Withdrawal
WARNING: Cylinder head temperature must be below 38°C before operation. Let the car cool down for a few hours if you have recently arrived from somewhere.
1. Disconnect the negative cable from the battery.
2. Place a clean drain pan under the radiator, remove the drain plug and radiator cap, then drain the coolant from the system.
3. Remove the brake booster vacuum hose and air intake from the air filter housing.
-> All wires and hoses must be marked during removal. The amount of time saved during subsequent builds is well worth the extra effort.
4. If the vehicle is equipped with a fuel injection system, reduce the fuel pressure using the correct procedures. Disconnect the fuel return hose from the pressure regulator. Remove the banjo nut and fuel supply hose; make sure you replace the washers.
5. Disconnect the earth cable from the valve cover.
6. Tag and disconnect the hoses from the air filter.
7. On models with a carburetor, disconnect the wires from the temperature sensor, idle cut solenoid valve, primary/main cutoff solenoid valve, and automatic choke.
8. Disconnect the throttle control cable and/or the accelerator cable from the carburetor or from the throttle body.
9. Tag and disconnect all emission hoses from the carburetor (ov).
10. Mark and disconnect electrical connectors and hoses from the distributor; remove the distributor.
11. On fuel injected models, mark and disconnect the following harness connectors and couplers from the cylinder head and intake manifold:
- four injector connectors;
- TA-sensor connector;
- ground connector located next to the gas pipeline;
- throttle sensor connector;
- TW sensor connector;
- crankshaft angle sensor hitch;
- EGR valve connector;
- harness clamps with 4 wires;
- oxygen sensor connector;
12. On carbureted models, separate the following parts:
- a. Tag and disconnect control box No. 1 emission hoses from manifold pipe.
- b. Disconnect the hoses of the air jet regulator.
13. Remove the coolant hoses from the cylinder head.
14. If the vehicle is equipped with power steering, perform the following procedures:
- A. Remove the pump mount from the cylinder head.
- b. Remove the hose clamp bolt from the cylinder head.
- c. Remove the power steering pump mount from the cylinder head.
15. If the vehicle is equipped with air conditioning, disconnect the idle control solenoid hoses.
16. If the vehicle is equipped with a motion control mechanism (cruise-control), remove the cruise control actuator. Do not disconnect the cable; simply move the drive out of the work area.
17. Remove the nuts of the main exhaust pipe, pipe fastening, and take the pipe away from the exhaust manifold.
18. Remove the air filter base mounting bolts. Disconnect the hose connecting the intake manifold to the breather chamber.
19. Remove the valve cover and the top cover of the camshaft drive belt.
20. Loosen the adjusting bolt of the tension mechanism, and remove the camshaft drive belt.
When removing the camshaft drive belt, DO NOT bend or twist it.
21. Remove the cylinder head bolts, in strict sequence, working from the ends to the center. Loosen each bolt ½ turn each time and make several passes to relieve tension evenly. Failure to follow this procedure may result in deformation of the head.
22. Remove the cylinder head from the engine. The head may resist due to being attached to the gasket. Loosen the head by gently tapping it with a plastic or rubber mallet. Raise the head straight up until it is removed.
23. Remove the exhaust manifold from the cylinder head.
24. Remove the base of the air filter from the intake manifold; remove the carburetors.
25. Remove the intake manifold from the cylinder head.
26. Using a putty knife or similar blunt tool, clean the gasket mounting surface. Inspect parts for damage, replace if necessary.
For installation:
24. Assemble the manifolds and carburetor to the head. Use new gaskets for each manifold. Make sure the carburetor is properly tightened.
25. Install a new cylinder head gasket to the surface of the engine, making sure the gasket is installed correctly. Cylinder head dowel pins and oil jet must be in place.
26. Install the head. Lower it directly onto the block, properly aligning.
27. Apply clean engine oil to the bolt threads and in front of the contact head of the bolt. Hand tighten the head bolts. Install the bolts that secure the intake manifold to the mounting bracket, but do not tighten them yet.
28. Correctly install the camshaft and pulley; label "UP" should be up and the alignment marks on the edge of the pulley are aligned with the edge of the head. Carbureted Preludes use a small round mark or dot on the pulley; she should be at the top.
29. Tighten the head bolts in two steps following the sequence shown in fig. 106. On the first pass, tighten the bolts to approximately 30 Nm; after the second and final pass, the total tightening torque should be 68 Nm.
30. Tighten the intake manifold bracket bolts.
31. Install the camshaft drive belt. Loosen the tensioner against the belt.
32. Correct the valve clearance. Install the valve cover and camshaft timing belt top cover.
33. Connect the hose from the intake manifold to the breather.
34. Install the air filter base mountings.
35. Install the main exhaust pipe to the place of its fastening; install new nuts.
36. Reinstall the cruise control actuator.
37. Connect the hoses of the idle control solenoid.
38. Install the power steering pump and belt.
39. Connect coolant hoses to thermostat housing and intake manifold.
40. Connect the upper radiator hose, heater hoses, and bypass inlet hose.
41. Connect the air jet regulator hoses. Connect the control box hoses to the vacuum manifold.
42. Attach wires and hoses to the distributor.
43. Connect the fuel lines and throttle cable and/or accelerator cable.
44. Connect the electrical lines to the carburetor and related components.
45. Install the air filter and cover. Connect the vacuum hoses.
46. On fuel injected engines, reconnect the harness and wire connectors removed in Step 11.
47. Connect the wires and hoses of the carbon filter.
48. Connect the fuel supply hoses to the fuel injection throttle body.
49. Connect the ignition wires, ignition coil wire and radio noise silencer.
50. Connect the engine ground cable to the valve cover. Connect the vacuum hose to the brake booster.
51. Double check all installed parts, paying special attention to slack hoses or wires, loose nuts in the engine area.
52. Fill the cooling system.
53. Connect the negative cable to the battery.