Cylinder Head Assembly: Service and Repair

*** The cylinder head torque specifications listed in this article have been updated by Technical Service Bulletin # 97-20-002, dated January1, 1997. ***






REMOVAL
1. Drain the coolant and disconnect the upper radiator hose.
2. Remove the breather hose (between the air cleaner and the head cover).
3. Remove the air-intake hose.
4. Remove the vacuum hose, fuel hose and coolant hose.
5. Remove the cables from the spark plugs. The cables should be removed by holding the boot portion.
6. Remove the ignition coil.
7. Remove the power steering oil pump and bracket.
8. Remove the intake manifold.
9. Remove the heat protector and exhaust manifold assembly.






10. Remove the coolant pump pulley and the crankshaft pulley.
11. Remove the timing belt cover.
12. Remove the timing belt tensioner pulley.
13. Remove the timing belt.
14. Remove the head cover.

Tightening Sequence:

15. Using sequence shown in the illustration and wrench tool No. 09221-32001 or 09221-11000, or equivalents, loosen cylinder head bolts in two to threes steps, then remove the cylinder head.
16. Remove the gasket pieces from the cylinder block top surface and cylinder head bottom surface.

NOTE: Make sure that the gasket pieces do not fall in the engine.

INSTALLATION
1. Clean all gasket surfaces of the cylinder block and the cylinder head.
2. Install a new cylinder head gasket onto the cylinder head assembly.

CAUTION:
- Do not apply sealant to the gasket.
- Do not reuse the old cylinder head gasket.
3. Install the cylinder head and bolts.

Tightening Sequence:

4. Using sequence shown in the illustration and wrench tool No. 09221-32001 or 09221-11000, or equivalents, tighten cylinder head bolts as follows:
10 mm CYLINDER HEAD BOLT;
a. Tighten in sequence to 30 Nm (300 kg. cm, 22 ft. lbs.).
b. Turn in sequence 60°- 65°.
c. Turn in sequence an additional 60°- 65°.
12 mm CYLINDER HEAD BOLT;
a. Tighten in sequence to 35 Nm (350 kg. cm, 26 ft. lbs.).
b. Turn in sequence 60°- 65°
c. Turn in sequence an additional 60°- 65°.

5. Install and adjust timing belt components as described under Timing Components.
6. Install the rocker cover and tighten the bolts to 8-10 Nm (80-100 kg. cm, 5.9-7.4 ft. lbs.)
7. Install the timing belt cover.
8. Install the new intake manifold gasket and the intake manifold/surge tank, then tighten the nuts and bolts to 15-20 Nm (150-200 kg. cm, 11-14 ft. lbs.).
9. Install the new exhaust manifold gasket and the exhaust manifold, then tighten attaching nuts to 15-20 Nm (150-200 kg. cm, 11-14 ft. lbs.).
10. Install the power steering oil pump and bracket.






11. Install the ignition coil.
12. Install the air intake hose.
13. Connect the vacuum hose, fuel hose and water hose.
14. Install breather hose.