Cylinder Head Assembly: Service and Repair

1. Disable coded theft protection system as described under Accessories and Optional Equipment / Antitheft and Alarm Systems / Service and Repair.
2. Disable airbag system as described under Air Bags and Seat Belts / Air Bags (Supplemental Restraint Systems / Airbag System Disarming).
3. Disconnect battery ground cable.
4. Position No. 1 cylinder at TDC compression stroke, then drain coolant.
5. Relieve fuel pressure, remove fuel filler cap, place shop towel over area, then slowly loosen service bolt on filter one turn at a time.
6. Remove air flow tube.
7. Remove fuel feed hose and charcoal canister hose from intake manifold.
8. On models with automatic transaxles, remove throttle cable and throttle control cable from throttle body.
9. On all models, disconnect fuel return hose and brake booster vacuum hose.
10. Disconnect the following electrical connectors:
a. Fuel injectors.
b. TA sensor and throttle sensor.
c. EACV and ground cable.
d. EGR valve lift sensor.
e. Thermoswitch for cooling fan.
f. Oxygen sensor and TW sensor.
g. Temperature unit and ignition coil.
h. Crank/TDC/Cylinder sensor.
i. Speed sensor.
11. Remove engine ground cable from cylinder head cover.
12. Remove power steering belt and pump, then position aside. Do not disconnect pump hoses.
13. Disconnect alternator electrical connector, then remove engine wiring harness from cylinder head cover.
14. Remove ignition coil.
15. Remove emission vacuum hoses and water bypass hoses from intake manifold assembly.
16. Remove upper radiator hose and heater inlet hose from cylinder head.
17. Disconnect water bypass hose from thermostat housing, then remove thermostat assembly from intake manifold.
18. Remove intake manifold bracket and intake manifold.
19. Remove self-locking nuts, then disconnect exhaust manifold and pipe.
20. Remove heat insulator, if equipped.
21. Remove exhaust manifold bracket and exhaust manifold.
22. Disconnect PCV hose, then remove cylinder head cover.
23. Remove timing belt middle cover, then loosen timing belt adjusting nut 180°.
24. Push tensioner to release tension from timing belt, then retighten adjusting bolt.
25. Remove belt from crankshaft pulley. Do not crimp or bend timing belt more than 90° or less than 1 inch in diameter.
26. Remove crankshaft pulley. Loosen rocker arm adjusting screws, then remove crankshaft holders and camshafts.
27. Remove side engine mount bracket and timing belt back cover.

Fig. 11 Cylinder Head Bolt Loosening Sequence:

28. Remove cylinder head attaching bolts in sequence, Fig. 11. To prevent warpage, loosen bolts in sequence 1/3 turn at a time repeat until all bolts are loosened.
29. Separate cylinder head from block. Use an appropriate pry tool, if necessary.

Fig. 12 Cylinder Head Bolt Tightening Sequence:

30. Reverse procedure to install, noting the following:
a. Clean cylinder head and engine mating surfaces prior to installation.
b. Ensure UP mark on camshaft pulley is positioned on top when installing cylinder head.
c. Install cylinder head using a new gasket, ensuring dowel pin and oil control jet are properly aligned with cutouts in gasket.
d. Apply clean engine oil to cylinder head attaching bolts and washers.
e. Torque cylinder head attaching bolts in three steps in sequence shown in Fig. 12 first to 29 ft. lbs., second to 51 ft. lbs., then to 72 ft lbs.
f. Turn crankshaft to No. 1 piston TDC.
g. Tighten intake manifold nuts to specifications in crossing pattern in two or three steps beginning with inner nuts.
h. Rearm airbag and restore coded theft protection system.