Replacement

REMOVAL
1. Relieve fuel pressure according to procedure.
2. Disconnect negative cable at battery.
3. Drain engine oil.
4. Drain coolant.
5. Remove strut tower bar.
6. Remove air cleaner outlet hose.





7. Disconnect accelerator cable and Automatic Transmission (A/T) throttle cable to throttle body.
8. Remove 1st timing chain.
9. Remove camshafts and valve lash adjuster.





10. Disconnect following electric lead wires:
- Exhaust Gas Recirculation (EGR) valve coupler
- Idle Air Control (IAC) valve coupler
- Throttle Position (TP) sensor coupler
- Manifold Absolute Pressure (MAP) sensor coupler
- Evaporative Emission (EVAP) solenoid purge valve coupler.
- Ground terminal from intake manifold
- Heated oxygen sensor coupler
- Coolant temperature switch coupler
- Engine Coolant Temperature (ECT) sensor coupler
- Injector wire harness coupler
- Wire harness clamps





11. Disconnect following hoses:
- Brake booster hose from intake manifold
- MAP sensor hose for intake manifold
- Canister parge hose from EVAP canister
- Water hose from throttle body
- Fuel feed hose from delivery pipe
- Fuel return hose from fuel pressure regulator
- Heater hose from heater outlet pipe
- Radiator inlet hose from water outlet pipe





12. Remove intake manifold front stiffener.





13. Disconnect water pipe from intake manifold.





14. Remove exhaust pipe No.1





15. Remove exhaust manifold stiffener.





16. Loosen cylinder head bolts in such order as indicated in figure and remove them.

NOTE: Don't forget to remove bolt (M6) as shown in figure.

17. Check all around cylinder head for any other parts required to be removed or disconnected and remove or disconnect whatever necessary.
18. Remove cylinder head with intake manifold, exhaust manifold and water outlet pipe.

INSTALLATION





1. Clean mating surface on cylinder head and cylinder block. Remove oil, old gasket and dust from mating surface.
2. Install knock pins to cylinder block.
3. Install new cylinder head gasket to cylinder block.





4. Install cylinder head to cylinder block. Apply engine oil to cylinder head bolts and tighten them gradually as follows:
a. Tighten all bolts to 53 Nm (5.3 kg-m, 38.5 ft. lbs.) according to numerical order in figure.
b. In the same manner as in (1), tighten them to 84 Nm (8.4 kg-m, 61.0 ft. lbs.).





c. Loosen all the bolts until tightening torque is reduced to 0 in the illustrated order.





d. Tighten all bolts to 37 Nm (3.7 kg-m, 27.0 ft. lbs.) according to numerical order in figure.
e. In the same manner as in (4) again, tighten them to specified torque.
Tightening Torque:
(a): 105 Nm (10.5 kg-m, 76.0 ft. lbs.).
(b): 11 Nm ( 1.1 kg-m, 8.0 ft. lbs.).

NOTE: Be sure to tighten M6 bolt after securing the other bolt.





5. Check timing mark on crankshaft as shown in figure.
6. Reverse removal procedure for installation.
7. Adjust cooling fan belt tension.
8. Adjust accelerator cable play and Automatic Transmission (A/T) throttle cable play.
9. Check to ensure that all removed parts are back in place. Reinstall any necessary parts which have not been reinstalled.
10. Refill engine with engine oil.
11. Refill cooling system.
12. Refill front differential housing with gear oil.
13. Connect negative cable at battery.
14. Check ignition timing and adjust as necessary.
15. Verify that there is no fuel leakage, water leakage, oil leakage and exhaust gas leakage at each connection.
16. Check wheel alignment.