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.
8. 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, then drain cooling system.
3. Rotate crankshaft until No. 1 cylinder is at TDC.
4. Relieve fuel pressure as described under Technician Safety Information.
5. Remove air flow tube.
6. Remove fuel feed and EVAP canister hoses from intake manifold.
7. Remove throttle cable at throttle body.
8. On models equipped with automatic transaxles, remove throttle control cable from throttle body.
9. Disconnect fuel return hose and brake booster vacuum hose.
10. Disconnect the following electrical connectors:
a. Fuel injectors.
b. TA sensor.
c. IAT sensor and IAC valve.
d. EACV and throttle sensor.
e. MAP sensor and ground cable.
f. Engine coolant temperature sensor.
g. TW switch and oxygen sensor.
h. TW sensor and temperature unit.
i. Engine coolant temperature gauge sending unit.
j. Spool valve.
k. Oil pressure switch.
l. EGR lift sensor.
m. TDC/CKP/CYP sensor.
11. Remove spark plug caps and distributor.
12. Remove engine ground cable on cylinder head cover.
13. Remove power steering belt, pump and bracket, then position aside. Do not disconnect pump hoses.
14. Disconnect emission vacuum hoses and water bypass hoses from intake manifold assembly.
15. Disconnect upper radiator hose and heater hose from cylinder head.
16. Disconnect water bypass hose from thermostat.
17. Remove intake manifold bracket, then the self-locking nuts and disconnect exhaust manifold and exhaust pipe.
18. Remove exhaust manifold bracket, then disconnect Positive Crankcase Ventilation (PCV) hose and remove cylinder head cover.
19. Remove timing belt upper cover. Loosen timing belt adjusting bolt 180degrees to release belt tension.
20. Push tensioner to release tension from timing belt, then retighten adjusting bolt.
21. Remove belt from camshaft pulley. Do not crimp or bend timing belt more than 90° or less than one inch in diameter.

Fig. 17 Cylinder Head Bolt Loosening Sequence:

22. Remove cylinder head attaching bolts in sequence, Fig. 17. To prevent warpage, loosen bolts in sequence 1/3 turn at a time. Repeat until all bolts are loosened.
23. Separate cylinder head from block. Use an appropriate pry tool, if necessary.
24. Remove intake manifold and exhaust manifold from cylinder head.
25. Reverse procedure to install, noting the following:

Fig. 18 Cylinder Head Bolt Tightening Sequence:

a. Clean cylinder head and engine mating surfaces prior to installation.
b. Turn crankshaft to No. 1 piston TDC.
c. Tighten intake and exhaust manifold nuts to specifications in crossing pattern in two or three steps, beginning with inner nuts.
e. Torque cylinder head attaching bolts in two steps using sequence shown in Fig. 18; first to 22 ft. lbs., then to 53 ft. lbs.
f. Adjust valve timing as necessary.
26. 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.