Removal & Installation
- Disconnect the negative battery cable.
- Remove the engine undercover.
- Remove the radiator shroud, the fan and the pulleys.
Drain the coolant from the radiator and remove the water pump hose.
CAUTIONWhen draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant could be reused unless it is contaminated or several years old.
- Remove the radiator.
- Remove the power steering, air conditioning compressor and alternator drive belts.
- Remove the spark plugs.
- Remove the distributor protector (dust shield).
- Remove the air conditioning compressor drive belt idler pulley and bracket.
- Remove the fresh air intake tube at the cylinder head cover.
- Disconnect the radiator hose at the thermostat housing.
- Remove the crankshaft pulley bolt, then pull off the pulley with a suitable puller.
- Press the crankshaft pulley onto the shaft, then tighten the bolt to 90 - 98 ft. lbs. (123 - 132 Nm).
- Connect the radiator hose to the thermostat housing.
- Reconnect the fresh air intake tube at the cylinder head cover.
- Install the air conditioning compressor drive belt idler pulley and bracket.
- Install the distributor protector (dust shield).
- Install the spark plugs.
- Install the power steering, air conditioning compressor and alternator drive belts.
- Install the radiator.
- Reconnect the water pump hose and fill the engine with coolant. Install the fan shroud and pulleys.
- Install the engine undercover.
- Start the engine and check for any leaks.
- Release fuel pressure.
- Remove the battery.
- Remove the radiator.
- Drain engine oil.
- Remove the drive belts and idler pulley with brackets.
- Remove the cooling fan with bracket.
Remove the engine cover.
- Remove the air duct with air cleaner case, collector, blow-by hose, vacuum hoses, fuel hoses, water hoses, wires, harnesses, connectors and so on.
- Remove the air compressor, and tie it down using rope or the like to keep it from interfering.
- Remove the power steering oil pump and reservoir tank. Tie them down using rope or the like to keep them from interfering.
- Remove the alternator.
Remove the following.
Remove the camshaft position sensor (PHASE), intake valve timing control position sensors and crankshaft position sensor.
NOTEAvoid impact such as dropping. Do not disassemble the components. Do not place them on areas where iron powder may adhere. Keep away from the objects susceptible to magnetism.
- Remove the upper intake manifold collector in reverse order of installation.
- Remove the intake manifold collector support bolts.
- Remove the lower intake manifold collector in reverse order of installation.
- Disconnect injector harness connectors.
- Remove the fuel tube assembly in reverse order of installation.
- Remove the ignition coils.
- Remove the RH and LH rocker covers from cylinder head.
- Set No. 1 piston at TDC on the compression stroke by rotating crankshaft. Align pointer with TDC mark on crankshaft pulley. Check that intake and exhaust cam nose on No. 1 cylinder are installed as shown left. If not, turn the crankshaft one revolution (360°) and align as above.
- Remove the starter motor, and set ring gear stopper using the mounting bolt hole. Be careful not to damage the signal plate teeth.
- Loosen the crankshaft pulley bolt.
- Remove the crankshaft pulley with a suitable puller.
- Install crankshaft pulley to crankshaft. Align pointer with TDC mark on crankshaft pulley.
- Install crankshaft pulley bolt. Lubricate thread and seat surface of the bolt with new engine oil. Tighten to 29-36 ft. lbs. (39-49 Nm). Put a paint mark on the crankshaft pulley. Again tighten by turning 60° to 66°, about the angle from one hexagon bolt head corner to another.
- Install camshaft position sensor (PHASE), crankshaft position sensors (REF)/(POS) and intake valve timing control position sensors.
- Reinstall removed parts in the reverse order of removal. After starting engine, keep idling for three minutes. Then rev engine up to 3,000 rpm under no load to purge air from the high-pressure chamber of the chain tensioners. The engine may produce a rattling noise. This indicates that air still remains in the chamber and is not a matter of concern.
- Before servicing the vehicle, refer to the Precautions Section.
- Drain the engine oil.
- Drain the cooling system.
- Relieve the fuel system pressure.
Remove the or disconnect the following:
Negative battery cable
Rotate the crankshaft pulley and align the timing mark with the timing indicator to put the No. 1 cylinder at Top Dead Center (TDC).
- Remove the starter motor.
- Remove the crankshaft pulley.
Install or connect the following:
Crankshaft pulley and tighten to 33 ft. lbs. (44 Nm) plus 60 degrees
- Refill the engine oil to the correct level.
- Fill the cooling system to the correct level.
- Start the engine and check for leaks.