the three nuts and heat insulator.
(b) Remove the six nuts, exhaust manifold and gasket.
21. Remove lefthand exhaust manifold.
(a) Remove the bolt, two nuts and heat insulator.
(b) Remove the six nuts, exhaust manifold and gasket.
22. Remove spark plugs.
23. Remove timing belt, camshaft timing pulleys and No. 2 idler pulley. Refer to TIMING BELT.
24. Remove No. 3 timing belt cover.
25. Remove cylinder head covers, then the spark plug tube gaskets.

Fig. 11 Cam Timing Locations:

Fig. 12 Cam Sub-gear Location:

26. Remove camshafts as follows:
a. Align righthand camshaft timing marks, Fig. 11.
b. Secure righthand exhaust cam sub-gear to driven gear with a service bolt, Fig. 12.
c. Remove bearing caps, then the righthand exhaust camshaft.
d. Remove bearing caps, then the righthand intake camshaft.
e. Align lefthand camshaft timing marks, Fig. 11.
f. Secure righthand exhaust cam sub-gear to driven gear with a service bolt, Fig. 12.
g. Remove bearing caps, then the lefthand exhaust camshaft.
h. Remove bearing caps, then the lefthand intake camshaft.
27. Remove cylinder heads.
28. Reverse procedure to install, noting the following:

Fig. 14 Cylinder Head Tightening Sequence. ES 300:

Fig. 15 Intake Cam Installation:

Fig. 16 No. 1 Cam Cap Sealing Location:

a. Follow cylinder head tightening sequence, Figs. 14.
b. Refer to SPECIFICATIONS/MECHANICAL SPECIFICATIONS/TIGHTENING SPECIFICATIONS for torque values.
c. When installing intake camshafts, install at a 90° angle from timing mark, Fig. 15.
d. Apply seal packing to No. 1 bearing cap, Fig. 16.
e. Check and adjust valve clearance. Refer to Engine/Cylinder Head Assembly/Valve, Intake/Exhaust/Adjustments.
f. Install new camshaft seals using seal installer 09223-46011 or equivalent.
g. Refill coolant.
h. Adjust timing.
i. Rearm Airbag System, refer to MAINTENANCE PROCEDURE/AIRBAG SYSTEM DISARMING.