Contents: Removal ⇊ Installation ⇊
Caution! Wait until the engine has cooled down completely before starting work.
Removal
1. Bring the piston of the first cylinder to the TDC position at the end of the compression stroke (see Bringing the piston of the first cylinder to the top dead center (TDC) position).
2. Disconnect the negative cable from the battery.
Warning! If the car stereo system is equipped with a security code, make sure you have the correct combination to activate the audio system before disconnecting the battery!
3. Drain the cooling system and remove the spark plugs (see Chapter Routine maintenance).
4. Remove the air cleaner with the air intake sleeve (see Chapter Power and exhaust systems).
5. Remove the accessory drive belts (see Chapter Routine maintenance). Unbolt the steering pump and move it to the side without disconnecting the hydraulic lines, then remove the steering pump bracket (see Chapter Suspension and steering).
6. Disconnect the accelerator cable and release the pressure in the fuel system (see Chapter Power and exhaust systems).
7. Disconnect the following hoses and lines (see Chapters Power and exhaust systems and Engine management systems):
- a) Fuel supply hose;
- b) Evaporative emission control system (EVAP) hose;
- c) Ventilation hose (breather pipe);
- d) PCV hose.
8. Disconnect the coolant bypass hose, heater hose and upper radiator hose (see Chapter Cooling and heating systems).
9. Disconnect the electrical wiring from the following components:
- a) Fuel injection injectors;
- b) Coolant Temperature Sensor (CTS);
- c) Coolant temperature switch sensor;
- d) Temperature sensor;
- e) Throttle Position Sensor (TPS);
- f) Absolute pressure sensor in the pipeline (MAP);
- g) Oxygen sensor (and secondary oxygen sensor on models with D16Y7 engine);
- h) EGR valve sensor (D16Y5);
- i) VTEC solenoid valve (D16Y5 and D16Y8);
- j) VTEC pressure switch sensor (D16Y5 and D16Y8);
- k) Idle speed control valve (IAC).
10. Support the engine with a jack (to distribute the load between the jack head and the oil pan, place a wooden block). Remove the upper engine mount bracket (see Checking the condition and replacing the powertrain suspension supports).
11. Remove the mounting bracket supporting the intake manifold and unscrew the exhaust manifold flange bolts.
Note: If desired, the intake manifold and/or exhaust manifold can be separated from the engine (see Removal and installation the intake manifold and Removal and installation the exhaust manifold) to facilitate further manipulation of the head.
12. Remove the cylinder head cover (see Removal and installation the cylinder head cover).
13. Remove the ignition distributor (see Chapter Engine electrical equipment) together with the cover and high-voltage wires connected to it.
14. Remove the timing belt (see Removal, condition check and installation of the timing belt and timing drive gears), rocker arm assembly (see Removal, condition check and installation of rocker arm assembly) and the camshaft (see Removal, condition check and installation of the camshaft).
15. Proceed in the reverse order to that shown in the illustration (see below), in several steps (1/4 turn per set) loosen the head mounting bolts enough to be able to unscrew them manually. Try to remember the location of each of the mounting bolts - when assembling, they must be screwed in strictly in their original places.
16. Remove the cylinder head from the engine. If the head does not separate from the block, you can use a lever, which should be inserted between the steering pump bracket and the block (do not under any circumstances pry the head under the mating surface). Place the head removed from the engine on a couple of wooden blocks to avoid damaging the gasket surfaces.
17. A description of the procedures for disassembling the head and checking the condition of its internal components is given in Part General and major engine repairs of this Chapter. At this stage, evaluate only the flatness of the mating surface.
Installation
1. The mating surfaces of the cylinder head and block must be absolutely clean and dry.
2. Thoroughly clean the mating surfaces of the cylinder head and block. After scraping off the remaining gasket material and carbon deposits, wipe the surfaces with a rag soaked in acetone. The presence of old gasket material on the mating surfaces at the time of installation may lead to a violation of the seal of the gasket fit and, as a result, the development of leaks. When processing the block, plug the cylinder holes with a rag to prevent small debris and various foreign objects from getting into them (as a last resort, vacuum the cylinders thoroughly). Since the cylinder head and block are made of soft aluminum alloy, proceed with extreme caution, trying not to leave scratches and burrs on the mating surfaces (use only copper or plastic tools to scrape off deposits).
3. Check the mating surfaces of the head and block for deep scratches, burrs, and other damage. Light defects can be removed with fine-grained sandpaper. In more serious cases, the only alternative is to resurface the components.
4. Using a tap of the appropriate size, run the threaded holes for the head mounting bolts. Clamping the bolts one by one in a vice by the head, go over their threads with a die. The presence of old sealant, dirt and corrosion products in the threads leads to a discrepancy between the actual tightening force of the fastener and the readings of the torque wrench indicator.
5. Place a new sealing gasket (with the "TOP" marking facing up) on the cylinder block. Lubricate the edges of the timing belt cover that are mated with the block with sealant. Carefully install the cylinder head on the block.
6. Lubricate the threads and the underside of the heads of the mounting bolts with clean engine oil and screw the fasteners back into their original positions. Proceed in the order shown (see accompanying illustration), tighten the cylinder head mounting bolts in four stages to the required torque (see Specifications). Due to the critical nature of the bolts, the authors of this Guide recommend that the following precautions be taken when tightening them:
- a) It is preferable to use a torque wrench equipped with a ratchet drive with a torque limiter. Otherwise, proceed with extreme caution, trying not to accidentally strip the threads.
- b) If the bolt starts to make any noise when screwed in (squealing, squeaking, clicking, etc.), turn it out completely and try again. 7. Place the timing belt on the camshaft journal, then install the timing belt (see Removal, condition check and installation of the timing belt and timing drive gears).
8. Installation of the remaining components is carried out in the reverse order of their dismantling.
9. Manually turn the crankshaft slowly counterclockwise two full turns.
Caution: If resistance occurs when turning the shaft, stop immediately to avoid damaging the valves when they come into contact with the piston crowns.
10. Start the engine and check that the ignition timing is set correctly (see Chapter Routine maintenance).
11. Warm up the engine to normal operating temperature and check for signs of leaks. Make sure the engine is functioning properly.
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