Cylinder Head Assembly

CYLINDER HEAD ASSEMBLY

COMPONENTS:

REMOVAL

Engine removal is not required for this procedure.

CAUTION:
^ Use fender covers to avoid damaging painted surfaces.
^ To avoid damaging the cylinder head, wait until the engine coolant temperature drops below normal temperature before removing it.
^ When handling a metal gasket, take care not to fold the gasket or damage the contact surface of the gasket.
^ To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

NOTE:
^ Mark all wiring and hoses to avoid mis-connection.
^ Inspect the timing belt before removing the cylinder head.
^ Turn the crankshaft pulley so that the No. 1 piston is at top dead center.

l. Remove the side cover(A, B, C) and the engine cover(D).





2. Disconnect the battery terminal and the battery.





3. Remove the radiator cap to speed draining.
4. Remove the radiator drain plug and drain engine coolant.
5. Remove the air cleaner assembly.
1) Disconnect the air flow sensor (AFS) connector (A).
2) Remove the breather hose (B) from intake hose(C).
3) Remove the intake hose (C) and air cleaner upper cover (D).
4) Remove the air cleaner lower cover (A).





6. Remove the upper radiator hose(A) and lower radiator hose(B).





7. Remove the heater hoses(A).





8. Remove the engine wire harness connectors and wire harness clamps from the cylinder head and the intake manifold.
1) Throttle position sensor (TPS) connector(A).
2) Idle speed actuator (ISA) connector(B).
3) Purge control solenoid valve(PCSV) connector(C).
4) Injector connector(E).
5) Knock sensor connector(F).
6) Camshaft position sensor(CPS) connector(G).
7) Engine ground line (F).
8) Heated oxygen sensor (Bank 2, Sensor l) connector (H).





9) Engine temperature coolant sensor connector(A).
10) Ignition coil connector (B).
11) Crankshaft position sensor connector (C).
12) Heated oxygen sensor (Bank 1, Sensor 2) connector (D).





13) Three fuel injector connectors(A).





9. Remove the fuel inlet from delivery pipe(A).





10. Disconnect the purge control solenoid valve (PCSV) hose (A).





11. Remove the brake booster vacuum hose(A).





12. Remove the accelerator cable by loosening the lock-nut, then slip the cable end out of the throttle linkage.
13. Remove the auto-cruise connector (A) and the auto-cruise cable (B).





14. Remove the PCV hose(A).





15. Remove the intake manifold.
16. Remove the power steering pump.
17. Remove the exhaust manifold.
18. Remove the timing belt.
19. Remove the spark plug cable. .
20. Remove the cylinder head covers(A).





21. Remove the camshaft sprocket.
22. Remove the camshaft bearing caps(A).








23. Remove the camshafts(A).








24. Remove the timing belt rear cover(A).





25. Remove the water temperature control assembly(A) and water pipe.





26. Remove the cylinder head bolts, then remove the cylinder heads.
1) Uniformly loosen and remove the 8 cylinder head bolts on each cylinder head in several passes and in the sequence shown, then repeat for the other side, as shown. Remove the 18 cylinder head bolts and plate washer.





CAUTION: Head warpage or cracking could result from removing bolts in an incorrect order.

2) Lift the cylinder head from the dowels on the cylinder block and place the cylinder head on wooden blocks on a bench.

CAUTION: Be careful not to damage the contact surfaces of the cylinder head and cylinder block.

INSTALLATION

NOTE:
^ Thoroughly clean all parts to be assembled.
^ Always use a new head and manifold gasket.
^ The cylinder head gasket is a metal gasket. Take care not to bend it.
^ Rotate the crankshaft, set the No.1 piston at TDC.

1. Install the cylinder head gaskets on the cylinder block.





NOTE: Be careful of the installation direction.

2. Place the cylinder head quietly in order not to damage the gasket with the bottom part of the end.
3. Install cylinder head bolts.

Tightening torque 24.5Nm (2.5kgf.m, 18.1 lb-ft) + 60° + 45°

1) Apply a light coat if engine oil on the threads and under the heads of the cylinder head bolts.
2) Install the plate washer to the cylinder head bolt.
3) Install and uniformly tighten the cylinder head bolts on each cylinder head in several passes and in the sequence shown, then repeat for the other side, as shown.





If only one of the cylinder head bolts dose not meet the torque specification, replace the cylinder head bolt.





4) Retighten the cylinder head bolts by 60° in the numerical order shown.
5) Retighten the cylinder head bolts by 45° in the numerical order shown.
4. Install the water pipe and water temperature control assembly(A).





5. Install the timing belt rear cover(A).





6. Install the camshafts.
1) Align the camshaft timing chain with the intake timing chain sprocket and exhaust timing chain sprocket as shown.





2) Install the camshaft(A).





3) Install the camshaft bearing caps(A).





NOTE:
^ Apply new engine oil to the thrust portion and journal of the camshafts.
^ Apply a light coat of engine oil on the threads and under the heads of the bearing cap bolts.

7. Using the SST (09214-21000), install the camshaft bearing oil seal.





8. Install the camshaft sprocket.
1) Temporarily install the camshaft sprocket bolts.
2) Hold the hexagonal head wrench portion of the camshaft with a wrench, and tighten the camshaft sprocket bats.

Tightening torque
Camshaft sprocket bolt 88.3 - 107.9Nm (9.0 - 11.014gf.m, 65.1 - 79.6lb-ft)

9. Install semi-circular packing.
10. Install the cylinder head cover.
1) Install the cylinder head cover gasket(A) in the groove of the cylinder head cover(B).





NOTE:
^ Before installing the head cover gasket, thoroughly clean the heed cover gasket and the groove.
^ When installing, make sure the head cover gasket is seated securely in the corners of the recesses with no gap.

2) Apply liquid gasket to the head cover gasket at the corners of the recess.

NOTE:
^ Use liquid gasket, locate No.5699.
^ Check that the mating surfaces are clean and dry before applying liquid gasket.
^ After assembly, wait at least 30 minutes before filling the engine with oil.

3) Install the cylinder head covers(A) with the 16 bolts. Uniformly tighten the bolts in several passes.








11. Install the spark plug cable.
12. Install the timing belt.
13. Install the exhaust manifold.
14. Install the power steering pump.
15. Install the intake manifold.
16. Install the PCV hose(A).





17. Connect the auto-cruise connector (A) and the auto-cruise cable (B).





18. Install the accelerator cable by loosening the locknut, then slip the cable end out of the throttle linkage.
19. Remove the brake booster vacuum hose(A).





20. Disconnect the purge control solenoid valve (PCSV) hose (A).





21. Remove the fuel inlet from delivery pipe(A).





l) Three fuel injector connectors(A).





2) Heated oxygen sensor (Bank l, Sensor 2) connector (D).
3) Crankshaft position sensor connector (C).
4) Ignition coil connector (B).
5) Engine temperature coolant sensor connector(A).





6) Heated oxygen sensor (Bank 2, Sensor l) connector (H).
7) Engine ground line (F).
8) Camshaft position sensor(CPS) connector(G).
9) Knock sensor connector(F).
10) Injector connector(E).
11) Purge control solenoid valve(PCSV) connector(C).
12) Idle speed actuator (ISA) connector(B).
13) Throttle position sensor (TPS) connector(A).
22. Remove the engine wire harness connectors and wire harness clamps from the cylinder head and the intake manifold.





23. Remove the heater hoses(A).





24. Remove the upper radiator hose(A) and lower radiator hose(B).





25. Remove the air cleaner assembly.
1) Remove the air cleaner lower cover (A).
2) Remove the intake hose (C) and air cleaner upper cover (D).
3) Remove the breather hose (B) from intake hose(C).
4) Disconnect the air flow sensor (AFS) connector (A).





26. Disconnect the battery terminal and the battery.





27. Remove the side cover(A, B, C) and the engine cover(D).