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. Splash shield
2. Fresh-air duct
3. Air cleaner assembly
4. Accelerator cable - See Accelerator Cable
5. Throttle cable - See Throttle Cable
6. High-tension lead
7. Hoses- removal/installation note
8. Harnesses - removal/installation note
9. Water bypass pipe nut - removal note
10. Drive belts P/S, A/C
11. Drive belt Alt
12. Water pump pulley
13. Cylinder head cover - installation note
14. Timing belt cover, upper
15. Timing belt cover, middle
16. Spark Plug
17. Timing belt - removal/installation note
18. Front exhaust pipe
19. Intake manifold bracket
20. Cylinder head bolt - removal/installation note
21. Cylinder head
22. Cylinder head gasket

Removal Notes:




Hoses - Disconnect the hoses shown in the figure.





Harnesses - Disconnect the harness connectors shown in the figure.




Water Bypass Pipe





1.Remove the transaxle installation bolt as shown.
2.Remove the exhaust manifold nut as shown.
3.Remove the water bypass pipe from the cylinder head assembly.



Timing Belt






1. Remove all spark plugs for easier rotation of the crankshaft.
2. Turn the crankshaft and align the timing marks.







3. Loosen the tensioner lock bolt.
4. Protect the tensioner with a rag. Temporarily secure the tensioner with the spring fully extended.







5. Remove the timing belt and secure it out of the way to prevent damage during removal and installation of the cylinder head.

Caution Do not allow any oil or grease on the timing belt.



Cylinder Head Bolt





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





Installation Notes:

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)


Cylinder Head Cover






1. Apply silicone sealant to the shaded areas shown.
2. Install the cylinder head cover.

Tightening torque:

5.O-8.8 N.m (50-90 kgf.cm, 44-78 in.lb)




Timing Belt






1. Check that the ignition timing mark (yellow) on the crankshaft pulley and the timing mark on the timing belt cover are aligned.





2. Verify that the timing marks are aligned with the seal plate marks. E for intake side, and I for exhaust side.





3. Install the timing belt so that there is no looseness at the idler side or between the two camshaft pulleys.
4. Turn the crankshaft two turns clockwise and align the timing belt pulley mark with the timing mark. Do not turn the crankshaft counterclockwise.






5. Verify that the timing marks are aligned with the seal plate marks. If not, remove the timing belt and repeat from tensioner installation.

6. Turn the crankshaft clockwise 1 and 5/6 turns and align the fourth tooth from the camshaft pulley marks with the seal plate mark.





7. Loosen the tensioner lock bolt to apply tension to the timing belt.

8. Tighten the tensioner lock bolt.

Tightening torque:
38-51 N.m (3.8-5.3 kgf.m, 28-38 ft.lb)

9. Turn the crankshaft 2 and 1/6 turns and verify that the timing marks are correctly aligned.





10. Measure the timing belt deflection by applying moderate pressure 98 N (10 kgf, 22 lbf) midway between the two camshaft pulleys.
If the deflection is not correct, repeat from step 7.

Deflection: 9.0-11.5mm (0.36-0.45 in) at 98N (10 kgf, 22 lbf)

Harness
Connect the harness connectors.

Hoses
Connect the hoses.


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.