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 air flow tube.
6. Remove fuel feed hose and EVAP canister hose from intake manifold.
7. On models with automatic transaxles, remove throttle cable and throttle control cable from throttle body.
8. Disconnect fuel return hose and brake booster vacuum hose.
9. Disconnect the following electrical connectors:
a. Fuel injectors.
b. IAC valve and IAT sensor.
c. TA sensor and throttle sensor.
d. EACV and ground cable.
e. EGR valve lift sensor.
f. Thermoswitch (engine coolant temperature switch) for cooling fan.
g. Oxygen sensor and TW sensor.
h. Engine coolant temperature sensor and engine coolant temperature gauge sending unit.
i. Temperature unit and ignition coil.
j. Ignition control module.
k. Crank/TDC/Cylinder sensor.
l. Intake air bypass solenoid valve.
m. Knock sensor.
n. Speed sensor.
o. VTEC solenoid valve and pressure switch.
10. Remove engine ground cable from cylinder head cover.
11. Remove power steering belt and pump, then position aside. Do not disconnect pump hoses.
12. Disconnect alternator electrical connector, then remove engine wiring harness from cylinder head cover.
13. Remove ignition coil.
14. Remove emission vacuum hoses and water bypass hoses from intake manifold assembly.
15. Remove upper radiator hose and heater inlet hose from cylinder head.
16. Disconnect water bypass hose from thermostat housing, then remove thermostat assembly from intake manifold.
17. Remove intake manifold bracket and intake manifold.
18. Remove self-locking nuts, then disconnect exhaust manifold and pipe.
19. Remove heat insulator.
20. Remove exhaust manifold bracket and exhaust manifold.
21. Disconnect PCV hose, then remove cylinder head cover.
22. Remove timing belt middle cover, then loosen timing belt adjusting nut or bolt 180°.
23. Push tensioner to release tension from timing belt, then retighten adjusting nut or bolt.
24. Remove belt from camshaft pulley. Do not crimp or bend timing belt more than 90° or less than one inch in diameter.
25. Remove crankshaft pulley.
26. 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. 15. 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. 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.
31. 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.