Cylinder Head Removal and Installation

NOTE:

Use fender covers to avoid damaging painted surfaces.

To avoid damage, unplug the wiring connectors carefully while holding the connector portion.

Connect the HDS to the DLC, and monitor ECT SENSOR 1. To avoid damaging the cylinder head, wait until the engine coolant temperature drops below 100 °F (38 °C) before loosening the cylinder head bolts.

Mark all wiring and hoses to avoid misconnection. Also, be sure that they do not contact other wiring or hoses, or interfere with other parts.

Keep the cam chain away from magnetic fields.

1.	Fuel Pressure - Relieve

2.	Engine Coolant - Drain

3.	12 Volt Battery - Remove

4.	Intake Manifold - Remove

5.	EVAP Canister Purge Hose - Disconnect

Disconnect the EVAP canister purge hose (A).

6.	Fuel Feed Hose - Disconnect

Remove the bracket (A).

Remove the quick-connect fitting cover (B).

Disconnect the fuel feed hose (C).

7.	Water Bypass Hose, and Heater Hose - Disconnect

Disconnect the water bypass hose (A) and the heater hose (B).

8.	Warm Up TWC - Remove

9.	Under-Floor TWC - Remove

10.	Connector (Injector) - Disconnect

11.	Cylinder Head Cover - Remove

12.	Harness Holder - Remove

Disconnect the connectors (A).

Remove the harness holder (B).

13.	Cam Chain - Remove

14.	Camshaft - Remove

15.	Rocker Arm Assembly - Remove

16.	Cylinder Head - Remove

Remove the cylinder head bolts. To prevent warpage, loosen the bolts in sequence 1/3 turn at a time; repeat the sequence until all bolts are loosened.

Remove the cylinder head.

1.	Cylinder Head - Install

Clean the cylinder head and the engine block surface.

Install a cooling control spacers (A) in the engine block whenever the engine block is replaced, and check for free play between the cooling control spacer and the engine block. If there is any free play, install a new cooling control spacer.

NOTE:

Make sure the cooling control spacer contacts the bottom of the water jacket (B).

The cooling control spacer upper end portions (C) and the clearance of the cylinder block end face (D) being more than 2.0 mm (0.079 in).

Install the dowel pins (E) and the new cylinder head gasket (F).

Install the cylinder head on the engine block.

Apply new engine oil to the threads and flange of all cylinder head bolts.

Torque the cylinder head bolts in sequence to 30 N·m (3.1 kgf·m, 22 lbf·ft) with a beam-type torque wrench if possible. When using a preset-click-type torque wrench, be sure to tighten slowly and do not overtighten. If a bolt makes any noise while you are torquing it, loosen the bolt and retighten it from the first step.

Tighten all cylinder head bolts an additional 120 °.

2.	Rocker Arm Assembly - Install

3.	Camshaft - Install

4.	Cam Chain - Install

5.	Harness Holder - Install

Connect the connectors (A).

Install the harness holder (B).

6.	Valve Clearance - Adjust

7.	Cylinder Head Cover - Install

8.	Connector (Injector) - Connect

9.	Warm Up TWC - Install

10.	Under-Floor TWC - Install

11.	Water Bypass Hose, and Heater Hose - Connect

Connect the water bypass hose (A) and the heater hose (B).

12.	Fuel Feed Hose - Connect

Connect the fuel feed hose (A).

Install the quick-connect fitting cover (B).

Install the bracket (C).

13.	EVAP Canister Purge Hose - Connect

Connect the EVAP canister purge hose (A).

14.	Intake Manifold - Install

15.	After Installation - Check

After installation, check that all tubes, hoses, and connectors are installed correctly.

16.	12 Volt Battery - Install

17.	Fuel Leak (Low Pressure) - Check

Turn the vehicle to the ON mode, but do not operate the starter. After the fuel pump runs for about 2 seconds, the fuel rail will be pressurized. Repeat this two or three times, then check for fuel leakage.

18.	Fuel Leak (High Pressure) - Check

19.	Engine Coolant - Refill

20.	Engine Coolant - Clean

Clean up any spilled engine coolant.

21.	CKP Pattern - Clear/Learn