Cylinder Head Assembly: Service and Repair

1. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures.
2. Disconnect battery ground cable.
3. Position No. 1 cylinder at TDC compression stroke, then drain coolant.
4. Relieve fuel pressure as described under Technician Safety Information.
5. Remove vacuum tube, breather hose and air flow tube.
6. Remove water bypass hose from cylinder head.
7. Remove fuel feed hose and EVAP canister hose from intake manifold.
8. On models equipped with automatic transaxles, remove brake booster vacuum hose and vacuum hose mount from intake manifold.
9. Disconnect fuel return hose and cruise control vacuum hose.
10. On models equipped with automatic transaxles, remove throttle cable and throttle control cable from throttle body.
11. Remove ignition coil, spark plug caps and distributor.
12. Disconnect alternator electrical connector, then remove engine wiring harness from cylinder head cover.
13. Disconnect the following electrical connectors from cylinder head and intake manifold:
a. Fuel injectors.
b. Intake Air Temperature (IAT) sensor and Idle Air Control (IAC) valve
c. TA sensor and throttle position sensor.
d. EACV and ground cable.
e. EGR valve lift sensor.
f. Thermoswitch (engine coolant temperature switch) for cooling fan.
g. Oxygen sensor.
h. Engine coolant temperature sensor and engine coolant temperature gauge sending unit connector.
i. Ignition coil connector.
j. CKP/TDC/CYP sensor.
k. Temperature unit and speed sensor.
14. Remove upper radiator hose and heater inlet hose from cylinder head.
15. Remove emission vacuum hoses and water bypass hoses from intake manifold assembly.
16. Disconnect water bypass hose from thermostat housing, then remove thermostat assembly from intake manifold.
17. Disconnect electrical connector and vacuum tube, then remove cruise control actuator.
18. Remove engine ground cable from cylinder head cover.
19. Remove power steering belt and pump, then position aside. Do not disconnect pump hoses.
20. Remove intake manifold bracket and intake manifold.
21. Raise and support vehicle, then remove front wheels and engine splash shield.
22. Remove heat insulator, if equipped.
23. Remove self-locking nuts, then disconnect exhaust manifold and pipe.
24. Remove exhaust manifold bracket and exhaust manifold.
24. Disconnect PCV hose, then remove cylinder head cover.
26. Remove timing belt upper cover, then loosen timing belt adjusting nut 270°-360°.
27. Push tensioner to release tension from timing belt, then retighten adjusting nut.
28. Remove belt from camshaft pulley. Do not crimp or bend timing belt more than 90° or less than one inch in diameter.

Fig. 6 - Cylinder Head Bolt Loosening Sequence:

29. Remove cylinder head attaching bolts in sequence Fig. 9. To prevent warpage, loosen bolts in sequence 1/3 turn at a time. Repeat until all bolts are loosened.
30. Separate cylinder head from block. Use an appropriate pry tool, if necessary.

Fig. 9 Cylinder Head Bolt Tightening Sequence:

31. 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. Using sequence shown in Fig. 16, torque cylinder head attaching bolts in three steps; first step to 29 ft. lbs., second step to 51 ft. lbs., third step 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.
32. On models equipped with radio coded theft protection system, refer to Vehicle Damage Warnings for system disarming and arming procedures. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures.