Cylinder Head Assembly: Service and Repair

Cylinder Head Removal & Installation



Removal

Caution: To avoid damaging the cylinder head, wait until the coolant temperature drops below 38°C (1OO°F) before loosening the retaining bolts.

Note: Inspect the timing belt before removing the cylinder head. Turn the crankshaft pulley so that the No.1 cylinder is at top-dead-center. Mark all emissions hoses before disconnecting them.

1. Disconnect the negative terminal from the battery.
2. Drain the cooling system.
3. Remove the brake booster vacuum hose from the brake booster.
4. Remove the engine secondary ground cable from the valve cover.
5. Remove the air intake pipe and the air chamber.
6. Relieve fuel pressure.

Caution: Do not smoke while working on fuel system keep open flame or spark away from work area. Drain fuel only into an approved container.

7. Disconnect the fuel hose and fuel return hose.
8. Remove the air intake pipe and air cleaner pipe joint.
9. Disconnect the throttle cable at the throttle body.
10. Disconnect the throttle control cable at the throttle body (A/T only).

Note: Take care not to bend the cable when removing it. Always replace a kinked cable with a new one.

11. Disconnect the charcoal canister hose at the throttle valve.
12. Disconnect the engine wire connectors from the cylinder head and the intake manifold:

14 P connector (from main wire harness)
EACV connector
Intake air temperature sensor connector
Throttle angle sensor connector
Injector connectors
Ignition coil connector (from distributor)
TDC/CRANK sensor connector (from distributor)
Coolant temperature gauge sender connector
Coolant temperature sensor connector
Oxygen sensor connector






13. Disconnect the vacuum hoses and the water bypass hoses from intake manifold and the throttle body.






14. Remove the upper radiator hose and the heater hose from the cylinder head.






15. Remove the PCV hose, charcoal canister hose and vacuum hose from intake manifold, and remove the vacuum hose from the brake master power booster.






16. Remove the power steering pump belt and the alternator belt.
17. Remove the air conditioning (A/C) idler pulley and bracket.






18. Remove the power steering pump bracket.
19. Remove the intake manifold bracket.
20. Remove the exhaust manifold bracket, then remove the EX pipe A.
21. Remove the exhaust manifold shroud, then remove the exhaust manifold.
22. Remove the distributor and valve cover.
23. Remove the timing belt upper cover.






24. Loosen the timing belt adjust bolt, then remove the timing belt from the camshaft pulley.
25. Remove the cylinder head.
26. Remove the intake manifold from the cylinder head.

Installation

1. Carefully remove all gasket material from the head and the block with gasket solvent and a heavy duty scraper. The head and block mating surfaces must be clean, flat, and smooth for the new head gasket to seal properly.

Note: Do not use power tools or abrasives to remove the gasket material; they would damage the head and block surfaces causing the new head gasket to leak.

2. Install the cylinder head in reverse order of removal. Always use a new head gasket. Do not use gasket sealers. Cylinder head and engine block surface must be clean. "UP" mark on timing belt pulley should be at the top.






3. Install the intake manifold and tighten the nuts in a crisscross pattern in 2 or 3 steps, beginning with the inner nuts.






4. Cylinder head dowel pins and oil control jet must be aligned.
5. Install the bolts that secure the intake manifold to its bracket but do not tighten them yet.
6. Position the cam correctly.






7. Apply engine oil to threads and washers of the cylinder bolts. Tighten cylinder head bolts in four steps in the sequence shown:
1) Tighten all 10 bolts to 20 Nm (14 lb-ft)
2) Tighten all 10 bolts to 49 Nm (36 lb-ft)
3) Tighten all 10 bolts to 67 Nm (49 lb-ft)
4) Tighten bolts 1 & 2 to 67 Nm (49 lb-ft)






8. Install the exhaust manifold and tighten the nuts in a criss-cross pattern in 2 or 3 steps, beginning with the inner nuts.
9. Install the EX pipe A on the exhaust manifold. Tighten the bolts for the intake manifold bracket.
10. After the installation, check that the tubes, hoses and connectors are installed correctly.
11. Adjust the valve timing.