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 misconnection.
^ Inspect the timing belt before removing the cylinder head.
^ Turn the crankshaft pulley so that the No. 1piston is at top dead center.

1. Remove the air duct(A).





2. Disconnect the negative terminal from the battery





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





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) TPS(Throttle Position Sensor) connector(A).
2) ISA(Idle Speed Actuator) connector(B).
3) PCSV(Purge Control Solenoid Valve) connector(C).
4) VIS actuator connector(D).
5) Injector connector(E).
6) Knock sensor connectors(F).
7) CMP(Camshaft Position Sensor) connector(G).





8) ECT(Engine Coolant Temperature) sensor connector(A).
9) Ignition coil connector(B).
10) Crankshaft position sensor connector(C).
11) Oxygen sensor connector(D).





12) Three fuel injector connectors(A).





13) Disconnect ground cable(A) from the cowl panel.





14) IAT(Intake Air Temperature) sensor connector(A),
15) VIS actuator connector(B).





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





10. Remove the PCSV hose.
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 PCV hose(A).





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





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








22. Remove the camshafts(A).








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





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





25. 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 16 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
23-27Nm (2.3-2.7kgf-m, 17-20lb-ft) + (58 degrees-62 degrees) + (43 degrees-47 degrees)
1) Apply alight 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 degrees in the numerical order shown.
5) Retighten the cylinder head bolts by 45 degrees 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 bolts.
Tightening torque
Camshaft sprocket bolt
90-110 Nm (9.0-11.0kgf-m, 65-80 lb-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 head 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, loctite 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. Install the accelerator cable.





18. Install the brake booster vacuum hose(A).





19. Install the PCSV hose.
20. Install the fuel inlet hose(A).





21. Install the engine wire harness connectors and wire harness clamps to the cylinder head and the intake manifold.
1) VIS actuator connector(B).
2) IAT(Intake Air Temperature) sensor connector(A).





3) Connect the ground cable(A) to the cowl panel.





4) Three fuel injector connectors(A).





5) Oxygen sensor connector(D).
6) Crankshaft position sensor connector(C).
7) Ignition coil connector(B).
8) ECT sensor connector(A).





9) CMP(Camshaft position sensor) connector(G).
10) Knock sensor connector(F).
11) Injector connector(E).
12) VIS actuator connector(D).
13) PCSV(Purge Control Solenoid Valve) connector(C).
14) ISA connector(B).
15) TPS connector(A).





22. Install the heater hoses(A).





23. Install the upper radiator hose(A) and lower radiator hose(B).





24. Install the intake air hose and air cleaner assembly.
1) Install the intake air hose and air cleaner assembly(C).
2) Connect the breather hose(B) from air cleaner hose.
3) Connect the AFS connector(A).





25. Install the engine cover.
26. Connect the negative terminal to the battery.





27. Install the air duct(A).





28. Fill with engine coolant.
29. Start the engine and check for leaks.
30. Recheck engine coolant level and oil level.