4. DISASSEMBLY, INSPECTION AND REASSEMBLY OF ENGINES 82E-5 – 98E-5 SERIES 4-9 Step Removal Parts Remarks 10 1) Remove cylinder head tightening bolt. 2) Remove cylinder head assembly. 3) Remove cylinder head gasket. 1) Lay a cardboard or the like on the floor and place cylinder head assembly on it so as not to damage the combustion surface. 2) Order of loosening the cylinder head tighten- ing bolts. 3) To remove the intake/exhaust valves from cyl- inder head assembly, take the following steps. (a) Using a valve spring compressor (see Chapter 5, 5-1), compress valve spring and remove valve cotter. (b) Remove valve retainer and valve spring. (c) Remove intake valve and exhaust valve.
11 1) Remove crankshaft V-pulley clamping bolt. 2) Using a puller, extract crankshaft V-pulley. 1) Extract crankshaft V-pulley by hitting the bolt of the puller using a plastic hammer or the like. 12 1) Remove oil pan mounting bolt under gear case. 2) Remove gear case mounting bolt. 3) Remove gear case. 1) Never fail to removes stiffner bolt at the center of the gear case. 2) When removing the gear case, carefully pro- tect oil seal from damage. 13 1) Remove the nut from fuel injection pump drive gear. Extract fuel injection pump drive gear using a puller.
1) Before removing fuel injection pump, make sure of the position of the arrow of the pump body for adjusting fuel injection timing as well as the position of the scribed line of the gear case flange. (Applies only to direct injection system.) 14 1) Remove lubricating oil pump. 15 1) Remove starting motor from flywheel housing. 16 1) Remove flywheel mounting bolt. 2) Remove flywheel. 1) Carefully protect the ring gear from damage. 17 1) Remove flywheel housing. 2) Remove oil seal case with a screwdriver or the like by utilizing grooves on both sides of oil seal case. 1) Carefully protect the oil seal from damage.