Cylinder Head Assembly: Service and Repair

CYLINDER HEAD GASKET - Replacement

Warning - Release the fuel pressure. Keep sparks and open flame away from the fuel area.

Caution - Position the hose clamp in the original location on the hose, and squeeze the clamp lightly with large pliers to ensure a good fit.





1. Disconnect the negative battery cable.
2. Drain the engine coolant.
3. Remove in the order shown in the figure, referring to Removal Notes.
4. Install in the reverse order of removal, referring to Installation Notes.







1. Air hose assembly
2. Resonance chamber
3. Accelerator cable - installation note
4. Throttle cable (ATX) - removal/installation note
5. Hoses- removal/installation note
6. Harnesses - removal/installation note
7. Water bypass pipe nut
8. Drive belt
9. Water pump pulley
10. Cylinder head cover
11. Timing belt cover, upper
12. Timing belt - removal/installation note
13. Front exhaust pipe
14. Intake manifold bracket
15. Cylinder head bolt - removal/installation note
16. Cylinder head
17. Cylinder head gasket

Removal Notes:





Hoses - Disconnect the hoses shown in the figure.





Harnesses - Disconnect the harness connectors shown in the figure.

Timing Belt - See Timing Belt Removal/Installation. Timing Belt





Cylinder Head Bolt

1. Loosen the cylinder head bolts in two or three steps in the order shown in the figure.
2. Remove the cylinder head bolts.





Installation Notes:

Timing Belt - See Timing Belt Removal/Installation. Timing Belt


Cylinder Head Bolt

1. Apply clean engine oil to the bolt threads seat faces.
2. Install the cylinder head bolts.





3. Tighten the cylinder head bolts in two or three steps in the order shown in the figure.

Tightening Torque:
76-81 N.m (7.7-8.3 kgf.m, 56-60 ft.lb)



Accelerator Cable

1. Install the accelerator cable.






2. Check the accelerator cable deflection.
If the deflection is not correct, adjust by turning nuts A.
Deflection: 1-3 mm (0.04-0.11 in)

Steps After Installation

1. Fill the radiator with the specified amount and type of engine coolant.
2. Connect the negative battery cable.
3. Start the engine and check as follows:

(1) Engine oil and engine coolant leakage.
(2) Ignition timing, idle speed.
(3) Operation of emission control system.
(4) Recheck the engine coolant levels.