Cylinder Head Assembly: Service and Repair
1. Relieve fuel system pressure as outlined under Technician Safety Information. On models with airbag system, refer to Technician Safety Information for system disarming and arming procedures.2. Mark position of hood to hood hinges for alignment during installation, then remove hood.
3. Disconnect battery ground cable, then insulate cable end with electrical tape, or equivalent.
4. Drain radiator coolant, then remove air cleaner assembly.
5. Remove radiator fan lower cover from radiator.
6. Disconnect radiator hoses from engine, then the coolant reserve hose from radiator.
7. Disconnect transmission cooling lines from radiator, then remove radiator.
8. Disconnect accelerator cable from throttle body assembly.
9. Mark position of all vacuum hoses, then disconnect vacuum hoses from engine assembly.
10. Mark position of all engine electrical connectors, then disconnect from engine.
11. Disconnect spark plug wires from cylinder head covers, then the three DIS electrical connectors.
12. Remove three DIS module bracket retaining bolts, then the DIS module with spark plug wires attached.
13. Remove four throttle body retaining bolts, then the EGR assembly.
14. Remove four bolts, four nuts and three bracket bolts retaining common chamber duct.
15. Disconnect ground cable from rear side of common chamber.
16. Disconnect coolant hose from throttle body.
17. Remove common chamber from engine assembly, then disconnect fuel supply and return hoses from fuel rail.
18. Remove intake manifold as outlined under Intake Manifold.
19. Disconnect heater hoses from coolant manifold, then remove four coolant manifold retaining bolts.
20. Remove coolant manifold.
21. Remove power steering drive belt, then the air conditioning and alternator drive belts.
22. Remove power steering pump from engine, then position aside.
23. Using crankshaft securing tool No. J-8614-01, or equivalent, remove crankshaft pulley.
24. Remove two oil cooler bracket retaining bolts from timing belt cover.
25. Remove timing belt cover.
26. Remove belt tensioner pusher cylinder. Do not allow air to enter pusher oil chamber. To prevent air from entering pusher, inner rod must always be facing upward.
27. Remove timing belt, then the cylinder head covers from engine assembly.
28. Disconnect ground cable from power steering bracket, then remove bracket from engine assembly.
29. Disconnect front exhaust pipe from manifolds, then carefully remove cylinder head from engine.
30. Reverse procedure to install, noting the following:
a. When installing a new cylinder head, transfer oil check and relief valve and/or cylinder head plug from old cylinder head, refer to fig 21.
Fig. 21 Cylinder Head Oil Relief Valve Transfer:
b. Using sequence shown, refer to fig. 22, torque cylinder head M11 X 1.5 bolts to 47 ft. lbs., then the M8 X 1.25 bolts to 15 ft. lbs.
Fig. 13 Cylinder head bolt tightening sequence:
c. Tighten cylinder head cover to specification.
1. Relieve fuel system pressure as outlined under Technician Safety Information. On models with airbag system, refer to Technician Safety Information for system disarming and arming procedures.
2. Mark position of hood to hood hinges for alignment during installation, then remove hood.
3. Disconnect battery ground cable, then insulate cable end with electrical tape, or equivalent.
4. Drain radiator coolant, then remove air cleaner assembly.
5. Remove radiator fan lower cover from radiator.
6. Disconnect radiator hoses from engine, then the coolant reserve hose from radiator.
7. Disconnect transmission cooling lines from radiator, then remove radiator.
8. Disconnect accelerator cable from throttle body assembly.
9. Mark position of all vacuum hoses, then disconnect vacuum hoses from engine assembly.
10. Mark position of all engine electrical connectors, then disconnect from engine.
11. Disconnect spark plug wires from cylinder head covers, then the three DIS electrical connectors.
12. Remove three DIS module bracket retaining bolts, then the DIS module with spark plug wires attached.
13. Remove four throttle body retaining bolts, then the EGR assembly.
14. Remove four bolts, four nuts and three bracket bolts retaining common chamber duct.
15. Disconnect ground cable from rear side of common chamber.
16. Disconnect coolant hose from throttle body.
17. Remove common chamber from engine assembly, then disconnect fuel supply and return hoses from fuel rail.
18. Remove intake manifold as outlined under Intake Manifold.
19. Disconnect heater hoses from coolant manifold, then remove four coolant manifold retaining bolts.
20. Remove coolant manifold.
21. Remove power steering drive belt, then the air conditioning and alternator drive belts.
22. Remove power steering pump from engine, then position aside.
23. Using crankshaft securing tool No. J-8614-01, or equivalent, remove crankshaft pulley.
24. Remove two oil cooler bracket retaining bolts from timing belt cover.
25. Remove timing belt cover.
26. Remove belt tensioner pusher cylinder. Do not allow air to enter pusher oil chamber. To prevent air from entering pusher, inner rod must always be facing upward.
27. Remove timing belt, then the cylinder head covers from engine assembly.
28. Disconnect ground cable from power steering bracket, then remove bracket from engine assembly.
29. Disconnect front exhaust pipe from manifolds, then carefully remove cylinder head from engine.
Fig. 21 Cylinder Head Oil Relief Valve Transfer:
Fig. 13 Cylinder head bolt tightening sequence:
Fig. 14 Alignment of crankshaft timing mark:
Fig. 24 Timing Belt Installation & Timing Mark Alignment:
Fig. 16 Belt tension pusher installation:
Fig. 26 Belt Tension Pusher Clearance:
30. Reverse procedure to install, noting the following:
a. When installing a new cylinder head, transfer oil check and relief valve and/or cylinder head plug from old cylinder head, Fig. 21.
b. Using sequence shown, Fig. 22, torque cylinder head M11 X 1.5 bolts to 47 ft. lbs., then the M8 X 1.25 bolts to 15 ft. lbs.
c. Tighten cylinder head cover to specification.
d. Install timing belt by aligning groove of crankshaft timing pulley with mark on oil pump, Fig. 23.
e. Align mark on camshaft timing pulley with mark on front plate, Fig. 24.
f. For correct timing belt installation, letters printed on belt should be read as viewed from front of engine assembly and arrows pointing in direction of engine rotation.
g. Press the pusher to retract rod and insert 1.4 mm pin as shown in Fig. 25.
h. Push tensioner pulley against belt, then install pusher. Tighten pusher retaining bolts to specification.
i. Loosen adjusting bolt on tension pulley, rotate tension pulley counterclockwise with pliers to tension belt, then torque adjusting bolt to 32 ft. lbs.
j. Pull lockpin out of pusher.
k. Install crankshaft pulley temporarily, then tighten by hand. Do not use a wrench at this time.
l. Rotate crankshaft clockwise two turns, ensure rod protrusion is within 0.16-0.24 inch as shown in Fig. 26.
m. If not within limits, remove pusher, loosen adjusting bolt and repeat procedure.
n. Remove crankshaft pulley previously installed.
31. On models equipped with airbag system, refer to Technician Safety Information for system disarming and arming procedures.