Operation CHARM: Car repair manuals for everyone.

Cylinder Head Assembly: Service and Repair

Removal & Installation

Removal

Note: Engine removal is not required for this procedure.

Caution: To avoid damaging the cylinder head, wait until the engine coolant temperature drops below 100°F (38°C) before removing it.


Note: Inspect the timing belt before removing the cylinder head. Turn the crankshaft pulley so that the No.1 piston is at top dead center (TDC). Mark all emissions hoses before disconnecting them. The original radio has a coded theft protection circuit. Be sure to get the customer's code number before disconnecting the battery, removing the No.32 (7.5 A) fuse from the under-hood fuse & relay box, or removing the radio. After service, reconnect power to the radio and turn it on. When the word "CODE" is displayed, enter the customer's 5-digit code to restore radio operation.

1. Disconnect the negative terminal from the battery.
2. Drain the engine coolant. Remove the radiator cap to speed draining.
3. Relieve fuel pressure.

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






4. Remove the intake air duct.
5. Remove the fuel feed hose and evaporative emission (EVAP) control canister hose from the intake manifold.
6. Remove the throttle cable at the throttle body.
7. Remove the throttle control cable from the throttle body (A/T only).

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






8. Remove the fuel return hose and brake booster vacuum hose.
9. Remove the engine wire harness connectors and wire harness clamps from the cylinder head and the intake manifold:
Four injector connectors
Intake air temperature (IAT) sensor connector
Idle air control (IAC) valve connector
Throttle position sensor connector
Manifold absolute pressure (MAP) sensor connector
Ground terminal (at thermostat cover)
Heated oxygen sensor (HO2S) connector
Engine coolant temperature (ECT) sensor connector
ECT switch connector
ECT gauge sending unit connector
TDC/CKP/CYP sensor connector
10. Disconnect ignition wires at spark plugs. Remove the distributor.
11. Remove the engine ground cable on the cylinder head cover.






12. Remove the power steering (P/S) belt and pump. Do not disconnect the P/S hoses.






13. Remove the P/S bracket.
14. Remove the emission vacuum hoses and water bypass hoses from the intake manifold assembly.
15. Remove the upper radiator hose and heater hose from the cylinder head.






16. Remove the water bypass hose from thermostat housing.
17. Remove the intake manifold bracket.
18. Remove the self-locking nuts and disconnect the exhaust manifold and exhaust pipe A.
19. Remove the exhaust manifold bracket.
20. Remove the positive crankcase ventilation (PCV) hose, then remove the cylinder head cover.
21. Remove the upper cover.
22. Loosen the adjusting bolt 180°.






23. Push the tensioner to release tension from the timing belt, then retighten the adjusting bolt.






24. Remove the timing belt from the camshaft pulley.






25. Remove the cylinder head bolts then remove the cylinder head.

Caution: To prevent warpage, unscrew the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened.






Note: Separate the cylinder head from the block with a flat blade screwdriver as shown.

26. Remove the intake manifold and exhaust 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. Turn the crankshaft so that No 1 piston is at TDC . Make sure oil control orifice is not clogged.






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






3. Install the exhaust manifold and tighten the nuts in a criss-cross pattern in 2 or 3 steps, beginning with the inner nut.











4. Install the three way catalytic converter on the exhaust manifold, then install the exhaust manifold assembly.






5. Install two dowel pins head gasket, and cylinder head.
6. Install the bolts that secure the intake manifold to its bracket, but do not tighten them yet.

D15B7 Engine:






D15B8 Engine:






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 exhaust pipe A on the exhaust manifold.
9. Tighten the bolts for intake manifold bracket.
10. Install exhaust pipe A on its bracket.
11. After the installation, check that the tubes, hoses and connectors are installed correctly.
12. Install the timing belt.






13. Apply liquid gasket to the head mating surface of the No.1 and No.5 or No.6 camshaft holders, then install the cylinder head cover.